Engine Manual - LM6000 PF+ PDF

Customer Facing No.
: 1370344
MFG Project No.: 7277395, 7280414, 7280415
Main Table Of Contents

GEK LM6000 PF+
GEK 119319 - Operation and Maintenance

GEK 119320 - Illustrated Parts Breakdown
Planta de Generación Termoyopal August 2019

Customer Facing No.: 1370344
MFG Project No.: 7277395, 7280414, 7280415
GEK 119319 - Operation and Maintenance
GEK 119319 Volume I

GEK119319_V1FM01
Cover Page . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C00
GEK119319_V1FM02
Highlights of GEK 119319 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C02
GEK119319_V1FM03
GE Proprietary Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C02
GEK119319_V1FM04
List of Effective Pages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C02
GEK119319_V1FM05
Table of Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C02
GEK 119319 Volume I / Technical Manual
GEK119319_V1TM01
Chapter 01 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C00
Chapter 02 Gas Turbine General Description and GEK119319_V1TM02
Model Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C00
GEK119319_V1TM03
Chapter 03 Gas Turbine Package . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C00
GEK119319_V1TM04
Chapter 04 Gas Turbine Assembly Description . . . . . . . . . . . . . . . . . .C00
Chapter 05 LM6000 PF+ Model System GEK119319_V1TM05
Descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C01
GEK119319_V1TM06
Chapter 06 Service and Support Requirements . . . . . . . . . . . . . . . . . . .C00
GEK119319_V1TM07
Chapter 07 Installation and Startup . . . . . . . . . . . . . . . . . . . . . . . . . . . .C00
GEK119319_V1TM08
Chapter 08 Engine Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C00
GEK119319_V1TM09
Chapter 09 Abnormal Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C00
GEK119319_V1TM10
Chapter 10 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C02
GEK119319_V1TM11
Chapter 11 Maintenance Considerations . . . . . . . . . . . . . . . . . . . . . . . .C00
GEK119319_V1TM12
Chapter 12 Preventive Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . .C02
Chapter 13 Critical Parts Life Management - GEK119319_V1TM13
LM6000 PF+ Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C02
Appendix A GE Aero Derivative Gas Turbine GEK119319_V1TMA
Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P.C00
GEK 119319 Volume II
GEK119319_V2FM01
Cover Page . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C00

MFG Project No.: 7277395, 7280414, 7280415
GEK119319_V2FM02
Highlights of GEK 119319 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C02
GEK119319_V2FM03
GEK119319_V2FM04
GEK119319_V2FM05
GEK 119319 Volume II / Level 1 Maintenance

WP 0001 00 Numerical List of Support Equipment, GEK119319_0001.00.
Consumables, and Expendables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C02
WP 1110 00 Axial Inlet Centerbody Assembly GEK119319_1110.00.
Replacement - Hot End Driven . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C00
WP 1111 00 Low Pressure Compressor Inlet GEK119319_1111.00.
Temperature/Pressure (T2/P2) Sensor Replacement . . . . . . . . . . . . . . C00
WP 1112 00 Variable Inlet Guide Vane (VIGV) GEK119319_1112.00.
Actuator Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C00
System Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C00
GEK119319_1114.00.
WP 1114 00 Forward Seal Cover Plate Replacement . . . . . . . . . . . . . C00
WP 1310 00 High Pressure Compressor Inlet
Temperature/Pressure (T25/P25) Sensor GEK119319_1310.00.
Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C00
WP 1311 00 Variable Bypass Valve (VBV) Actuator GEK119319_1311.00.
Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C00
WP 1312 00 Variable Bypass Valve (VBV) System GEK119319_1312.00.
Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C00
WP 1313 00 Bypass Valve, Bellcrank, and Actuating GEK119319_1313.00.
Ring Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C01
WP 1410 00 Variable Stator Vane (VSV) Actuator GEK119319_1410.00.
Components Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C00
GEK119319_1411.00.
WP 1411 00 Variable Stator Vane (VSV) Rigging . . . . . . . . . . . . . . . C00
WP 1412 00 Variable Stator Vane (VSV) Stages 3 to
5 Bushing Replacement (High-Boss HPC Stator GEK119319_1412.00.
Case) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C00
GEK119319_1510.00.
WP 1510 00 Gas Fuel System Replacement . . . . . . . . . . . . . . . . . . . . C00
GEK119319_1511.00.
WP 1511 00 Dual Fuel System Replacement . . . . . . . . . . . . . . . . . . . C00
WP 1515 00 Ultraviolet Flame Sensor, L44819,
Flame Sensor Sight Glass, and Flame Sensor GEK119319_1515.00.
Bracket Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C00
GEK119319_1516.00.
WP 1516 00 Igniter Plug Replacement . . . . . . . . . . . . . . . . . . . . . . . . C00
WP 1517 00 High Pressure Compressor Discharge GEK119319_1517.00.
Temperature (T3) Sensor Replacement . . . . . . . . . . . . . . . . . . . . . . . . C00

MFG Project No.: 7277395, 7280414, 7280415
WP 1610 00 Compressor Discharge Pressure (CDP) GEK119319_1610.00.

and Stage 8 Bleed Valves Replacement . . . . . . . . . . . . . . . . . . . . . . . . C00
GEK119319_1611.00.
WP 1611 00 Acoustic Sensor Replacement . . . . . . . . . . . . . . . . . . . . . C00
WP 1710 00 Low Pressure Rotor Speed (XNSD) GEK119319_1710.00.
Sensor Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C00
WP 1711 00 Low Pressure Turbine Inlet
Temperature (T48) Thermocouple GEK119319_1711.00.
Replacement/Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C00
WP 1712 00 Low Pressure Turbine Inlet Pressure GEK119319_1712.00.
(P48) Probe Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C00
WP 1714 00 Balance Piston Orifice Plate GEK119319_1714.00.
Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C00
WP 1811 00 Hydraulic Control Unit (HCU) and GEK119319_1811.00.
Hydraulic Filter Assembly Replacement . . . . . . . . . . . . . . . . . . . . . . . C00
SWP 1811 01 Hydraulic Accumulator
Removal/Installation, Assembly/Disassembly, and GEK119319_1811.01.
Pre-Charge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C02
WP 1812 00 Variable Geometry Hydraulic Pump GEK119319_1812.00.
Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C00
GEK119319_1813.00.
WP 1813 00 Lube and Scavenge Pump Replacement . . . . . . . . . . . . . C00
GEK119319_1814.00.
WP 1814 00 Pneumatic Starter Replacement . . . . . . . . . . . . . . . . . . . C00
WP 1816 00 High Pressure Compressor Speed GEK119319_1816.00.
(XN25) Sensor Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C00
WP 1817 00 Lube Resistance Temperature Detector GEK119319_1817.00.
(RTD) Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C00
GEK119319_1910.00.
WP 1910 00 Magnetic Chip Detector Replacement . . . . . . . . . . . . . . C00
GEK119319_1911.00.
WP 1911 00 Accelerometer Replacement . . . . . . . . . . . . . . . . . . . . . . C00
WP 1913 00 External Piping, Hoses, and Electrical GEK119319_1913.00.
Harness Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C00
SWP 1913 01 Front Frame Module External Tubing, GEK119319_1913.01.
Harnesses, and Clamping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C00
SWP 1913 02 Core Module External Tubing, GEK119319_1913.02.
Electrical Leads, and Clamping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C00
SWP 1913 03 Low Pressure Turbine (LPT) Module GEK119319_1913.03.
External Tubing, Harnesses, and Clamping . . . . . . . . . . . . . . . . . . . . . C00
SWP 1913 04 Engine Assembly External Tubing, GEK119319_1913.04.
Harnesses, and Clamping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C00
GEK119319_1915.00.
WP 1915 00 Heat Shields Replacement . . . . . . . . . . . . . . . . . . . . . . . C00
WP 1916 00 Spray Inter-Cooled Turbine GEK119319_1916.00.
(SPRINT®) Kit Removal and Installation . . . . . . . . . . . . . . . . . . . . . . C00
GEK 119319 Volume II / Level 2 Maintenance


MFG Project No.: 7277395, 7280414, 7280415
Assembly Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C00

WP 2210 00 Low Pressure Compressor (LPC) GEK119319_2210.00.
Module Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C00
WP 2211 00 Low Pressure Compressor (LPC) Stage GEK119319_2211.00.
0 Rotor Blades Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C00
WP 2212 00 Low Pressure Compressor (LPC)
Stages 0-3 Upper and Lower Stator Case GEK119319_2212.00.
Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C00
Stages 0-3 Stator Vanes Replacement . . . . . . . . . . . . . . . . . . . . . . . . . C00
Stages 1-3 Rotor Blades Replacement . . . . . . . . . . . . . . . . . . . . . . . . . C00
WP 2215 00 Low Pressure Compressor (LPC) Aft GEK119319_2215.00.
Fan Case Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C00
4 Stator Vanes Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C00
4 Rotor Blades Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C00
GEK119319_2310.00.
WP 2310 00 Front Frame Air Collector Replacement . . . . . . . . . . . . . C00
WP 2411 00 High Pressure Compressor (HPC) GEK119319_2411.00.
Upper and Lower Stator Case Replacement . . . . . . . . . . . . . . . . . . . . C00
SWP 2411 01 High Pressure Compressor GEK119319_2411.01.
Upper/Lower Stator Case Opening/Closing . . . . . . . . . . . . . . . . . . . . C00
Stator Vanes Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C00
Rotor Blades Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C02
Stator Outlet Guide Vanes Replacement . . . . . . . . . . . . . . . . . . . . . . . C00
GEK119319_2510.00.
WP 2510 00 Combustion Chamber Replacement . . . . . . . . . . . . . . . . C00
WP 2511 00 Stage 1 High Pressure Turbine (HPT) GEK119319_2511.00.
Nozzle Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C02
WP 2610 00 High Pressure Turbine (HPT) Module GEK119319_2610.00.
Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C00
Nozzle (On Engine) Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . C00
Nozzle (Off Engine) Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . C00
WP 2710 00 Low Pressure Turbine (LPT) Module GEK119319_2710.00.
Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C00
WP 2711 00 Rear Drive Adapter or Aft Seal Spacer GEK119319_2711.00.
Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C00

MFG Project No.: 7277395, 7280414, 7280415
GEK119319_2810.00.
WP 2810 00 Radial Drive Shaft Replacement . . . . . . . . . . . . . . . . . . . C00
WP 2811 00 Transfer Gearbox Assembly GEK119319_2811.00.
Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C00
WP 2812 00 Spur Gearshaft Assemblies GEK119319_2812.00.
Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C00
WP 2813 00 Accessory Gearbox Carbon Seals GEK119319_2813.00.
Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C00
GEK 119319 Volume II / Preservation, Handling, Storage, and Balance

GEK119319_3010.00.
WP 3010 00 Gas Turbine in Enclosure Replacement . . . . . . . . . . . . . C00
GEK119319_3011.00.
WP 3011 00 Preservation/Depreservation . . . . . . . . . . . . . . . . . . . . . . C00
WP 3012 00 Gas Turbine Maintenance Dolly GEK119319_3012.00.
Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C00
WP 3013 00 Gas Turbine/Support Pedestal Removal GEK119319_3013.00.
and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C00
WP 3014 00 Gas Turbine in Shipping Container GEK119319_3014.00.
Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C00
GEK119319_3014.01.
SWP 3014 01 Air Ride Kit Installation . . . . . . . . . . . . . . . . . . . . . . . . C02
WP 3015 00 Gas and Dual Fuel Manifold Support GEK119319_3015.00.
Fixture Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C00
WP 3017 00 LPT Module in Shipping Container, GEK119319_3017.00.
106C7158, Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C02
GEK 119319 Volume II / Periodic Inspections Maintenance
GEK119319_4010.00.
WP 4010 00 Gas Turbine Inlet Inspection . . . . . . . . . . . . . . . . . . . . . . C00
GEK119319_4011.00.
WP 4011 00 External Engine Cleaning . . . . . . . . . . . . . . . . . . . . . . . . C00
WP 4012 00 Gas Turbine External Inspection GEK119319_4012.00.
(Visual) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C00
GEK119319_4013.00.
WP 4013 00 Gas Turbine Exhaust System Inspection . . . . . . . . . . . . C00
GEK119319_4014.00.
WP 4014 00 Gas Turbine Water-Wash . . . . . . . . . . . . . . . . . . . . . . . . C00
GEK119319_4015.00.
WP 4015 00 Borescope Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . C02
GEK119319_4016.00.
WP 4016 00 Lube Oil Sampling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C00
WP 4017 00 Lube and Scavenge Pump Chip GEK119319_4017.00.
Detector Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C00
WP 4020 00 Lube and Scavenge Pump Screen GEK119319_4020.00.
Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C00
WP 4021 00 Variable Geometry Pump/Hydraulic GEK119319_4021.00.
Control Unit Filter Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C01

MFG Project No.: 7277395, 7280414, 7280415
GEK119319_4022.00.
WP 4022 00 Pneumatic Starter Servicing . . . . . . . . . . . . . . . . . . . . . . C00
GEK119319_4023.00.
WP 4023 00 Ignition System Functional Check . . . . . . . . . . . . . . . . . C00
WP 4024 00 Vibration Monitoring System GEK119319_4024.00.
Functional Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C00
GEK119319_4025.00.
WP 4025 00 Overspeed Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . C00
GEK119319_4026.00.
WP 4026 00 Overtemperature Inspection . . . . . . . . . . . . . . . . . . . . . . C00
GEK119319_4027.00.
WP 4027 00 Bearing Sump Flow Tests . . . . . . . . . . . . . . . . . . . . . . . . C00
WP 4028 00 Variable Stator Vane Off-Schedule GEK119319_4028.00.
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C02
WP 4029 00 Acoustic Signal Conditioner GEK119319_4029.00.
Calibration and Checkout Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . C00
GEK119319_4031.00.
WP 4031 00 Fuel System Pressure Check . . . . . . . . . . . . . . . . . . . . . . C00
WP 4032 00 Individual Fuel Nozzle Flow Test GEK119319_4032.00.
Using 9400M86 Test Stand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C02
WP 4033 00 Shipping Container Inspection and GEK119319_4033.00.
Reconditioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C02
WP 4034 00 Maintenance Logger Installation and GEK119319_4034.00.
Usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C02

GEK 119319
VOLUME I
ON-SITE OPERATION AND MAINTENANCE MANUAL

FOR
GENERAL ELECTRIC LM6000® PF+ SERIES
GAS TURBINES
GE INDUSTRIAL
AERODERIVATIVE GAS TURBINES
GE Industrial AeroDerivative Gas Turbines

Mail Drop S-133
One Neumann Way
P.O. Box 156301
Cincinnati, Ohio 45215-6301, USA
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ORIGINAL INSTRUCTIONS
/03) *(.

Chapter 1
Introduction
1-1 Purpose and Scope of covers removal and reinstallation of one or more major
Technical Manual sections of the engine, including, but not limited to, the
low pressure turbine (LPT) and high pressure turbine
Volumes I and II of this manual contain information to (HPT) modules, the combustor, the low pressure
be used for the on-site installation, operation, and compressor (LPC) module, and the variable inlet guide
maintenance of the GE LM6000 PF+ Series Gas vane (VIGV) module.
Turbine.
Each work package in Volume II (or subordinate work
package, as required) is numbered and arranged in the
1-2 Arrangement and Use of following general sequence:
Technical Manual
1. Introduction
This manual consists of two volumes, each arranged to 2. Reference Material
provide easy access to all required information. 3. Support Equipment
Volume I provides general descriptions of the engine 4. Consumable Material
and associated systems, as well as, operating and 5. Expendable Material
troubleshooting information. 6. Component Removal
7. Component Installation
The chapters in Volume I are numbered with Arabic
numerals. Figures, tables, and pages are each numbered
sequentially, starting with the number one (1), preceded
1-3 Warnings, Cautions, and Notes
by the chapter number and a dash, for each chapter; Definitions
e.g., figure 1-1. Paragraphs are identified and layered
in the following manner: Warnings, Cautions, and Notes are in a number of parts
of this manual. Before use, make sure you read and
1-1 Main Topic/Paragraph know important safety instructions in this manual.
1-1.1 First-level subordinate paragraph Refer to these definitions:
1-1.1.1 Second-level subordinate paragraph
WARNING
1-1.1.1.1 Third-level subordinate paragraph
1-1.1.1.1.1 Fourth-level subordinate paragraph WARNINGS REFER TO PROCEDURES THAT CAN
CAUSE INJURY OR DEATH IF NOT OBEYED.
Volume II contains the individual work packages for
on-site maintenance, including engine changeout. CAUTION
Volume II also contains the recommended tooling and CAUTIONS REFER TO PROCEDURES THAT CAN
consumables provisioning for on-site maintenance, as CAUSE DAMAGE TO EQUIPMENT IF NOT
well as, storage and shipment preparation procedures. OBEYED.
Level 1 maintenance covers all work on the exterior of NOTE
an installed gas turbine, including scheduled
inspections, compressor cleaning (water-wash), and Notes give more information to a procedure or required
engine changeout. Level 2 modular maintenance special condition.

*(. /03)

1-4 Changes to Technical Manual 1-5 Measurement Units

A manual change is defined as the reissue of selected The Système International d'Unités (SI) or metric
pages of the manual. A revision is defined as the system is being adopted throughout the world. For this
reissue of the entire manual. reason, SI unit conversion tables are shown in
table 1-1 through table 1-3. Fractions and decimal
Changes are indicated by a vertical bar | in the margin, equivalents are shown in table 1-4.
alongside the text change. Changes to illustrations,
diagrams, and schematics are indicated in the same The introduction of torque wrenches calibrated in
manner. Since previous change symbols are deleted Newton-meters has been commensurate with the
when a page is subsequently changed, the symbols adoption of the SI system. These will eventually
show the latest changes only. replace torque wrenches calibrated in kilogram-meters
(kg m). A quick method to convert kilogram-meters
Manual changes and revisions are mailed to all (kg m) to N·m, is to move the decimal point one place
authorized LM6000 manual holders at the time the to the right. For example, 3.5 kg m would become 35
issues are published. When changes are received, insert N·m. Although this technique is not mathematically
the latest change pages and dispose of superseded precise (3.5 kg m actually equals 34.3 N·m), it is
pages. Page changes are designated by the change considered adequate for general purposes. To convert
number of the effective change at the bottom of each kilogram-centimeters (kg cm) to Newton-meters, move
affected page. Refer to the list of effective pages for the decimal point one place to the left. For example, 50
current change page applicability. kg cm would become 5.0 N·m.
Illustrations (line art and photographs) represent the

equipment configuration at time of inclusion in this
technical manual. They will not necessarily be changed
to represent all and/or the latest equipment or
configuration. They are to be used only as an aid to
supplement the text and the parts list.
Changes or additions deemed necessary for proper

operation, maintenance, and safety improvements
should be submitted to your appropriate Product Line
Contact at GE using the form shown in figure 1-1.

/03) *(.

TECHNICAL MANUAL GE Marine Engines &

PUBLICATION CHANGE REQUEST GE Industrial Aeroderivatives
Complete ALL blocks. Forward to Appropriate Product Line Contact.
APPLICABILITY COMPLETE EACH SECTION PCR NUMBER
LM500 LM1600 INDUSTRIAL ORIGINATOR:
LM5000 LM6000 FOREIGN MARINE DATE:
LMS100 LM2500 COMMERCIAL MARINE ADDRESS:
UDS/M3 OTHER U.S. NAVY
IDENTIFICATION PHONE NO.:
MANUAL IDENTIFICATION: GEK
(if applicable) SCOPE OF CHANGE
LATEST CHANGE DATE: (Determined by product line Program Manager)
MANUAL NAME:
MANUAL CHANGE/REVISION
WP/SWP/CHAPTER NO.:
PAGE NO.:
CHANGE NO.: INTERIM CHANGE NOTICE (ICN)
FIGURE NO.:
PARAGRAPH NO.:
TABLE NO.:
INSTRUCTIONS
SUBJECT OF CHANGE (TITLE FOR DATABASE ID):
Description Summary:
SPECIFIC CHANGE REQUIRED:
Description of Change:
SOURCE DATA
(IDENTIFY RELATED CID, ECP, DRAWING, PARTS LIST, ETC. ATTACH OTHER PERTINENT INFORMATION)
ACTIONS
ROUTE TO: DUE DATE: COMPLETED:
Figure 1-1. Publication Change Request

*(. /03)

Table 1-1. Metric and SI Unit Conversion Factors
To Convert From To Multiply By

μin (microinches) μm (micrometers) 0.0254
μm (micrometers) μin (microinches) 39.3701
bhp (brake horsepower) kW (kilowatts) 0.7457
Btu (British thermal units) J (Joules) 1055.0560
Btu/hr (Btu per hour) kcal/hr (kilocalories per hour) 0.2520
Btu/hr (Btu per hour) kJ/hr (kilojoules per hour) 1.0551
Btu/kW-hr (Btu per kilowatt hour) Btu/hp-hr (Btu per horsepower hour) 1.3410
Btu/kW-hr (Btu per kilowatt hour) kcal/kW-hr (kilocalories per kilowatt 0.2520
hour)
Btu/kW-hr (Btu per kilowatt hour) kJ/kW-hr (kilojoules per kilowatt 1.0551
hour)
Btu/lb (Btu per pound) kcal/kg (kilocalories per kilogram) 0.5556
cm (centimeters) in. (inches) 0.3937
cm (centimeters) m (meters) 0.0100
cm (centimeters) mm (millimeters) 10.0000
cm/sec (centimeters per second) ft/sec (feet per second) 0.0328
F -32 (degrees Fahrenheit -32) C (degrees Celsius) 0.5556
ft (feet) cm (centimeters) 30.4800
ft (feet) m (meters) 0.3048
ft/min (feet per minute) km/hr (kilometers per hour) 0.0183
ft/sec (feet per second) cm/sec (centimeters per second) 30.4800
ft/sec (feet per second) m/sec (meters per second) 0.3048
ft2 (square feet) m2 (square meters) 0.0929
ft3/hr (cubic feet per hour) l/hr (liters per hour) 28.3168
ft3/hr (cubic feet per hour) m3/hr (cubic meters per hour) 0.0283
ft3/min (cubic feet per minute) l/min (liters per minute) 28.3168
ft3/min (cubic feet per minute) m3/min (cubic meters per minute) 0.0283
g (grams) oz (ounces) 0.0353
g/cm3 (grams per cubic centimeter) lb/in3 (pounds per cubic inch) 0.0361
gal (gallons) l (liters) 3.7854
gal/min (gallons per minute) l/sec or lps (liters per second) 0.0631

/03) *(.

Table 1-1. Metric and SI Unit Conversion Factors (Continued)

gpm (gallons per minute) l/sec or lps (liters per second) 0.0631
hp(l) (U.S. horsepower)See Note 1 kW (kilowatts) 0.7457
hp(l) (U.S. horsepower)See Note 1 hp(M) (metric horsepower)See Note 2 1.0138
in. (inches) cm (centimeters) 2.5400
in. (inches) m (meters) 0.0254
in. (inches) mm (millimeters) 25.4000
in. H2O (inches of water at 60°F) Pa (Pascals) 248.8430
in. Hg (inches of hydrogen at 60°F) Pa (Pascals) 3376.8500
in2 (square inches) m2 (square meters) 0.0006
in3 (cubic inches) cm3 (cubic centimeters) 16.3871
kg (kilograms) lb (pounds) 2.2046
kg cm (kilogram centimeters) lb ft (foot pounds) 7.2330
kg cm (kilogram centimeters) lb in. (pound inches) 0.8680
kg/m2 (kilograms per square meter) lb/ft2 (pounds per square feet) 0.2048
km (kilometers) mi (miles) 0.6214
kW (kilowatts) bhp (brake horsepower) 1.3410
lb (pounds) g (grams) 453.5924
lb (pounds) kg (kilograms) 0.4536
lb (pounds) N (Newtons) 4.4482
lb ft (foot pounds) Btu (British thermal units) 0.0013
lb ft (foot pounds) kg m (kilogram meters) 0.1383
lb ft (foot pounds) N·m (Newton meters) 1.3558
lb ft/min (foot pounds per minute) ft lb/sec (foot pounds per second) 0.0167
lb in. (inch pounds) kg cm (kilogram centimeters) 1.1521
lb in. (inch pounds) N·m (Newton meters) 0.1130
lb/ft2 (pounds per square feet) kg/m2 (kilograms per square meter) 4.8824
lb/gal (pounds per gallon) kg/l (kilograms per liter) 0.1198
lb/hr (pounds per hour) kg/hr (kilograms per hour) 0.4536
lb/in2 (pounds per square inch) kg/cm2 (kilograms per square 0.0703
centimeter)
lb/in2 (pounds per square inch) kPa (kilopascals) 6.8948

*(. /03)

Table 1-1. Metric and SI Unit Conversion Factors (Continued)

lb/in2 (pounds per square inch) Pa (Pascals) 6894.7573
m (meters) cm (centimeters) 100.0000
m (meters) ft (feet) 3.2808
m (meters) in. (inches) 39.3701
m2 (square meters) ft2 (square feet) 10.7639
m3 (cubic meters) in3 (cubic inches) 61,023.7441
mi (miles, statute) km (kilometers) 1.6093
mm (millimeters) in. (inches) 0.0394
N (Newtons) lb (pounds) 0.2248
N·m (Newton meters) lb ft (foot pounds) 0.7376
N·m (Newton meters) lb in. (pound inches) 8.8507
oz (ounces) g (grams) 28.3495
oz/gal (ounces per gallon) g/l (grams per liter) 7.4892
psi (pounds per square inch) kPa (kilopascals) 6.8948
qt (quarts) l (liters) 0.9464
Note 1: Also known as mechanical horsepower

Note 2: Also known as cv, hk, pk, ks or ch
Table 1-2. Pressure Conversions
Kilograms per Pounds per

Standard
square centimeter square inch
Bar (b) Atmosphere (atm) Pascals (Pa)
(kg/cm2) (lb/in.2)
1.0000 0.9869 1.0197 14.5038 100,000

1.0132 1.0000 1.0332 14.6959 101,325
0.9807 0.9678 1.0000 14.2233 98,066
0.0689 0.0680 0.0703 1.0000 6,895
The SI units shown in this manual are direct temperatures, torque values, pressures, etc. Examples
mathematical conversions and may be rounded off, in of SI units that may not be rounded off are those used
most instances, at the user's discretion. Examples of for drop checks, rigging adjustments, runouts, etc.
units that may be rounded off are those used for

/03) *(.

Table 1-3. Temperature Conversion Chart
To convert a temperature between Fahrenheit and Celsius, find the temperature (either Celsius or
Fahrenheit) in one of the blue grey columns of this three-page table and read its Fahrenheit
equivalent in the right column (under °F) or its Celsius equivalent in the left column (under °C).
For example, to convert a temperature of 32°F to Celsius, find 32 in the center column and its Celsius
equivalent of 0.0° is in the left column. Conversely, to convert 32°C to Fahrenheit, find 32 in the
center column, and its Fahrenheit equivalent of 89.6° is in the right column.
Temperatures between 0 and 100 (in the blue grey column) are converted to one decimal place under
°F or °C. All other temperatures are converted to a whole number under °F or °C.
Temperature Conversion Formulas
Temperature (°C) = (Temperature °F - 32) ÷ 1.8 Temperature (°F) = (1.8 x Temperature °C) + 32
°C °F °C °F °C °F °C °F °C °F °C °F
-51 -60 -76 -7.2 19 66.2 6.7 44 111.2 20.6 69 156.2 34.4 94 201.2 143 290 554
-46 -50 -58 -6.7 20 68.0 7.2 45 113.0 21.1 70 158.0 35.0 95 203.0 149 300 572
-40 -40 -40 -6.1 21 69.8 7.8 46 114.8 21.7 71 159.8 35.6 96 204.8 154 310 590
-34 -30 -22 -5.6 22 71.6 8.3 47 116.6 22.2 72 161.6 36.1 97 206.6 160 320 608
-29 -20 -4 -5.0 23 73.4 8.9 48 118.4 22.8 73 163.4 36.7 98 208.4 166 330 626
-23 -10 14 -4.4 24 75.2 9.4 49 120.2 23.3 74 165.2 37.2 99 210.2 171 340 644
-17.8 0 32 -3.9 25 77.0 10.0 50 122.0 23.9 75 167.0 37.8 100 212.0 177 350 662
-17.2 1 33.8 -3.3 26 78.8 10.6 51 123.8 24.4 76 168.8 43 110 230 182 360 680
-16.7 2 35.6 -2.8 27 80.6 11.1 52 125.6 25.0 77 170.6 49 120 248 188 370 698
-16.1 3 37.4 -2.2 28 82.4 11.7 53 127.4 25.6 78 172.4 54 130 266 193 380 716
-15.6 4 39.2 -1.7 29 84.2 12.2 54 129.2 26.1 79 174.2 60 140 284 199 390 734
-15.0 5 41.0 -1.1 30 86.0 12.8 55 131.0 26.7 80 176.0 66 150 302 204 400 752
-14.4 6 42.8 -0.6 31 87.8 13.3 56 132.8 27.2 81 177.8 71 160 320 210 410 770
-13.9 7 44.6 0.0 32 89.6 13.9 57 134.6 27.8 82 179.6 77 170 338 216 420 788
-13.3 8 46.4 0.6 33 91.4 14.4 58 136.4 28.3 83 181.4 82 180 356 221 430 806
-12.8 9 48.2 1.1 34 93.2 15.0 59 138.2 28.9 84 183.2 88 190 374 227 440 824
-12.2 10 50.0 1.7 35 95.0 15.6 60 140.0 29.4 85 185.0 93 200 392 232 450 842
-11.7 11 51.8 2.2 36 96.8 16.1 61 141.8 30.0 86 186.8 99 210 410 238 460 860
-11.1 12 53.6 2.8 37 98.6 16.7 62 143.6 30.6 87 188.6 104 220 428 243 470 878
-10.6 13 55.4 3.3 38 100.4 17.2 63 145.4 31.1 88 190.4 110 230 446 249 480 896
-10.0 14 57.2 3.9 39 102.2 17.8 64 147.2 31.7 89 192.2 116 240 464 254 490 914
-9.4 15 59.0 4.4 40 104.0 18.3 65 149.0 32.2 90 194.0 121 250 482 260 500 932
-8.9 16 60.8 5.0 41 105.8 18.9 66 150.8 32.8 91 195.8 127 260 500 266 510 950
-8.3 17 62.6 5.6 42 107.6 19.4 67 152.6 33.3 92 197.6 132 270 518 271 520 968
-7.8 18 64.4 6.1 43 109.4 20.0 68 154.4 33.9 93 199.4 138 280 536 277 530 986

*(. /03)

Table 1-3. Temperature Conversion Chart (Continued)
°C °F °C °F °C °F °C °F °C °F °C °F
282 540 1004 477 890 1634 671 1240 2264 866 1590 2894 1060 1940 3524 1254 2290 4154
288 550 1022 482 900 1652 677 1250 2282 871 1600 2912 1066 1950 3542 1260 2300 4172
293 560 1040 488 910 1670 682 1260 2300 877 1610 2930 1071 1960 3560 1266 2310 4190
299 570 1058 493 920 1688 688 1270 2318 882 1620 2948 1070 1970 3578 1271 2320 4208
304 580 1076 499 930 1706 693 1280 2336 888 1630 2966 1082 1980 3596 1277 2330 4226
310 590 1094 504 940 1724 699 1290 2354 893 1640 2984 1088 1990 3614 1282 2340 4244
316 600 1112 510 950 1742 704 1300 2372 899 1650 3002 1093 2000 3632 1288 2350 4262
321 610 1130 516 960 1760 710 1310 2390 904 1660 3020 1099 2010 3650 1293 2360 4280
327 620 1148 521 970 1778 716 1320 2408 910 1670 3038 1104 2020 3668 1299 2370 4298
332 630 1166 527 980 1796 721 1330 2426 916 1680 3056 1110 2030 3686 1304 2380 4316
338 640 1184 532 990 1814 727 1340 2444 921 1690 3074 1116 2040 3704 1310 2390 4334
343 650 1202 538 1000 1832 732 1350 2462 927 1700 3092 1121 2050 3722 1316 2400 4352
349 660 1220 543 1010 1850 738 1360 2480 932 1710 3110 1127 2060 3740 1321 2410 4370
354 670 1238 549 1020 1868 743 1370 2498 938 1720 3128 1132 2070 3758 1327 2420 4388
360 680 1256 554 1030 1886 749 1380 2516 943 1730 3146 1138 2080 3776 1332 2430 4406
366 690 1274 560 1040 1904 754 1390 2534 949 1740 3164 1143 2090 3794 1338 2440 4424
371 700 1292 566 1050 1922 760 1400 2552 954 1750 3182 1149 2100 3812 1343 2450 4442
377 710 1310 571 1060 1940 766 1410 2570 960 1760 3200 1154 2110 3830 1349 2460 4460
382 720 1328 577 1070 1958 771 1420 2588 966 1770 3218 1160 2120 3848 1354 2470 4478
388 730 1346 582 1080 1976 777 1430 2606 971 1780 3236 1166 2130 3866 1360 2480 4496
393 740 1364 588 1090 1994 782 1440 2624 977 1790 3254 1171 2140 3884 1366 2490 4514
399 750 1382 593 1100 2012 788 1450 2642 982 1800 3272 1177 2150 3902 1371 2500 4532
404 760 1400 599 1110 2030 793 1460 2660 988 1810 3290 1182 2160 3920 1377 2510 4550
410 770 1418 604 1120 2048 799 1470 2678 993 1820 3308 1188 2170 3938 1382 2520 4568
416 780 1436 610 1130 2066 804 1480 2696 999 1830 3326 1193 2180 3956 1388 2530 4586
421 790 1454 616 1140 2084 810 1490 2714 1004 1840 3344 1199 2190 3974 1393 2540 4604
427 800 1472 621 1150 2102 816 1500 2732 1010 1850 3362 1204 2200 3992 1399 2550 4622
432 810 1490 627 1160 2120 821 1510 2750 1016 1860 3380 1210 2210 4010 1404 2560 4640
438 820 1508 632 1170 2138 827 1520 2768 1021 1870 3398 1216 2220 4028 1410 2570 4658
443 830 1526 638 1180 2156 832 1530 2786 1027 1880 3416 1221 2230 4046 1416 2580 4676
449 840 1544 643 1190 2174 838 1540 2804 1032 1890 3434 1227 2240 4064 1421 2590 4694
454 850 1562 649 1200 2192 843 1550 2822 1038 1900 3452 1232 2250 4082 1427 2600 4712
460 860 1580 654 1210 2210 849 1560 2840 1043 1910 3470 1238 2260 4100 1432 2610 4730
466 870 1598 660 1220 2228 854 1570 2858 1049 1920 3488 1243 2270 4118 1438 2620 4748
471 880 1616 666 1230 2246 860 1580 2876 1054 1930 3506 1249 2280 4136 1443 2630 4766

/03) *(.

Table 1-3. Temperature Conversion Chart (Continued)
°C °F °C °F °C °F °C °F °C °F °C °F
1449 2640 4784 1482 2700 4892 1516 2760 5000 1549 2820 5108 1582 2880 5216 1616 2940 5324
1454 2650 4802 1488 2710 4910 1521 2770 5018 1554 2830 5126 1588 2890 5234 1621 2950 5342
1460 2660 4820 1493 2720 4928 1527 2780 5036 1560 2840 5144 1593 2900 5252 1627 2960 5360
1466 2670 4838 1499 2730 4946 1532 2790 5054 1566 2850 5162 1599 2910 5270 1632 2970 5378
1471 2680 4856 1504 2740 4964 1538 2800 5072 1571 2860 5180 1604 2920 5288 1638 2980 5396
1477 2690 4874 1510 2750 4982 1543 2810 5090 1577 2870 5198 1610 2930 5306 1643 2990 5414
1649 3000 5432

*(. /03)

Table 1-4. Conversion Table - Fractions to Decimals to Metric
Fraction Decimal (in.) Metric (mm) Fraction Decimal (in.) Metric (mm)
1/64 0.0156 (0.396) 33/64 0.5156 (13.096)
1/32 0.0312 (0.792) 17/32 0.5312 (13.492)
3/64 0.0469 (1.191) 35/64 0.5469 (13.891)
1/16 0.0625 (1.588) 9/16 0.5625 (14.288)
5/64 0.0781 (1.984) 37/64 0.5781 (14.684)
3/32 0.0937 (2.380) 19/32 0.5937 (15.080)
7/64 0.1094 (2.779) 39/64 0.6094 (15.479)
1/8 0.1250 (3.175) 5/8 0.6250 (15.875)
9/64 0.1406 (3.571) 41/64 0.6406 (16.271)
5/32 0.1562 (3.967) 21/32 0.6562 (16.576)
11/64 0.1719 (4.366) 43/64 0.6719 (17.066)
3/16 0.1875 (4.763) 11/16 0.6875 (17.463)
13/64 0.2031 (5.159) 45/64 0.7031 (17.859)
7/32 0.2187 (5.555) 23/32 0.7187 (18.255)
15/64 0.2344 (5.954) 47/64 0.7344 (18.654)
1/4 0.2500 (6.350) 3/4 0.7500 (19.050)
17/64 0.2656 (6.746) 49/64 0.7656 (19.446)
9/32 0.2812 (7.142) 25/32 0.7812 (19.842)
19/64 0.2969 (7.541) 51/64 0.7969 (20.241)
5/16 0.3125 (7.938) 13/16 0.8125 (20.638)
21/64 0.3281 (8.334) 53/64 0.8281 (21.034)
11/32 0.3437 (8.730) 27/32 0.8437 (21.430)
23/64 0.3594 (9.129) 55/64 0.8594 (21.829)
3/8 0.3750 (9.525) 7/8 0.8750 (22.225)
25/64 0.3906 (9.921) 57/64 0.8906 (22.621)
13/32 0.4062 (10.317) 29/32 0.9062 (23.017)
27/64 0.4219 (10.716) 59/64 0.9219 (23.416)
7/16 0.4375 (11.113) 15/16 0.9375 (23.813)
29/64 0.4531 (11.509) 61/64 0.9531 (24.209)
15/32 0.4687 (11.905) 31/32 0.9687 (24.605)
31/64 0.4844 (12.304) 63/64 0.9844 (25.004)
1/2 0.5000 (12.700) 1 1.0000 (25.400)

/03) *(.

1-6 Glossary of Terms • CADMIUM, CAS # 7440-43-9
Table 1-5 lists and defines the abbreviations most • COBALT DICHLORIDE, CAS #
commonly used in this manual. 7646-79-9
• 4,4'-DIAMINODIPHENYLMETHANE (MDA),
1-7 Safety Precautions CAS # 101-77-9
This technical manual is designed to provide safe • HEXAVALENT CHROMIUM, CAS # 7440-47-3
procedures and processes for accomplishing the
installation, operation, and maintenance tasks required • AMMONIUM DICHROMATE, CAS # 7789-09-5
for the LM6000. It is therefore very important that all
Warnings and Cautions be clearly understood and • LEAD CHROMATE, CAS # 7758-97-6
observed by users of this manual.
• LEAD CHROMATE MOLYBATE
This section describes general safety precautions that SULFATE, CAS # 12656-85-8
are not related to specific procedures and therefore do
not appear elsewhere in this manual. The precautions • LEAD SULFOCHROMATE YELLOW,
should be clearly understood and applied wherever CAS # 1344-37-2
appropriate in all phases of installation, operation, and
maintenance. • POTASSIUM CHROMATE, CAS
# 7789-00-06
1-7.1 Hazardous and Regulated Material • POTASSIUM DICHROMATE, CAS # 7778-50-9
WARNING • SODIUM CHROMATE, CAS # 7775-11-3
• SODIUM DICHROMATE, DIHYDRATE, CAS

# 7789-12-0
• STRONTIUM CHROMATE, CAS

# 7789-06-2
: 3 0
• ZINC CHROMATE PRIMER, CAS # 11103-86-9
BEFORE MAINTENANCE, OBEY THE
PRECAUTIONS THAT FOLLOW. • KRYPTON 85, Kr-85, CAS # 13983-27-2
Part numbers with the ' symbol after them contain • REFRACTORY CERAMIC FIBERS (RCF),
hazardous or regulated materials. THORIUM, Th-232/Th-228, CAS # 7440-29-1
Example: 9644M07G01 ' • URANIUM, U-238, CAS # 7440-61-1
Refer to the subsequent list to find the types of BEFORE MAINTENANCE STARTS, LOOK IN THE
hazardous or regulated material in parts. ILLUSTRATED PARTS BREAKDOWN (IPB)
MANUAL TO SEE IF THE PART CONTAINS
Obey all warnings in all manuals. HAZARDOUS OR REGULATED MATERIALS.
PARTS CAN CONTAIN THE SUBSEQUENT BEFORE YOU REMOVE MATERIAL FROM
HAZARDOUS OR REGULATED MATERIAL: PARTS THAT CONTAIN HAZARDOUS OR
REGULATED MATERIALS, YOU MUST PUT ON
• ASBESTOS, CAS # 1332-21-4 PERSONAL PROTECTIVE EQUIPMENT AND

*(. /03)

OBEY ALL SPECIFIED SITE, LOCAL, STATE, NOTE

AND REGULATORY PROCEDURES. ZIRCONIUM ON PARTS CAN CONTAIN SMALL
AMOUNTS OF RADIOACTIVE MATERIAL:
READ THE MATERIAL SAFETY DATA SHEET
(MSDS) AND OTHER PRODUCT DATA TO • THORIUM, Th-232/Th-228, CAS #
CORRECTLY USE MATERIALS THAT CAN 7440-29-1
DAMAGE THE ENVIRONMENT IF USED
INCORRECTLY. • URANIUM, U-238, CAS # 7440-61-1
BEFORE YOU MOVE OR DISCARD HAZARDOUS SAFETY RISKS ARE SMALL.
OR REGULATED MATERIALS, YOU MUST OBEY
ALL SPECIFIED SITE, LOCAL, STATE, AND BEFORE YOU MOVE OR DISCARD HAZARDOUS
REGULATORY PROCEDURES. OR REGULATED MATERIALS, YOU MUST OBEY
ALL SPECIFIED SITE, LOCAL, STATE, AND
1-7.2 Ionizing Radiation Hazards REGULATORY PROCEDURES.
NOTE
:
THE IGNITION EXCITER CONTAINS A

CONTROLLED AMOUNT OF RADIOACTIVE
MATERIAL:
• KRYPTON 85, Kr-85, CAS # 13983-27-2
POTENTIAL SAFETY AND EXPOSURE RISKS

ARE NEGLIGIBLE GIVEN THE ACTUAL
RADIATION LEVELS AS DETERMINED BY
TESTING AND ANALYSIS, THE TYPE OF
RADIATION EMITTED, AND THE LOCATION
WITHIN A CLOSED IONIZATION CHAMBER.
ADDITIONAL INSTRUCTIONS ARE AVAILABLE.

/03) *(.

Table 1-5. Abbreviations

*(. /03)

Table 1-5. Abbreviations (Continued)

/03) *(.

1-7.3 Chemical Hazards WARNING
WARNING
: 0 0
: 0 DO NOT GET CHEMICALS IN YOUR EYES. PUT

ON GOGGLES AND OTHER SAFETY
READ THE PRODUCT LABEL AND THE EQUIPMENT TO PREVENT EYE INJURY. IF
MANUFACTURER’S (MATERIAL) SAFETY DATA CHEMICALS GET IN YOUR EYES, FLUSH EYES
SHEET FOR INSTRUCTIONS ON THE HAZARDS, IMMEDIATELY AND GET MEDICAL AID.
STORAGE, SAFE HANDLING AND PROPER USE
OF THIS PRODUCT. WARNING
WARNING
: 0
: DO NOT LET CHEMICALS TOUCH YOUR SKIN.

PUT ON GLOVES AND OTHER SAFETY
DO NOT BREATHE CHEMICAL FUMES EQUIPMENT TO COVER SKIN. IMMEDIATELY
BECAUSE FUMES CAN BE POISONOUS. USE REMOVE CHEMICALS FROM SKIN WITH SOAP.
CHEMICALS IN APPROVED AREAS WITH
AIRFLOW TO REMOVE FUMES. WARNING
WARNING
:
: 0 0 0 DO NOT SPILL COLD CHEMICALS ON YOUR

SKIN. EVAPORATION OR CHEMICALS THAT
APPLY PAINT IN APPROVED ISOLATED AREAS DRY QUICKLY CAN CAUSE INJURY.
WITH AIRFLOW TO REMOVE FUMES. MAKE
SURE AREA LIGHTS AND ELECTRICAL
EQUIPMENT CAN NOT CAUSE AN EXPLOSION.
DO NOT BREATHE THE PAINT FUMES BECAUSE

FUMES CAN BE POISONOUS. PUT ON MASK,
GOGGLES, AIR FILTER, AND OTHER SAFETY
EQUIPMENT. PUT ON PROTECTIVE CLOTHES
TO COVER SKIN.

*(. /03)

WARNING WARNING
: :
DO NOT LET ADHESIVES BOND YOUR SKIN USE ONLY APPROVED CONTAINERS FOR
TOGETHER OR TO OTHER OBJECTS. IF SKIN STORAGE OF FLAMMABLE CHEMICALS. KEEP
BONDS TOGETHER OR TO OTHER OBJECTS, THE COVER ON THE CHEMICAL CONTAINER
GET MEDICAL AID IMMEDIATELY. DO NOT WHEN NOT IN USE.
FORCE THE SEPARATION OF BONDED SKIN.
1-7.5 Electrical Hazards
1-7.4 Fire Hazards
WARNING
WARNING
:
:
ELECTRICAL EQUIPMENT CAN SHOCK, BURN,
KEEP FLAMMABLE CHEMICALS AWAY FROM CAUSE OTHER INJURIES, OR DEATH. MAKE
HOT SURFACES, FLAMES, OR SPARKS. MAKE SURE ONLY APPROVED PERSONNEL WORK
SURE THE CORRECT FIRE PROTECTION WITH ELECTRICAL EQUIPMENT. MAKE SURE
EQUIPMENT IS AVAILABLE. ELECTRICAL EQUIPMENT IS ISOLATED TO
PREVENT INJURY.
WARNING
DO NOT CONNECT OR DISCONNECT
ELECTRICAL PARTS DURING OPERATION.
BEFORE YOU ADJUST ELECTRICAL PARTS, DE-
ENERGIZE THE ELECTRICAL SOURCE.
: 3
DO NOT SMOKE NEAR FLAMMABLE FUMES.

ADHESIVES, FUELS, OILS, AND SOLVENTS
RELEASE FLAMMABLE FUMES.

/03) *(.

WARNING REFER TO ASSEMBLY PARTS LISTS TO FIND

APPROVED ELECTRICAL COMPONENTS FOR
SAFE OPERATION.
USE OF REPLACEMENT ELECTRICAL

COMPONENTS, NOT APPROVED BY
: HAZARDOUS AREA CERTIFICATES AND
INSTRUCTIONS, CAN INCREASE THE RISK OF
IGNITION EXCITERS CAN CAUSE ELECTRICAL FIRE OR EXPLOSION AND CAN PREVENT OR
SHOCK. CANCEL ALL CERTIFICATIONS.
DO NOT ENERGIZE UNLESS IGNITION EXCITER 1-7.6 Tooling Hazards

OUTPUT CONNECTION IS ISOLATED, EXCITER
INPUT CONNECTION IS INSTALLED, OR IN AN WARNING
ISOLATED TEST CHAMBER.
DO NOT ENERGIZE UNLESS PERSONNEL ARE

AT LEAST 5.0 FEET (1.5 METERS) AWAY.
WARNING
:
INCORRECT TOOL MAINTENANCE CAN INJURE

PERSONNEL AND DAMAGE PARTS. OBEY
RECOMMENDED INSPECTIONS TO PREVENT
:
POSSIBLE FAILURES.
THE INSTALLATION AND OPERATION OF USE TOOLS CORRECTLY. LOOK FOR DAMAGE
EQUIPMENT MUST AGREE WITH APPROVED TO TOOLS AND START APPROVED REPAIR
HAZARDOUS AREA CERTIFICATES AND IMMEDIATELY.
INSTRUCTIONS.
WARNING
USE ONLY APPROVED ELECTRICAL
COMPONENTS FOR SAFE OPERATION. REFER
TO INSTRUCTION MANUAL FOR ELECTRICAL
RATINGS.
CERTIFICATES INCLUDE GE AVIATION :

TURBINE IF ATTACHED.
OBEY MANUFACTURER’S INSTRUCTIONS
SPECIAL REGULATORY NOTE: FULLY TO PREVENT DANGEROUS OPERATION
OF TOOL. BEFORE A TORQUE MULTIPLIER IS
PART NUMBERS WITH A (EU CERTIFIED) USED, CHECK THE TORQUE CAPACITY OF THE
NOTE AFTER THEM ARE APPROVED TOOL.
ELECTRICAL COMPONENTS FOR
OPERATION IN THE EUROPEAN UNION (EU)
AND COUNTRIES THAT ACCEPT THE EU
DIRECTIVES.

*(. /03)

NOTE WARNING
: 0 :
DO NOT USE METRIC TOOLS ON PARTS OR IF AIR PRESSURE IS USED TO REMOVE

ITEMS MADE TO UNITED STATES (US) UNITS UNWANTED MATERIALS FROM PARTS, USE IN
OF MEASURE. METRIC TOOLS CAN VOID PART APPROVED AREA TO PREVENT INJURY AND
WARRANTY. EQUIPMENT DAMAGE.
MAKE SURE METRIC TOOLS HAVE ADAPTERS CAUTION

TO CONNECT TO TOOLS WITH US UNITS. USE
US AND METRIC UNIT TABLES TO CALCULATE
CLEARANCES.
1-7.7 Compressed Air Hazards

:
WARNING
BEFORE OPERATION OF COMPRESSED AIR TO
COOL, CLEAN, OR DRY PARTS, MAKE SURE
THE AMOUNT OF AIR PRESSURE CANNOT
DAMAGE PARTS.
: 0 0 1-7.8 Hot or Cold Parts Hazards

KEEP COMPRESSED AIR PRESSURE IN WORK WARNING
AREA TO 29 PSI (200 KPA) OR LESS.
PUT ON PERSONAL PROTECTIVE EQUIPMENT

(PPE) TO PREVENT EYE INJURY.
DO NOT POINT COMPRESSED AIR OUTLET AT

YOUR SELF OR OTHER PERSONNEL. : 0
PUT ON GLOVES WITH THERMAL

INSULATION TO HOLD PARTS AND PREVENT
INJURY. IN VERY LOW TEMPERATURE, -65°F
TO -40°F (-54°C TO -40°C), PARTS QUICKLY
FREEZE SKIN.

/03) *(.

WARNING WARNING
: 0 :
PUT ON GLOVES WITH THERMAL INSULATION DO NOT ALIGN OR CHECK PART HOLES OR
TO HOLD PARTS AND PREVENT INJURY. SLOTS WITH YOUR FINGERS. DO NOT USE A
TEMPERATURES HIGHER THAN 104°F (40°C) LESS NUMBER OF BOLTS, OR SHORTER
CAN BURN SKIN. IF BURNED, GET MEDICAL LENGTH, OR LOWER QUALITY BOLTS THAN
AID IMMEDIATELY. REQUIRED.
1-7.9 Procedural Hazards 1-7.10 Operating Hazards

WARNING WARNING
: 0 : 0
READ ALL WARNINGS TO PREVENT INJURY OR THE GAS TURBINE DOES NOT HAVE
DAMAGE TO EQUIPMENT. OBEY SAFETY INSULATION. DO NOT TOUCH HOT GAS
PROCEDURES TO ASSEMBLE AND TURBINE SURFACES. PUT ON GLOVES WITH
DISASSEMBLE EQUIPMENT. THERMAL INSULATION TO PREVENT INJURY.
HOT TEMPERATURES CAN BURN SKIN. IF
WARNING BURNED, GET MEDICAL AID IMMEDIATELY.
WARNING
: 0
PUT ON GOGGLES AND OTHER PERSONAL : 0

PROTECTIVE EQUIPMENT TO WORK WITH
LOCKWIRE. DO NOT LET LOCKWIRE PUT ON EAR PROTECTION DURING
PARTICLES HIT YOUR EYES OR OTHER OPERATION. THE GAS TURBINE MAKES A
PERSON’S EYES WHEN CUT. VERY LOUD NOISE.

*(. /03)

WARNING WARNING
: 3 :
THE GAS TURBINE ROTATES AT A VERY HIGH MAKE SURE FIRE EXTINGUISHER EQUIPMENT
SPEED. THE GAS TURBINE CASE CANNOT STOP IS AVAILABLE DURING INSTALLATION.
ALL FAILED ROTOR FRAGMENTS.
USE CARBON DIOXIDE, HALIDES, FOG, WATER,
DO NOT LOCATE FUEL PIPES, VALVES, OR OR CHEMICAL FIRE EXTINGUISHER SYSTEMS.
CONTROL EQUIPMENT IN GAS TURBINE
PLANE OF ROTATION. IF THE FIRE EXTINGUISHERS DISCHARGE
WHILE PERSONNEL ARE INSIDE THE
ADD GUARDS TO EQUIPMENT LOCATED IN ENCLOSURE, SEND ALL PERSONNEL OUT OF
THE GAS TURBINE PLANE OF ROTATION. DO THE ENCLOSURE TO PREVENT INGESTION OF
NOT LOCATE PERSONNEL STATIONS IN THE EXTINGUISHER CHEMICALS.
GAS TURBINE PLANE OF ROTATION.
FIRE EXTINGUISHER CHEMICAL CAN GET ON
THE STARTER ROTATES AT A VERY HIGH GAS TURBINE CASES WITHOUT DAMAGE.
SPEED. DO NOT LOCATE PERSONNEL
STATIONS IN THE STARTER PLANE OF AFTER FIRE EXTINGUISHER DISCHARGES,
ROTATION. DISASSEMBLE AND CLEAN THE GAS TURBINE.
WARNING WARNING
: 3 :
DO NOT LET PERSONNEL NEAR THE GAS SPECIAL DETECTORS SENSE FUEL LEAKS IN
TURBINE INLET DURING OPERATION. THE GAS THE ENCLOSURE AND STOP THE GAS
TURBINE AIRFLOW CAN PULL OBJECTS AND TURBINE.
PERSONNEL INTO THE GAS TURBINE.
BEFORE RESTART, FIND AND CORRECT THE
CAUSE OF THE FUEL LEAK.
BEFORE RESTART, CLEAR THE ENCLOSURE

AND ADJACENT AREA OF FUMES.

/03) *(.

WARNING 1-7.11 SPRINT System Hazard
WARNING
:
GAS TURBINES USE A NUMBER OF :

DETECTORS AND CONTROLS NECESSARY FOR
SAFE OPERATION. DO NOT BYPASS THE PROTECTIVE CONTROL
FUNCTION IN THE SPRINT® SYSTEM.
A BYPASSED DETECTOR OR CONTROL CAN
DAMAGE THE GAS TURBINE. THIS INCLUDES DO NOT OPERATE THE SPRINT® SYSTEM TO
BYPASS OF A SENSOR WITH MORE THAN ONE CLEAN THE COMPRESSOR DURING A CRANK
OF THE SAME SENSOR. SOAK.
FOR EXAMPLE: THE ATOMIZED WATER ENTERS THE ROTOR

COOLING HOLES AND CAN CAUSE WATER TO
• ONE BYPASSED EXHAUST GAS COLLECT IN THE ROTOR BORE. THIS CAN
TEMPERATURE SENSOR CAN CAUSE THE TURBINE TO BE OUT OF BALANCE
DAMAGE THE HIGH PRESSURE AND DAMAGE THE GAS TURBINE.
TURBINE
1-7.12 Enclosure Access Hazard
• A BYPASSED VIBRATION SENSOR CAN
DAMAGE THE GAS TURBINE. WARNING
WARNING
W001 P004
: DO NOT LET PERSONNEL ACCESS THE GAS
TURBINE ENCLOSURE DURING OPERATION.
DO NOT OVERRIDE GAS TURBINE CONTROL
PROTECTIVE FUNCTIONS. BEFORE PERSONNEL ENTER THE ENCLOSURE,
STOP THE GAS TURBINE.
OVERRIDE CAN CAUSE GAS TURBINE
PROBLEMS, DAMAGE, AND INJURE DURING OPERATION, KEEP AWAY FROM
PERSONNEL. ENCLOSURE DOORS. DO NOT LOOK THROUGH
ENCLOSURE WINDOWS. PUT ON EAR
PROTECTION.
MAKE SURE ONLY APPROVED PERSONNEL

MEASURE VOLTAGE DURING OPERATION. IF
ACCESS IS NECESSARY DURING OPERATION,
SPEAK TO PERSONNEL, APPROVED BY GE
FIELD SERVICE, TO ENTER THE ENCLOSURE.

*(. /03)

STOP THE ENCLOSURE AIRFLOW. IT IS SPECIAL REGULATORY NOTES:

POSSIBLE FOR DOORS TO NOT OPEN OR CLOSE
WITH AIRFLOW ON. KEEP THE ENCLOSURE THE (CE MARKED) NOTE AFTER THE PART
DOORS OPEN. NUMBER SHOWS THE PARTS ARE MARKED
AND APPROVED PRESSURE EQUIPMENT
OBEY PROCEDURES TO ENTER A CONFINED FOR OPERATION IN THE EUROPEAN UNION
SPACE. MAKE SURE A SECOND PERSON IS (EU) AND COUNTRIES THAT ACCEPT THE EU
NEAR AND MONITORS ENCLOSURE DOORS AT PRESSURE EQUIPMENT DIRECTIVE 97/23/EC.
ALL TIMES.
THE (AS1210 CERTIFIED AND ASME
STOP THE FIRE EXTINGUISHER SYSTEM. LET CERTIFIED) NOTE AFTER THE PART
THE GAS TURBINE COOL DOWN. DO NOT NUMBER SHOWS THE PARTS ARE MARKED
TOUCH HOT GAS TURBINE PARTS. PUT ON AND APPROVED PRESSURE EQUIPMENT
GLOVES WITH THERMAL INSULATION. FOR OPERATION IN THE UNITED STATES,
AUSTRALIA, AND COUNTRIES THAT
DURING MAINTENANCE, DE-ENERGIZE ACCEPT THESE STANDARDS.
ELECTRICAL COMPONENTS TO PREVENT
SHOCKS AND BURNS. REFER TO THE ASSEMBLY PARTS LIST TO FIND
THE APPROVED PRESSURE EQUIPMENT.
INSTALL SAFETY LOCKS ON CONTROLS TO
PREVENT ACCIDENTAL START OF GAS OPERATION OR REPLACEMENT PRESSURE
TURBINE. EQUIPMENT, NOT CERTIFIED, CAN PREVENT
OR CANCEL ALL EQUIPMENT
MAKE SURE PORTABLE FIRE PROTECTION CERTIFICATIONS.
EQUIPMENT IS AVAILABLE.
CAUTION
1-7.13 Replacement Parts Hazard
WARNING
:
IF SHIPPING DOCUMENTS OR PART NUMBER

: DOES NOT AGREE WITH THE PART
IDENTIFICATION IN THE IPB, SPEAK TO YOUR
DO NOT USE AIRCRAFT ENGINE PARTS ON GE CUSTOMER SERVICE MANAGER.
MARINE AND INDUSTRIAL GAS TURBINES.
USE ONLY APPROVED PARTS FROM THE THE GE CUSTOMER SERVICE MANAGER
ILLUSTRATED PARTS BREAKDOWN (IPB) MAKES SURE THE PART NUMBER IS CORRECT
MANUAL. BEFORE INSTALLATION AND CAN PREVENT
INSTALLATION OF THE WRONG PART AND
POSSIBLE DAMAGE TO THE GAS TURBINE.

/03) *(.

1-8 Special Inspections turbines exposed to abnormal conditions. These may

include, for example, failures with significant damage
The maintenance of the gas turbine requires that and other abnormal exposure such as an installation
inspection checks be made periodically. The inspection fire or mishap during transportation, handling, or
requirements and limits throughout this manual are storage. This manual includes routine inspection
based on operation within specified limits. In addition requirements to be accomplished for preventive
to the regular inspections, there are those necessary maintenance and for troubleshooting. It also includes
when the gas turbine has been operated outside of the criteria for determining if special inspections are
specified limits, for example, off-schedule variable necessary because of exposure to abnormal
geometry operation, overspeed, or overtemperature. conditions. Refer to Chapter 9 for Abnormal Operation
There are also special inspections necessary for gas and Special Inspections.
%ODQN
/03) *(.

Chapter 2
Gas Turbine General Description and Model Summary
2-1 Purpose and Scope Air enters the gas turbine at the VIGV and passes into
the LPC. The LPC compresses the air by a ratio of
This chapter provides a general description of the approximately 2.5:1. Air leaving the LPC is directed
LM6000 PF+ Gas Turbine and its design features into the HPC. Variable bypass valves (VBV) are
(figure 2-1). It also summarizes the various model arranged in the flow passage between the two
configurations available. Standard and optional compressors to regulate the airflow entering the HPC at
equipment lists are also provided. idle and at low power. To further control the airflow,
the HPC is equipped with variable stator vanes (VSVs).
2-2 General Description and The HPC compresses the air to a ratio of approximately
15:1, resulting in a total compression ratio of 37:1,
Features relative to ambient. From the HPC, the air is directed
into the triple annular combustor section, where it
2-2.1 General Description mixes with the fuel from the 75 air/gas premixers that
are packaged in 30 externally removable modules. The
The LM6000 PF+ is a dual-rotor gas turbine that fuel/air mixture is initially ignited by an igniter and,
consists of a variable inlet guide vane assembly once combustion is self-sustaining, the igniter is turned
(VIGV), a 5-stage low pressure compressor (LPC), a off. The hot gas that results from combustion is
14-stage variable-geometry high pressure compressor directed into the HPT which drives the HPC. This gas
(HPC), a dual annular combustor, a 2-stage high further expands through the LPT, which drives the LPC
pressure turbine (HPT), a 5-stage low pressure turbine and the output load.
(LPT), an accessory gearbox assembly (AGB), and
accessories.
2-2.2 Model Summary
The low pressure (LP) rotor consists of the LPC and
The information in this manual covers LM6000 PF+
the LPT that drive it. Attachment flanges are available
Gas Turbine models listed in table 2-1. Additional
on both the front and/or rear of the LP rotor for
model designations will be assigned based on
connection to the packager-supplied power shaft and
configuration requirements for future applications.
load. The high pressure (HP) rotor consists of the
14-stage HPC and the 2-stage HPT that drive it. The
HP core consists of the HPC, the combustor, and the
HPT. The HPT and LPT drive the HPC and LPC
through concentric drive shafts.
Table 2-1. LM6000 PF+ Model Summary

Model Designation Description
LM6000-PF1-NGD Gas fuel; equipped with gas fuel manifold and 75 air/gas premixers that are
packaged in 30 externally removable modules; 12 staging valves.
LM6000-PF1-NDD Dual Fuel; equipped with gas fuel manifold and 75 air/gas premixers that are
packaged in 30 externally removable modules; 12 gas staging valves and 18 liquid
staging valves.

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Figure 2-1. LM6000 PF+ Gas Turbine Section Identification (Sheet 1 of 2)

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Figure 2-1. LM6000 PF+ Gas Turbine Section Identification (Sheet 2 of 2)

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2-2.3 Summary of Changes from the 2-2.4 Standard and Optional Equipment
LM6000 PF
The LM6000 PF+ Gas Turbine comes fully assembled
The latest configuration of the LM6000 DLE is with the following standard equipment installed and
designated the PF+ model and incorporates changes to tested at the factory:
the combustor, fuel system, HPT, and LPT airfoils.
• Single-stage VIGV system
The LM6000 PF+ LPC is common with that in the
LM6000 PF, but has a new shaft and stage 0 blade aero • Five-stage LPC
optimization.
• LPC discharge bypass air collector and actuators
The HPC rotating structure has been redesigned to
accommodate higher gas path pressures and • 14-stage HPC
temperatures. Airfoil material changes and improved
• Triple annular combustor
performance features of super finish and leading edge
profile are incorporated. The compressor rear frame • Fuel system (premixers, connectors, manifolds,
has changes for increased flow and improved cooling and staging valves)
technology.
• Eighth stage and compressor discharge bleed
The LM6000 PF+ combustion system (fuel system) is valves (off engine)
similar to the PF with optimization for emissions and
heat shield cooling. One gas staging valve is replaced • Ignition system (igniter and exciter)
with an orifice in both the gas and dual fuel systems
and the associated gas fuel tube and electrical harness • Two-stage HPT
configuration is changed.
• Five-stage LPT with PCC system
The HPT is a new design derived from the CF6-80E.
Rotor construction and new materials in the rotor and • Output shaft coupling adapter
airfoils are introduced along with cooling changes in
the airfoils and stator. • AGB assembly, consisting of the transfer gearbox
and the AGB
The LM6000 PF+ LPT has a higher temperature
capability case and redesigned airfoils in all stages. • AGB-driven lube oil supply and scavenge pumps
New materials and coatings are introduced for and gas turbine-mounted interconnecting piping
improved durability. The Passive Clearance Control
• Forward side-mount trunnions
(PCC) system has also been redesigned to improve
LPT case cooling and PCC durability. The aft drive • Aft-mount clevises
shaft has the same optional coupling flange for rear
drive units as the LM6000 PF, but is made with a new • Variable-geometry (VG) control systems for the
material. VIGV, VBV, and VSV systems
The thrust balance piston control is via a combination • Thrust Balance/Ejector System
of 8th stage bleed and compressor discharge pressure
(CDP) bleed mixed in an ejector. This air is metered by Certain items of optional equipment, not listed above,
an orifice in the piping to the balance piston manifold are provided as packager-installed kits. The specific
on the turbine rear frame. configuration of the LM6000 PF+ and installation will
determine which of these kits are installed. For
additional information, refer to the packager's manual.

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/03) *(.

2-2.5 Standard and Optional • LPC inlet pressure (P2)

Instrumentation
• HPC inlet pressure (P25)
The LM6000 PF+ gas turbine is equipped with the • HPC inlet static pressure (PS25 - front frame)
standard sensors shown in table 2-2. Optional sensors
are listed in table 2-3. • LPT inlet total pressure (P48)
Pressure taps are provided at the following locations • Thrust balance cavity pressure (PTB)
for packager-supplied pressure sensors:
• VG pump filter inlet and outlet pressure taps
• Lube oil supply line
• Balance piston pressure reference (PBPV)
• Lube oil scavenge return line
• Gas manifold supply pressures (GP3A, GP3B,
• HPC discharge static pressure (PS3) (2 locations) GP3C, GP3E)
Table 2-2. Standard Instrumentation

Qty/Engine Parameter/Sensor Description
2 HP rotor speed (XN25) sensors - magnetic pickup type - located on AGB.
2 LPT rotor (XNSD) speed sensors - magnetic pickup type - located in the turbine rear frame.
8 LPT inlet temperature (T48) sensors - dual-element KP/KN thermocouples - located on LPT case.
2 Accelerometers - located on the compressor rear frame and turbine rear frame.
7 Resistance temperature detectors (RTDs) - dual-element lube oil supply and scavenge - located in
on-engine lube line (redundant dual - element RTD is optional).
3 Chip detectors - remote-indicating type - located in transverse gearbox (TGB) sump, A-sump,
B-sump, and common lube oil scavenge lines (AGB, C-, D-, and E-sump chip detectors optional).
1 LPT inlet pressure (P48) probe - total pressure - located on the LPT casing.
1 LPC inlet temperature and total pressure (T2/P2) probe - dual element RTD and P2 sensing
port - located on the VIGV case (redundant probe optional).
1 HPC inlet temperature and total pressure (T25/P25) probe - dual-element RTD and P25 sensing
port - located on front frame (redundant probe optional).
2 VSV position sensors - linear variable differential transformer (LVDT) - located in both VSV
actuators.
2 VBV position sensors - LVDT - located in two of the actuators.
2 VIGV position sensors - LVDT - located in both VIGV actuators (VIGV assemblies only).
2 HPC discharge temperature (T3) sensor - dual-element KP/KN thermocouple mounted on the
compressor rear frame.
2* Stage 8 bleed valve position sensor - LVDT - located on actuator.
2* Compressor discharge (CDP) bleed valve position sensor - LVDT.
2 Combustor acoustic sensor - located on combustion case.
2 Ultraviolet flame detectors (UVFD) for flame sensing - mounted on compressor rear frame.
* Mounted off-gas turbine.

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Table 2-3. Optional Instrumentation

Qty/Engine Parameter/Sensor Description
2 Accelerometers - located on the compressor rear frame (CRF) and LPT rear frame. (Redundant*)
7 RTDs - dual-element lube oil supply and scavenge - located in on-engine lube line. (Redundant*)
3 Chip detectors - remote-indicating type - located in TGB sump, B-sump, and common lube oil
scavenge lines - AGB, C-, D-, and E-sump chip detectors optional.
1 LPC inlet temperature and total pressure (T2/P2) probe - dual element RTD and P2 sensing
port - located on the VIGV case. (Redundant*)
1 HPC inlet temperature and total pressure (T25/P25) probe - dual-element RTD and P25 sensing
port - located on front frame. (Redundant*)
* Single sensor is standard equipment. Dual sensors are optional.

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/03) *(.

Chapter 3
Gas Turbine Package
3-1 Purpose and Scope • Noise and emission suppression systems
This chapter provides a brief general description of the • Interconnecting wiring and piping
LM6000 gas turbine package and its packager-supplied
major components. Since individual packages will vary • Fire and safety systems
according to customer installation requirements,
• Anti-icing and water-wash systems
detailed information is not provided in this chapter. For
more specific information, contact the packager. • Compressor bleed air discharge
Additional information is provided in other chapters of
this manual and in the packager's manual.
3-3 Gas Fuel Analysis and
3-2 Package Description Equipment Installation
For proper DLE operation, the gas lower heating value
The gas turbine package comprises a complete
(LHV) and specific gravity (SG) inputs to the fuel
electrical generating or mechanical drive system built
control must be within 1.0 percent of the actual values.
around the LM6000 gas turbine. The package provides
If the properties of the particular site gas supply could
the structure, interfaces, service connections, and
change by more than this amount, gas analysis
controls necessary to operate the LM6000 and to utilize
equipment must be supplied to ensure the fuel control
its energy and/or shaft output. This package needs only
is supplied with data of sufficient accuracy for proper
to be installed or erected at the customer's site and
operation.
connected to the appropriate interfaces and services
(fuel, electric, etc.). When selecting and installing the gas analysis
equipment, the total system response time should be
Typical package components include:
considered. The total response time is defined as the
• Gas turbine base time it takes for the gas sample to travel from the main
supply line to the gas analysis equipment plus the time
• Mounting structure for the gas LHV and SG to be determined for input to
the fuel control.
• Sound enclosure
To minimize the total system response time, it is
• Inlet and exhaust systems necessary to minimize the mass of gas between the
sampling point and the measurement device. A
• Controls and electrical systems schematic of typical gas analysis equipment is shown
(figure 3-1). Key elements of this installation are:
• Drains and vents
a. The location of the pressure regulator
• Fuel, lube, and hydraulic systems
b. The volume of gas in supply lines A and B, and
• Instrumentation and condition-monitoring systems
c. Analysis equipment update time.
• Cooling systems
• Front and/or rear drive interfaces

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The most important element in the design of the b. Make sure the sampling point of line A is
sampling pipe work is location of the pressure positioned so that it will not be influenced by gas
regulator, which should be located as close as possible stratification, boundary layers, or condensation.
to the main gas supply line.
c. Use 0.125 inch (3.18 mm) inside diameter tubing
To ensure quality sampling from the line, a pressure for all sample lines.
regulator probe should be installed in the main gas
supply line itself. The volumes for supply lines A and d. Locate gas analysis equipment no more than
B also impact total system response time and should be 15 feet (4.6 m) from pressure regulator.
kept to a minimum.
e. Select gas analysis equipment based on expected
The following recommendations are not new gas property changes and the installation. Data
installation requirements. The recommendations gathered from Original Equipment Manufacturer
provide guidelines to help meet the GE requirements (OEM’s) indicates that gas chromatographs have
for LHV and SG update times. update times between 3 and 8 minutes. Gas
calorimeters have update times between 20 and
a. Install a pressure regulator in the form of a 40 seconds.
pressure regulator probe located within the main
gas supply line itself. In no case should the f. Total system response time should be calculated.
regulator be located more than 3 feet (91.4 cm) Updates to the fuel control should be frequent
from the main gas supply line. The regulator enough to accommodate the rate of change of gas
should be set to maintain a pressure in line B of properties such that control input is within
approximately 1.5 to 2.0 atmospheres (1.52 to 1 percent of the actual values during steady state
2.03 bar), or just above the minimum pressure operation and within 3 percent of actual values
required by the gas analysis equipment. during gas property changes.
Figure 3-1. Gas Analysis Equipment Installation

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/03) *(.

Chapter 4
Gas Turbine Assembly Description
4-1 Purpose and Scope from aft, looking forward. The high pressure stator
system consists of the HPC and turbine stators.
This chapter describes the LM6000 PF+ Gas Turbine
assembly, equipment, and systems. The LP system is comprised of a five-stage LPC and a
five-stage LPT, both connected to a concentric drive
shaft. The LP rotor turns clockwise when viewed from
4-2 General Description
aft, looking forward. The LP stator system consists of
the LPC and turbine stators. Drive adapters are
4-2.1 Main Components provided on both the front and rear of the LP rotor for
connection to the customer-supplied power shaft and
The LM6000 PF+ gas turbine is a dual rotor, concentric
load.
drive shaft gas turbine, capable of driving a load from
the front and/or rear of the low pressure (LP) rotor. A Three structural frames provide bearing support for the
cross section of the engine (figure 4-1), shows the two rotors used in the LM6000 PF+ gas turbine. These
significant design features of the LM6000 PF+ gas include the front frame, the CRF, and the TRF. This
turbine. The principal LM6000 PF+ gas turbine configuration provides excellent dynamic and
components are identified (figure 4-2), as listed below: mechanical stability and allows more precisely
controlled compressor and turbine blade and vane tip
• Variable inlet guide vane (VIGV) assembly
clearances.
• Five-stage low pressure compressor (LPC)
4-2.2 Engine Airflow
• Front frame assembly and air collector
Air enters the engine at the inlet of the VIGV and
• 14-stage variable-geometry (VG) high pressure passes into the LPC (figure 4-1). The LPC compresses
compressor (HPC) the air by a ratio of approximately 2.5:1. Air leaving
the LPC is directed into the HPC and is regulated at
• Compressor rear frame (CRF) assembly idle and low power by variable bypass valves (VBV)
arranged in the flow passage between the two
• Triple annular combustor assembly compressors.
• High pressure turbine (HPT) The airflow in the 14-stage HPC is regulated by VIGV
and five stages of variable stator vanes (VSV). The
• Low pressure turbine (LPT) HPC compression ratio is approximately 15:1. HPC
discharge and stage 8 bleed air are extracted, as
• Turbine rear frame (TRF) assembly
necessary, for emissions control. Compressor discharge
• Accessory gearbox (AGB) assembly and air is then directed to the combustor section.
accessories
Air entering the combustor is mixed with the fuel
• Bearings provided by the 75 air/gas premixers that are packaged
in 30 externally removable modules. The fuel/air
The high pressure rotor (HPR) system is comprised of mixture is ignited by an igniter that deactivates once
a 14-stage HPC, a triple annular combustor, and a combustion becomes self-sustaining. Combustion
2-stage HPT. The HPC and the HPT are connected by gases then exit to the HPT.
mating splines. The HPR turns clockwise when viewed

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Figure 4-1. LM6000 PF+ Gas Turbine Airflow Cross Section (Sheet 1 of 2)

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Figure 4-1. LM6000 PF+ Gas Turbine Airflow Cross Section (Sheet 2 of 2)

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Figure 4-2. LM6000 PF+ Gas Turbine Major Components (Sheet 1 of 3)

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Hot gases from the combustor are directed into the 4-4.2 LPC Rotor
HPT, which drives the HPC. The exhaust gases exit the
HPT and enter the LPT, which drives both the LPC and Individual disks are used in stages 0 and 1. Stages 2
the output load. The exhaust gases pass through the through 4 of the LPC rotor are an integral spool. Stages
LPT and enter the exhaust duct. 0 through 3 blades have squealer tips.
Stage 0 blades are individually retained in the axial

4-3 Variable Inlet Guide Vanes
dovetail slots of the disk by a one-piece blade retainer.
The air intake section of the engine consists of an axial Stages 1 through 4 LPC blades are retained in
flow section containing a VIGV system. The VIGV circumferential slots in the stage 1 disk and stages 2
assembly is located at the front of the LPC and allows through 4 spool. The blade-retention features permit
flow modulation at partial power, resulting in increased individual blade replacement. Blades in stages 0
engine efficiency. The VIGV system consists of 43 through 3 can be removed without removing the rotor.
stationary leading edge vanes and variable trailing
flaps. The variable flaps can be rotated from 4-4.3 LPC Stator
-10 degrees open to +60 degrees closed by means of an
actuator ring (unison ring) driven by twin hydraulic The stages 0 through 3 titanium stator vanes are
actuators at the 3:00 and 9:00 o’clock positions. Both individually replaceable. The vanes are shrouded to
actuators are equipped with linear variable differential reduce vane response to aerodynamic forces. Wear
transformers (LVDTs). strips are utilized between the vane dovetails and the
LPC casing slots.
Normal engine operation range is approximately
-5 degrees open (full power) to +35 degrees closed The Teflon-lined stages 0 through 3 case is
(idle). The flaps will also close during large power horizontally split to allow top-casing. The feature
reductions to reduce the LPC flow rate quickly in order facilitates vane and blade replacement, and allows
to maintain the LPC stall margin. The VIGV system removal without affecting the front frame air collector.
improves performance for both simple cycle and heat The stages 0 through 3 shrouds are axially split to aid
recovery cycles. It also helps minimize VBV bypass in vane removal. Borescope ports are located at stages
flow and pressure levels, thereby reducing associated 1, 2, and 3 for diagnostic inspection without
flow noise. disassembly.
The air intake section is designed to interface with a The stage 4 stator vanes are mounted in the front frame
radial inlet duct (which allows inlet air to be drawn and supported on the ID by a support structure that is
from the side or top, rather than from the front) or an bolted to the engine front frame.
axial inlet system. The radial inlet duct is compatible
with either forward or rear drive installations; the axial 4-5 Front Frame and Air Collector
inlet can be used only in rear drive installations.
4-5.1 Front Frame
4-4 Low Pressure Compressor
The front frame is a major structure that provides
4-4.1 General Description support for the LPC rotor and the forward end of the
HPC rotor through the No. 1B, No. 2R, and No. 3R
The LM6000 PF+ LPC is a five-stage, axial-flow bearings. The frame also forms an airflow path
compressor. The LPC features a five-stage fixed stator. between the LPC and the HPC inlet. Front engine
mount provisions are located on the front frame at 3:00
Provision is made for LPC discharge flow to be and 9:00 o’clock positions. Two pads are included on
bypassed through modulating bypass doors to assure the frame outer case for mounting HPC inlet
adequate LPC stall margin at lower power settings and temperature sensors.
during large power reduction transients.

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The front frame is made from a high-strength steel Stages 1 and 2 blades are individually retained in axial
casting. Twelve equally spaced radial struts are used dovetail slots and the remaining blades are held in
between the hub and outer case to provide support for circumferential dovetail slots. These features allow
the inner hub. Twelve variable-position bypass valve individual blade replacement without disassembly of
doors are located on the outer wall for LPC discharge the rotor.
bleed.
Stage 1 blades are shrouded at mid-span for the
The front frame contains the engine A-sump, which purpose of reducing vibratory stress. All other blades
includes a thrust bearing (1B) and roller bearing (2R) are cantilevered from the rotor structure.
that support the LPC rotor, and a roller bearing (3R)
that supports the forward end of the HPC rotor. 4-6.3 HPC Stator
Lubrication oil supply and scavenge lines for the
A-sump are routed inside the frame struts. The inlet The HPC stator consists of a cast stator case that
gearbox is located in the A-sump with the radial drive contains the compressor stator vanes. The inlet guide
shaft extending outward through the strut located at the vanes and the stages 1 through 5 vanes can be rotated
6:00 o’clock position. about the axis of their mounting trunnions to vary the
pitch of the airfoils in the compressor flow path. Vane
4-5.2 Bypass Air Collector airfoils in the remaining stages are stationary. All fixed
and variable vanes are non-interchangeable with other
The LPC bypass air collector is a duct attached to the stages to prevent incorrect assembly. The casing is split
front frame. It collects LPC discharge air, vented along the horizontal split-line for ease of assembly and
through the LPC bypass doors, and directs it overboard maintenance. The stages 1 and 2 vane shrouds also
through packager-provided ducting. support interstage rotor seals. The shrouds are designed
to allow the removal of either half of the compressor
4-6 High Pressure Compressor casing. There are 14 axial stations provided for
borescope inspection of blades and vanes.
4-6.1 General Description
4-7 Compressor Rear Frame
The LM6000 PF+ HPC is a 14-stage, axial-flow
compressor. It incorporates VIGVs and variable stators The CRF consists of an outer case, 10 struts, and the B-
in stages 0 through 5 to provide stall-free operation and and C-sump housings. The outer case supports the
high efficiency throughout the starting and operating combustor and premixers. The hub provides support
range. for a ball bearing and two roller radial bearings to
support the midsection of the high pressure (HP) rotor
Stage 8 and compressor discharge air are used for system.
combustor flame temperature control. Eighth and
eleventh stage bleed air and compressor discharge air Bearing axial and radial loads and a portion of the first
are extracted for cooling and pressurization of the stage nozzle load are transmitted through the hub and
engine and bearing sump components. 10 radial struts to the case. The hub, struts, and outer
casing are a one-piece casting. The casting is welded to
4-6.2 HPC Rotor the fuel embossment ring and bolted to the aft case.
This serves as the structural load path between the
The HPC rotor consists of 14 stages. The stage 2 disk compressor casing and the HPT stator case. Six
has an integral forward shaft and the stages 10 through borescope ports are provided for inspection of the
14 spool has an integral rear shaft. combustor, premixers, and HPT. B- and C-sump
service lines are contained in, and pass through, the
CRF struts.

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4-8 Combustion System 4-9.2 HPT Rotor
The HPT rotor assembly consists of the stage 1 disk

and integral shaft, a forward outer seal with axial
The LM6000 PF+ gas turbine utilizes a lean premix inducer, a rotating interstage seal, and a stage 2 disk.
combustion system designed for operation on natural Forward and aft rotating air seals are assembled to the
gas fuel. The triple annular configuration enables the HPT rotor and provide air-cooled cavities around the
combustor to operate in uniformly mixed, lean fuel to rotor system. An integral coupling nut and pressure
air ratio (premix mode) across the entire power range, tube are used to form and seal the internal cavity. The
minimizing emissions even at low power. rotor disks and blades are cooled by a continuous flow
of compressor discharge air. This air is directed to the
internal cavity of the rotor through diffuser vanes that
4-8.2 Triple Annular Combustor
are part of the forward seal system.
The forward end or dome of the combustor supports 75
The stage 1 disk/shaft design combines the rotor
segmented heat shields that form the three annular
forward shaft and stage 1 disk into a one-piece unit.
burning zones in the combustor, known as the outer or
Torque is transmitted to the compressor rotor through
A dome, the pilot or B dome, and the inner or C dome.
an internal spline at the forward end of the disk/shaft.
In addition to forming the three annular domes, the heat
The stage 1 blades fit into axial dovetail slots in the
shields isolate the structural dome plate from the hot
disk. The stage 2 disk incorporates a flange on the
combustion gases. The heat shields are an investment-
forward side for transmitting torque to the stage 1 disk.
cast superalloy and are impingement and convection
An aft flange supports the aft air seal and the integral
cooled. The combustion liners are front mounted with
coupling nut and pressure tube. Stage 2 blades fit into
thermal barrier coating (TBC) and no film cooling.
axial dovetail slots in the disk.
Gas fuel is introduced into the combustor via 75 air/gas
Internally cooled turbine blades are used in both stages.
circuits packaged in 30 externally removable and
Both stages of blades are cooled by compressor
replaceable premixers. Half of these modules have two
discharge air flowing through the blade shank into the
cups and the other half have three. The premixers
airfoil.
produce a very uniformly mixed, lean fuel/air mixture.
The structural support between the turbine disks is an
4-8.3 Ignition System integral flange on each disk that are bolted together.
This joint also supports the rotating interstage seal. The
The ignition system produces the high-energy sparks rotating interstage seal forms the outer portion of the
that ignite the fuel/air mixture in the combustor during turbine rotor cooling air cavity and serves as the
starting. The system consists of two ignition exciters, rotating portion of the interstage gas path seal.
leads, and spark igniter. Once ignition occurs,
combustion becomes self-sustaining and continues
4-9.3 Stage 1 HPT Nozzle
without the spark igniter.
The stage 1 HPT nozzle consists of 23 two-vane
4-9 High Pressure Turbine segments bolted to a nozzle support attached to the hub
of the CRF.
Compressor discharge air is used to cool the nozzle
The LM6000 PF+ HPT is an air-cooled, two-stage vanes and support bands to maintain the metal
design with demonstrated high efficiency. The HPT temperatures at the levels required for extended
system consists of the HPT rotor and the stages 1 and 2 operating life.
HPT nozzles.

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4-9.4 Stage 2 HPT Nozzle Each LPT rotor stage consists of a bladed disk
subassembly comprised of a disk, turbine blades, blade
The stage 2 HPT nozzle assembly consists of 24 two- retainers, interstage air seals, assembly bolts, and
vane stage 2 nozzle segments, stages 1 and 2 HPT balance weights. Integral flanges on each disk provide
shrouds and shroud supports, HPT stator support assembly bolt holes in a low stress area of the disk.
(case), and interstage seals. The nozzle vanes are Blade retainers hold the turbine blades in the axial
internally cooled by HPC eleventh-stage air. dovetail slots.
The stage 2 nozzles are supported by the stage 1 shroud The turbine shaft assembly is a torque cone coupled to
support. They are also bolted to the stage 2 shroud the mid-shaft through a spline and is bolted to the stage
support forward leg, which is attached, by a flange, to 2 and stage 3 turbine disk flanges. It also provides the
the outer structural wall. The stage 1 shroud system journal for the D- and E-sump air oil seal and the No.
features segmented supports and shroud segments to 6R and No. 7R bearing interfaces. The rotating portion
maintain turbine clearance. of the balance piston system mounts on the shaft, aft of
the No. 7R bearing seals. Additionally, the aft shaft
The turbine shrouds form a portion of the outer spline provides for driving the output load from the
aerodynamic flow path through the turbine. They are rear through the aft drive adapter.
axially aligned with the turbine blades and form a
pressure seal to minimize HP gas leakage around tips 4-10.3 LPT Stator
of the blades.
The five-stage stator assembly consists of a one-piece
The interstage seal is composed of six segments bolted tapered 360° casing, five stages of interlocking tip
to the inner flange at the nozzle segments. The sealing shrouds, and a 12 segment LPT case external cooling
surface consists of a three-step honeycomb seal that manifold. Air-cooled first stage nozzle segments with a
mates with the rotating interstage seal. The interstage bolt-on pressure balance seal, four additional stages of
seal is designed to minimize leakage of core gas flow nozzle segments with bolt-on interstage seals, and
around the stage 2 nozzle. instrumentation and borescope ports also comprise the
stator assembly.
4-10 Low Pressure Turbine
The LPT casing is the load-carrying structure between
4-10.1 General Description the HPT stator case and the TRF. The casing contains
internal machined flanges that provide hooks to
The LPT drives the LPC and load device using the core support the nozzle segments and stops to assure nozzle
gas turbine discharge gas flow for energy. The principal alignment and seating. Borescope inspection ports are
components of the LPT module are a five-stage stator, provided along the right side, aft looking forward
a five-stage rotor supported by the No. 6R and No. 7R (ALF) from 2:30 to 4:30 o’clock positions at nozzle
bearings, and a cast TRF supporting the stator casing stages 1, 2, and 4.
and the No. 6R and No. 7R bearings.
The stage 1 nozzle vanes provide capability for LPT
inlet instrumentation. Holes are provided for
4-10.2 LPT Rotor thermocouple probes and a single pressure probe can
be inserted. There are eight nozzles to provide for
The LPT rotor assembly drives the LPC through the LP
thermocouples, one for a pressure probe, and four
mid-shaft and drives a load through either the mid-
nozzle segments without instrumentation holes.
shaft or from an aft drive adapter on the rear of the LPT
rotor. The LPT rotor assembly consists of five stages of Seals minimize the air leakage around the inner ends of
bladed disks and a shaft subassembly. The rotor is the nozzles and shrouds minimize air leakage over the
supported by the No. 6R and No. 7R bearings in the D- tips of the turbine blades.
and E-sump of the TRF.

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4-11 Turbine Rear Frame bearing supports the high pressure compressor rotor
(HPCR) forward shaft.
The TRF is a one-piece casting which provides the gas
turbine exhaust flow path and the supporting structure The B- and C-sump houses the No. 4R bearing, the No.
for the D- and E-sump, the LPT rotor thrust balance 4B bearing, and the No. 5R bearing. The No. 4R
assembly, the LPT rotor shaft, and the aft drive adapter. bearing supports the aft shaft of the HPCR. The No. 4B
Fourteen radial struts function as outlet guide vanes to bearing carries the thrust loads for the HPR (HPC and
straighten the exhaust air flow into the exhaust diffuser HPT). The No. 5R bearing supports the high pressure
for enhanced performance. Lubrication oil supply and turbine rotor (HPTR) at its forward shaft.
scavenge lines for the D- and E-sumps and LPT rotor The D- and E-sump houses the No. 6R and No. 7R
speed sensors are routed through the struts. bearings. The No. 6R bearing supports the forward end
The LPT rotor thrust balance system is designed to of the low pressure turbine rotor (LPTR) shaft. The No.
maintain the axial thrust loading on the No. 1B thrust 7R bearing is oil damped to suppress vibrations. It
bearing within design limits. The balance piston static supports the aft end of LPTR shaft and the balance
seal is mounted to the TRF hub. Stage 8 and CDP bleed piston system.
air, operated through an ejector, supply bleed air Labyrinth-type seals control the flow of air into the
through three TRF struts to generate the required axial sump areas to prevent excess oil consumption. The
loading through the rotor thrust balance system. A-sump drains into the TGB through the same front
frame strut that houses the gearbox shaft. Oil is then
4-12 Accessory Gearbox Assembly scavenged through the gearbox. The No. 4R/4B and
No. 5R bearing zones of the B- and C-sump are
The accessories are driven from the high pressure rotor
individually scavenged, as are the No. 6R and No. 7R
system by the inlet gearbox, a radial drive shaft, and
bearing zones of the D- and E-sumps. All sumps emit
the transfer gearbox (TGB) assembly. The TGB is
mist-carrying air and are vented to a packager-supplied
attached to the air collector at the 6:00 o’clock
air/oil separator.
position. The AGB (the accessory drive portion of the
TGB assembly), located below the HPC casing, is
driven from TGB by a short horizontal shaft. The 4-14 Low Pressure Rotor Balance
starter, lube and scavenge pump, VG hydraulic pump, Piston System
and other accessories are mounted on, and driven by,
the AGB. The balance piston system is designed to control thrust
loading on the No. 1B bearing. These loads are
imposed by LPC and LPT and vary with output power.
4-13 Bearings Forward axial loads are applied by varying air pressure
Eight bearings support the rotating components and the in the balance piston air cavity to maintain thrust loads
aerodynamic loads in the LM6000 PF+. Each rotating within the capability of the bearing. Air pressure at the
mass (the compressor, turbine, and balance-piston balance piston cavity is maintained at the correct level
system) is supported by roller bearings and axial thrust by an orifice in the bleed air supply line to the balance
loads are carried by ball bearings. These bearings are piston cavity.
located in the A-, B-, C-, D-, and E-sump areas
(figure 4-3).
The A-sump houses the No. 1B, No. 2R, and No. 3R
bearings. The No. 1B bearing is a ball-type thrust
bearing that carries the thrust loads for the LPR (LPC
and LPT). The No. 2R bearing supports the low
pressure compressor rotor (LPCR) and the No. 3R

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Figure 4-3. Sump Areas and Bearing Locations

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LM6000 PF+ GEK 119319
GE Industrial AeroDerivative Gas Turbines Volume I
Chapter 5
LM6000 PF+ Model System Descriptions
5-1 Purpose and Scope The VG control system consists of the VG hydraulic
pump, a hydraulic control unit (HCU) which houses
This chapter provides physical and functional torque motor-positioned hydraulic servos for porting
descriptions of the various secondary systems that are fluid at regulated pressure, two VIGV actuators, six
part of the LM6000 PF+ model gas turbine. VBV actuators, and two VSV actuators. The VG
hydraulic pump is a fixed-displacement design which
Systems described in this chapter include: supplies pressurized lube oil to the HCU for delivery to
the actuators.
• Variable-geometry (VG) systems
Positioning of the VIGVs, VSVs, and VBVs is
• Fuel systems scheduled by packager-supplied control system
electrical inputs to three separate servo valves in the
• Gearbox assemblies HCU, which is mounted on the VG hydraulic pump.
Position feedback to the control is provided by linear
• Starter system
variable differential transformers (LVDTs) integral to
• Lube system the individual system actuators.
• Sensors and indicating systems 5-2.1 VIGV System
• Bleed system The VIGV assembly is located at the front of the low
pressure compressor (LPC). It allows flow modulation
• Engine control unit (ECU) at partial power, resulting in increased engine
efficiency. The VIGV system consists of 43 stationary
• Low pressure rotor (LPR) balance piston system leading edge vanes and variable trailing flaps
(figure 5-1). The variable flaps can be rotated from
• Water-wash system
-10 degrees open to +60 degrees closed by means of an
• Air system tubing and frame strut functions actuation ring, which is driven by twin hydraulic
actuators at the 3:00 and 9:00 o’clock positions.
• SPRINT® System. Normal engine operation is approximately -5 degrees
open (full power) to +35 degrees closed (idle power).
The flaps will also close during large power reductions
5-2 Variable-Geometry Control
to quickly reduce the LPC flow rate in order to
System maintain the LPC stall margin. Both actuators are
equipped with LVDTs. The packager-supplied control
The VG control system includes the following: is designed to provide excitation and signal
conditioning for both LVDTs and to control VIGV
• Variable inlet guide vane (VIGV) system
position by means of closed-loop scheduling of VIGV
• Variable bypass valve (VBV) system actuator position, based on LPC inlet temperature (T2)
and high pressure compressor (HPC) discharge static
• Variable stator vane (VSV) system pressure, (PS3) corrected to gas turbine inlet pressure
conditions (P0).
Change 1 5-1
GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.
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GEK 119319 LM6000 PF+
Volume I GE Industrial AeroDerivative Gas Turbines
Figure 5-1. VIGV System
5-2.2 VBV System Actuators are installed at the 1:00, 3:00, 5:00, 7:00,
9:00, and 11:00 o’clock positions on the engine. The
The VBV system is located in the front frame six actuators are positioned with one VBV door on
assembly. This system is used to vent LPC discharge each side of each actuator. The actuators, the actuation
air overboard through the LPC bleed air collector in ring, and the VBV doors are mechanically linked by
order to maintain LPC stall margin during starting, bellcranks and pushrods. The actuator positions the
partial power operation, and large power transients. actuation ring, which opens and closes the VBV doors.
The VBV system consists of 12 variable-position The 5:00 and 11:00 o’clock actuators are equipped with
bypass valves, six VBV actuators (two with LVDTs), integral LVDTs for position indication. The packager-
six actuator bellcranks, 12 VBV door bellcranks, and supplied control is designed to provide excitation and
an actuation ring (figure 5-2). signal conditioning for both LVDTs, and to control
VBV position by means of closed loop scheduling of
VBV actuator position, based on LPC inlet temperature
(T2) and HP rotor speed corrected to inlet conditions
(XN25R2).
5-2 Change 1
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LM6000 PF+ GEK 119319
Figure 5-2. VBV System
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5-2.3 VSV System 5-3.1 Gas Fuel Systems
The VSV system is an integral part of the HPC stator, A simplified schematic of a natural gas fuel system is
consisting of two VSV actuators and levers, actuation provided (figure 5-4).
rings, and linkages for each VSV stage (figure 5-3).
The LM6000 PF+ model gas fuel system includes five
The LM6000 PF+ model is equipped with two fuel manifolds, flexible fuel hoses, air/gas premixers,
actuators on the VSV system, one at the 3:00 o’clock and 12 fuel staging valves.
position and one at the 9:00 o’clock position. Each
actuator incorporates an integral LVDT. The packager- The requirements for gas fuel are provided in
supplied control is designed to provide excitation and Appendix A1 in Volume I of this manual. The
signal conditioning for both LVDTs, and to control combination of entrained alkali metals entering the
VSV position by means of closed-loop scheduling of engine through inlet air and fuel contamination must
VSV actuator position, based on HP rotor speed not exceed 0.2 ppm. The use of unapproved fuels can
corrected to HPC inlet conditions (T25). cause severe damage to the engine. Inquiries
concerning fuels that don't meet the requirements as
5-3 Fuel Systems outlined in Appendix A1 in Volume 1 should be
directed to the packager.
This section provides functional descriptions of the
fuel systems included as standard equipment with the
LM6000 PF+ model.
Figure 5-3. VSV System
5-4 Change 1
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LM6000 PF+ GEK 119319
Figure 5-4. Natural Gas Fuel System (Sheet 1 of 2)
Change 1 5-5
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GEK 119319 LM6000 PF+
Figure 5-4. Natural Gas Fuel System (Sheet 2 of 2)
5-6 Change 1
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LM6000 PF+ GEK 119319
The LM6000 PF+ model gas turbine requires accurate 5-3.1.3 Fuel Staging Valves
metering of the total mass flow rate of gas fuel. As part
of the requirements to determine fuel metering valve One of the key controlling parameters in the LM6000
demand position, the fuel system must include PF+ model gas turbine is combustor flame temperature.
provisions for providing signals to the electronic Flame temperature control is required to limit NOx
control unit reflecting the following gas properties: emissions and control hot section component lives. To
specific gravity, ratio of specific heats, lower heating maintain flame temperature control in a narrow
value, and compressibility. The recommendations for temperature range during all gas turbine operating
gas analysis and equipment installation are included in conditions, it is necessary to stage the combustor, i.e. it
Chapter 3 of this manual. Rapid gas properties is necessary to turn sections of the combustor on and
fluctuations will require more frequent updates. off. The 12 fuel staging valves control fuel distribution
Improper properties can result in combustor flameout, to the three combustor rings as scheduled by the
acoustics, or reduced hot section life. electronic control unit. Five staging valves control the
A or outer ring, five staging valves control the C or
5-3.1.1 Gas Manifold and Fuel Hoses inner ring, one staging valve controls ELBO flow and
one valve controls the B3 circuit. The B2 ring dome
Gas fuel is metered to five on-engine fuel manifolds. has fuel available to it at all operating conditions. The
The five gas manifolds, one each for the A, C, B2, B3, operating modes over the LM6000 PF+ model power
and ELBO circuits, supply high pressure fuel to the range are schematically represented (figure 5-5). The
premixers via 90 flexible fuel hoses. The primary fuel combustor modes go from B mode at core idle (not
supply to the premixers uses 75 fuel hoses. The other shown) to ABC at full power. During ABC mode, all
15 fuel hoses are used for the enhanced lean blow-out staging valves are open and supplying fuel to each
(ELBO) circuit integral with 15 premixers. premixer cup. During B mode, fuel is only burning in
the B ring premixer cups. The staging valves are
5-3.1.2 Air/Gas Premixers mounted on brackets attached to the gas manifolds.
Gas fuel is introduced into the combustor via 75 air/gas 5-3.2 Dual Fuel System
circuits packaged in 30 externally removable and field
replaceable premixers. Half of the premixers have two The liquid fuel system is only available in the dual fuel
cups and the other half have three cups. The premixers configuration. The fuel system hardware supplied with
produce a very uniformly mixed, lean fuel/air mixture. the gas turbine includes base mounted liquid and gas
manifolds, hoses, staging valves, and a set of 30 dual
fuel premixers.
5-3.2.1 Premixers
Gas fuel is introduced into the combustor via 75 air/gas

premixers packaged in 30 externally removable and
replaceable modules. The premixers produce a very
uniformly mixed, lean fuel/air mixture. Half of these
modules have two premixers and the other half have
three. The fuel premixers include passages for liquid
fuel.
Change 1 5-7
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GEK 119319 LM6000 PF+
Figure 5-5. LM6000 PF+ Model Operating Modes
5-4 Gearbox Assemblies 5-5 Starter System

The LM6000 PF+ model transfer gearbox assembly The starter drives the engine HP rotor system through
consists of the transfer gearbox (TGB) and accessory the TGB assembly starter drive pad (figure 5-6). The
gearbox (AGB). It is an accessory drive system that is starter is required for starting, water-wash, and when
driven from the HP rotor system by the inlet gearbox required, for motoring the engine. The gear ratio of the
and radial drive shaft. The TGB assembly is supported starter to the HP rotor is approximately 0.96:1.
by the bypass air collector and provides mounting and Optional air, gas, and hydraulic starters are available
drive provisions for the following (figure 5-6): from the packager. For information on non-GE starters,
refer to the packager’s manual.
• Pneumatic or hydraulic starter that drives the high
pressure (HP) rotor through the TGB assembly 5-5.1 Starter Usage
• Lube and scavenge pump It is recommended the starter not be engaged unless the
HPC shaft is at rest. If necessary, engagement can
• VG hydraulic pump and HCU
occur at normal windmilling speeds not to exceed
• Packager-supplied accessories, optional 300 rpm. Engagement of the starter at XN25 speed of
GE-supplied fuel pump, and for manual rotation of 300 rpm to 1,700 rpm must be avoided to prevent
the HP rotor system during borescope inspection damage to the starter or TGB assembly.
5-8 Change 1
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Figure 5-6. Transfer Gearbox Assembly
Change 1 5-9
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Nominal cutout speed for the GE-supplied starter is • Motoring

4,600 rpm (XN25). During engine starting, minimum
acceptable starter output speed is 4,100 rpm. Maximum – 5 minutes On, 2 minutes Off for a maximum of
acceptable starter output speed is 4,900 rpm. two cycles or
– 5 minutes On, 18 minutes Off for any number
If air is used to drive the starter, it can be discharged of cycles or
directly from the starter with no additional piping. If
natural gas is used, the exhausted natural gas must be – 10 minutes On, 20 minutes Off for any number
vented to a safe location. Interfaces are provided for the of cycles. For 10 minutes of motoring,
starter lube system as part of the engine system, maximum starter air inlet temperature is 200°F
allowing constant oil flow through the starter. For (93.3°C).
details regarding the starter, refer to the packager's
manual. 5-5.2.2 Hydraulic Starter
5-5.2 Starter Duty Cycles The hydraulic starter consists of a variable

displacement type hydraulic motor. Piston stroke is
For information on starter types other than those controlled by a wobble plate, while displacement is
described here, contact the packager. controlled by means of a pressure compressor. The
starter is equipped with an over-running clutch to
5-5.2.1 Air and Gas Starters prevent the motor from being driven by the HP rotor
when the hydraulic supply pressure and flow are
During a normal start, the starter is energized for reduced to zero. Physical arrangement and starter
approximately 40-70 seconds. Air/gas consumption per performance are shown in figure 5-7 and figure 5-8,
start is approximately 120-250 lb (55-113 kg), respectively.
depending on the medium and conditions.
The hydraulic supply and control system are supplied
The maximum supply temperature is 475°F (246.1°C). by the gas turbine packager. Figure 5-9 is a simplified
Air or gas must be dry and filtered to 40 micrometers schematic of a typical packager supplied system. The
nominal. To purge and go directly into a start cycle starter interfaces are identified as B1 through B5
without stopping, the engine may be motored at (figure 5-7 and figure 5-9). The hydraulic starter
1,200 rpm (approximately 15 psig [103 kPa gage]) for requires a flow capability of 0-55 gpm (0-208.20 l/min)
2 minutes. The pressure can then be increased to of hydraulic fluid at a maximum differential pressure of
38 psig (262 kPa gage) and fuel and ignition systems 4200 psi (28,957 kPa). The maximum starter inlet
can be energized at 1,700 rpm. pressure (pump compensator pressure) is 4500 psig
(31,026 kPa gage). A list of the starter manufacturer's
The typical air/gas starter duty cycles are as follows: approved oil types is found in DEB-101. The oil
temperature to the start circuit shall be between
• Starting 32°F and 200°F (0°C and 93.3°C). The oil shall be
– 45 seconds On, 2 seconds Off for any number filtered to 10 micrometer (m) nominal
of cycles or (25 m absolute). The maximum starter discharge
pressure is 300 psig (2068 kPa gage). The supply
– 2 minutes On, 5 minutes Off for a maximum of pressure shall be reduced to zero after the gas turbine
two cycles or attains 4,000 to 4,600 rpm (XN25). Drive input power
for the hydraulic supply pump is approximately 180-
– 2 minutes On, 21 minutes Off for any number
200 horsepower.
of cycles.
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Figure 5-7. Hydraulic Starter
Figure 5-8. Hydraulic Starter Performance
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GEK 119319 LM6000 PF+
Figure 5-9. Typical Hydraulic Starter Schematic
The maximum flow through the starter cooling circuit (208.2 l/min) flow, an internal pressure compensator in
is 3.5 gal/min (13.25 l/min) and the maximum the starter maintains starter inlet pressure and
allowable backpressure is 25 psig (172.4 kPa gage). accelerates the starter while the hydraulic supply
The minimum allowable backpressure is 1.0 psig system maintains the 55 gal/min (208.2 l/min) flow.
(6.9 kPa gage). A maximum 2.0 gal/min (7.6 l/min) When the gas turbine is fired, it will eventually attempt
flows between the starting circuit and the cooling to drive the starter above its maximum speed. At this
circuit once the starting circuit is pressurized. Filtration point, an internal over-running clutch allows the gas
requirements are the same as the supply circuit. The turbine to continue to run at its maximum speed
starter torque characteristic is shown in figure 5-8. without driving the hydraulic starter. The hydraulic
supply system for the hydraulic starter should be shut
Cooling flow to lubricate the internal clutch is required down and cooling flow initiated. If the gas turbine is
during over-running conditions (once the start circuit unfired, such as for purge or compressor cleaning, the
flow is stopped). Supply shall be to the cooling supply starter speed will approach the steady state speed of
interface and return from the cooling return interface 1,900 to 2,200 rpm, by decreasing the pressure drop
(figure 5-7). The circuit uses the same hydraulic fluid across the starter or limiting fluid flow to less than
used in the supply circuit. 55 gal/min (208.2 l/min).
There are no duty cycle limitations on the hydraulic The seal drain connection allows hydraulic fluid that
starter, as long as the oil temperature is maintained has leaked across the starter carbon seal between the
under 140°F (59.9°C). The maximum cooling circuit starter and the AGB to be ported outside the package.
oil temperature limit is 200°F (93.3°C). 4,200 psi The drain is redundant with the AGB drain at the
(28,958 kPa) is supplied. starter location. The maximum flow through the starter
seal drain is 5.0 cc/hr and the maximum allowable
As starter speed increases, the flow will increase from backpressure is 1.0 psig (6.9 kPa gage).
0 to 55 gal/min (0 to 208.2 l/min). At 55 gal/min
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For new installations or where the start system has had The packager provides air/oil separator(s), lube oil,
maintenance performed, the hydraulic system supply lube conditioning and storage module, and the
and cooling lines should be flushed until clean without necessary flexible lines to interface with the engine at
the starter installed in the circuit. This should be three locations. The lube conditioning and storage
accomplished by circulating fluid through the system, system includes the lube oil supply filter(s), scavenge
including filters, at operating temperatures, pressure, oil filter(s), oil cooler, check valves, and the storage
and flows until the system is free of debris. The filter tank.
elements should then be changed and the starter
installed. The lubrication oil may be used with a packager-
supplied transfer gearbox assembly-mounted hydraulic
5-5.2.3 Gas Turbine Airflow During pump to provide hydraulic pressure to operate
Starter Operation packager-supplied fuel and water metering valves,
required by the system as supplied.
When operating on the starter, airflow through the gas
turbine for exhaust duct purge can be estimated using For new installations, following lube system
figure 5-10. maintenance, or after lube system component failure,
the package lube system lines should be flushed until
free of contamination. The flushing should occur
5-6 Lube System without the gas turbine installed in the circuit. Flushing
is accomplished by circulating fluid through the system
5-6.1 General Description and filters at operating temperatures and pressures.
Continue circulation until system filters are free of
Figure 5-11 is the lube system schematic. The engine debris. The filter elements should then be changed and
uses lubrication oil to: the lube system connected to the gas turbine. See
Chapter 7 for specific recommendations.
• Lubricate and cool the high-pressure and low-
pressure rotor bearings, sumps, and the inlet, Use of engine lubrication oil for purposes other than
transfer, and accessory gearboxes. described in this section must be reviewed by GE
M&IED.
• Operate the actuators for the VIGV, VBV, and
VSV systems; 8th stage and compressor discharge
pressure (CDP) bleed valves. 5-6.2 System Flows, Pressures, and
Temperatures
• Maintain a supply of oil to the optional pneumatic
starter. Table 5-1 provides the parameter values for the oil
supply and scavenge, actuator drain, and air/oil vents
The standard engine lube system components include for use in troubleshooting possible operational
the gearbox-driven engine lube oil supply and problems. Total flow from the oil tank to the engine
scavenge pump and the necessary on-engine piping for and return is approximately 19 gal/min (72 l/min) at
the HP and low pressure (LP) system bearings and rated power.
sumps, for the inlet gearbox, and for the TGB
assembly. Oil supply and scavenge temperature sensors
are included. The oil temperature sensors are dual-
element resistance temperature detectors (RTD). Three
chip detectors are also included. One monitors the
thrust bearing in the A-sump and one the thrust bearing
in the B-sump. The third or common detector monitors
the remaining bearings.
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Figure 5-10. Subidle Airflow
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Figure 5-11. LM6000 PF+ Model Lube System Schematic
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Table 5-1. Gas Turbine Lube/Scavenge System

Description Fluid Flow Pressure Temperature
Lube Pump Inlet Oil 10-19 gal/min 0-1.0 psig 90 to 100°F
(38-71 l/min) (0-6.8 kPa gage) (33 to 37°C)
Lube Supply to Filter Oil 10-19 gal/min 32-113 psig 130 to 150°F
(38-71 l/min) (221-779 kPa gage) (55 to 65°C)
Engine Lube Supply Oil 10-19 gal/min 27-71 psig 130 to 150°F
(38-71 l/min) (187-489 kPa gage) (55 to 65°C)
Scavenge Discharge to Filter Oil 10-19 gal/min 20-80 psig 175 to 275°F
(38-71 l/min) (138-551 kPa gage) (80 to 135°C)
Air 0.10-0.27 lb/min 0-1.0 psig 175 to 275°F
(0.38-1.02 kg/min) (0-6.8 kPa gage) (80 to 135°C)
A-, B- and C-Sump Vents Oil 0.23-1.5 gal/min
(0.88-5.6 l/min)
Air 75-225 ft3/m 0-1.0 psig 175 to 275°F
(2.13-6.37 m3/min) (0-6.8 kPa gage) (80 to 135°C)
D- and E-Sump Vents Oil 0.23-1.5 gal/min
(0.88-5.6 l/min)
Air 15-40 ft3/m 0-1.0 psig 175 to 275°F
(0.43-1.13 m3/min) (0-6.8 kPa gage) (80 to 135°C)
Combined Actuators Drain Oil 0-30 ml/hr 0-2 in. H2O 130 to 150°F
(0-0.5 kPa) (55 to 65°C)
Deleted
Combined Accessory Pad Drain Oil 0-10 ml/hr 0-2 in. H2O 130 to 150°F
(0-0.5 kPa) (55 to 65°C)
D- and E-Sump Drains Oil 0-0.5 ml/hr
Air 0-65 ft3/m 0-3 psig 225 to 300°F
(0.00-1.84 m3/min) (0-20 kPa gage) (108 to 148°C)
Stage 8 Bleed Valve Drain Oil 0-30 ml/hr 0-2 in. H2O 130 to 150°F
(0-0.5 kPa) (55 to 65°C)
Compressor Discharge Bleed Oil 0-30 ml/hr 0-2 in. H2O 130 to 150°F
Valve Drain (0-0.5 kPa) (55 to 65°C)
NOTE
Data provided are normal expected values from idle to maximum power.
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5-6.3 Oil Specification temperature measurement. Engine oil pressure is a

function of HP rotor speed and oil supply temperature.
Type II oil (MIL-PRF-23699) is the preferred lubricant Refer to Chapter 8 for oil supply characteristic.
for the LM6000 PF+ gas turbine. This type of synthetic Chapter 10 provides requirements for pressure and
oil has a coking temperature advantage of 20°F temperature instrumentation and operation limits.
(11.1°C) to 50°F (27.8°C) over Type I (MIL-PRF-
7808). Improved film effectiveness of MIL-PRF-23699 An antistatic leak check valve is provided in the
at higher temperatures also improves bearing life. packager's system to prevent oil drainage from the tank
Type I lubricant is not recommended for general use in into the engine during shutdown.
the LM6000 PF+ model. In applications where very
low temperature starting capability is required, Type I 5-6.4.2 Scavenge Oil Circuit
oil may be used provided the ambient temperature is
consistently lower than 68°F (20.0°C). Any use of Scavenge flow, an air/oil mixture, is approximately
Type I oil requires approval of M&IED for the specific proportional to HP rotor speed. Scavenge pump
site. Reference Appendix A for further guidance on capacity is approximately three times that of the oil
acceptable lubrication oils. supply element.
5-6.4 Lube Subsystems Oil returning to the tank is cooled and filtered to
3.0-6.0 m absolute to maintain a clean tank. The filter
should include a bypass relief valve and bypass alarm
5-6.4.1 Lube Supply Circuit
as described for the lube supply circuit. The tank must
The oil flow from the supply element of the engine be vented to ambient through an air/oil demister.
lube pump is approximately proportional to the engine
An oil pressure measurement fitting is provided in the
HP rotor speed. The pump internal relief valve for the
engine lube oil scavenge system. Limits in Chapter 10
lube supply elements is set to open at 300 psid
apply to pressures measured at this fitting.
(2,068 kPa differential) and bypass full flow (at
maximum speed) at 400 psid (2,758 kPa differential).
The pump requires a flooded inlet to maintain prime. 5-6.4.3 Engine Drains
Immediately following cold starts, oil pressure at the
In normal operation, the drains will have little or no oil
pump inlet may be as low as 5.0 psia (34.5 kPa
flow.
absolute). Oil pressure at the pump inlet shall not be
less than atmospheric pressure when the oil The B- and C-sump drains into the LP recoup vent line.
temperature is at normal operating conditions. Oil from Under normal conditions, insignificant amounts of oil
the lube and scavenge pump shall be filtered to will be entrained in the LP recoup air. In the event of
3.0-6.0 m absolute by packager-supplied off-engine sump seal oil leakage, the LP recoup vent line may
filters before being returned to the engine lube system. contain entrained oil. The D- and E-sump drains are
Filters include bypass relief valve with an alarm to alert expected to carry insignificant amounts of oil during
the operator to impending bypass. Oil filter pressure normal operation. The sump drains are sized to handle
drop shall not exceed 40 psid (276 kPa differential) at full air/oil flow in the event of seal oil leakage.
full oil flow.
A fluid drain collector system should be provided as
Oil supplied to the engine should not contain more than part of the installation and should comply with all
10 percent entrained air on a volume basis. applicable regulations relating to environmental
contamination or pollution. It is strongly recommended
An oil pressure measurement fitting is provided in the
that provisions be made to isolate the drain lines, when
engine lube oil supply system. Limits in Chapter 10
necessary, to enable troubleshooting for excessive
apply to pressures measured at this fitting. An on-
drain fluid flow. The collector system must not permit
engine temperature sensor is provided for oil supply
fluids to siphon back into the engine.
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The TGB assembly drive pad seal drain is a manifold temperature. Emergency shutdown from high power
drain for the fuel pump, the starter, the lube/scavenge requires a longer cooling period.
pump, the external shaft seal on end of the
lube/scavenge pump, and the forward accessory pad. Post-shutdown cooling air supply for the turbine rear
frame struts and the low pressure recoup line should
The TGB assembly drain manifold fluid may be lube conform to the same air quality requirements of gas
oil, fuel, or starter hydraulic oil and cannot be returned turbine inlet air. Discharge from the fan or blower may
to the lube storage tank. be water vapor saturated air but no water droplets or
slugs are permitted. Entrained oil is not to exceed
5-6.4.4 Sump Vent Circuit 3.0 lb/min, by weight.
The engine A-, B-, C-, D-, and E-sumps vent to the 5-6.5 Sump Pressurization
packager-supplied air/oil separator system. The
allowable vent pressures into the air/oil separator at full All sumps are pressurized by LPC discharge static air
power should not exceed 2.3 psig (15.9 kPa gage). See pressure. This airflow is of sufficient volume and
figure 5-12 for sump locations and figure 5-13 for a pressure to maintain a positive airflow inward across
sump-function diagram. the inner seals to the inner sump cavity. This positive
airflow carries with it any oil on the seals, thus
Oil entrained in the vent air is normally composed retaining the oil within the inner cavity.
primarily of liquid oil droplets. These oil droplets may
constitute as much as 0.5 gal/min (32 ml/sec) from Sump pressurization air enters the outer sump cavity
each sump vent interface. through a pressurizing port. This air then passes across
the oil seals into the inner sump cavity, where it is
The amount of oil vapor discharging from the air/oil vented to the air/oil separator.
separator exhaust will vary with separator efficiency.
The air/oil separator exhaust should be located to Sump pressurization air also passes outward across the
minimize oil vapor ingestion into the engine inlet outer seals to the engine cavity.
system. Oil mist will cause compressor fouling and
engine performance loss. 5-6.6 Oil Mixing
The drain lines from the air/oil separator and the oil Mixing of MIL-PRF-23699 and MIL-PRF-7808 oils
collector, if present, should be separately routed back should be avoided. If mixing does occur, the tank
to the lube storage tank without any traps in the lines. should be drained and serviced as soon as possible.
Mixing of different brands of oil to the same
5-6.4.5 Lube and Scavenge Line specification should be accomplished by topping off
Cooling the tank with new brand.
After engine shutdown, the turbine rear frame (lube 5-6.7 Oil Consumption
supply and scavenge lines) and compressor rear frame
(LP recoup line) will require packager-supplied vent air Oil consumption is not expected to exceed 0.4 gal/hr
cooling to prevent oil line coking. This cooling air flow (1.5 l/hr). Additional oil may be lost overboard through
enters fittings near internal lube piping and provides a the engine sump vents, depending upon the efficiency
cool air film around these lines and sump walls. of the air/oil separator(s).
Cooling flow at the gas turbine should be 120°F

(48.9°C) or less and 25 psig (172 kPa gage). The
cooling flow must be supplied for a minimum of
1.5 hours after shutdown from idle to provide sufficient
time for the frames to cool below the lube oil coking
5-18 Change 1
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LM6000 PF+ GEK 119319
Figure 5-12. LM6000 PF+ Engine Sumps and Main Bearing Locations
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Figure 5-13. Sump Function Diagram
5-7 Sensors and Indicating 5-7.1.2 HP Rotor Speed

Systems The engine is equipped with two reluctance-type speed
This section describes the various engine-mounted sensors mounted in the AGB section of the TGB
sensors and indicating systems required for normal assembly for sensing HP rotor speed. The speed signal
operation of the LM6000 PF+ model. is produced by sensing passing gear teeth frequency on
a spur gear in the AGB section. Harnesses are routed to
the No. 4 electrical panel.
5-7.1 Speed Indication
Two pairs of speed sensors (two per system) are 5-7.2 Acoustic Sensors
provided to monitor low pressure turbine (LPT) rotor
speed (XNSD) and HP rotor speed (XN25). The gas turbine is equipped with two combustor
dynamic pressure sensors. These sensors are mounted
on the compressor case. The GE supplied dynamic
5-7.1.1 LP Rotor Speed
pressure sensors control and monitor combustor
The engine is equipped with two reluctance-type speed dynamic pressure. These pressure transducers are
sensors, mounted in the turbine rear frame at struts piezoelectric charge devices similar to vibration
No. 4 and 12. These sensors detect and measure the monitoring accelerometers. Each sensor has an integral
tooth-passing frequency of a toothed sensor ring lead with connector.
attached to the LPT rotor shaft. Harnesses are routed to
the No. 4 electrical panel.
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5-7.3 Vibration Sensors connected to four of the probes, are routed to

connectors on the No. 4 electrical panel.
The engine is equipped with two accelerometers, one
on the compressor rear frame and one on the turbine 5-7.4.5 Lube Supply and Scavenge
rear frame. These accelerometers provide protection Temperature
against self-induced synchronous vibration. Each
sensor is capable of monitoring both high-speed and Seven dual-element platinum RTDs are provided as
low-speed rotor vibration levels. Each accelerometer standard equipment on the engine for measurement of
sensor has an integral lead that is routed to one of the the lube oil supply and scavenge oil temperatures.
electrical panels (CRF accelerometer to the No. 3 These RTDs sense temperatures of the bearing lube
electrical panel; TRF accelerometer to the No. 4 supply and scavenge from the individual sumps (AGB,
electrical panel). TGB/A, B, C, D, and E). The cables for these RTDs are
routed to the No. 2 electrical panel. Optional redundant
Optional redundant engine accelerometers may also be RTDs may also be included.
included.
5-7.5 Pressure Sensors
5-7.4 Temperature Sensors
5-7.5.1 LPC Inlet Pressure (P2)
5-7.4.1 LPC Inlet Air Temperature (T2)
The engine is equipped with a probe which measures
The engine is equipped with a probe to measure the LPC inlet total temperature (T2) and which provides a
LPC inlet total temperature (T2) and inlet total pressure tap to measure LPC inlet total pressure (P2). The P2 tap
(P2). The probe contains a dual-element RTD with an is a threaded boss that may be connected by a tube or
integral lead terminating at the No. 1 electrical panel. hose (supplied by the packager or user) to a transducer.
The probe is located in the VIGV case which also
5-7.4.2 HPC Inlet Air Temperature (T25) contains provisions for a second optional probe.
The engine is equipped with a probe to measure the
5-7.5.2 HPC Inlet Pressure (P25)
HPC inlet total temperature (T25) and the inlet total
pressure (P25) of the HPC. The probe contains a dual- The engine is equipped with a probe which measures
element RTD with an integral lead terminating at the HPC inlet total temperature (T25) and which provides
No. 2 electrical panel. a tap to measure HPC inlet total pressure (P25). The
P25 tap is a threaded boss that may be connected by
5-7.4.3 HPC Discharge Temperature means of a tube or hose (supplied by the packager or
(T3) user) to a transducer. This probe is located in the front
frame which also contains provisions for a second
Two T3 sensors are included as standard equipment. optional probe.
The T3 sensor is a dual-element KP-KN thermocouple
with readout capability for each element. The integral
leads are routed to the No. 3 electrical panel.
5-7.4.4 LPT Inlet Gas Temperature (T48)
Eight separate shielded KP-KN (type K) thermocouple

probes are installed on the LP turbine stator case to
sense LPT inlet temperature. Each dual-element T48
sensor reads an average of the two elements for a total
of eight control readings. Two flexible harnesses, each
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5-7.5.3 LPT Inlet Gas Total Pressure Of these, PS25 and PBPV can be used for condition
(P48) monitoring or troubleshooting. The remaining two
(PS3 and PTB) are vital to engine operation and are an
NOTE integral part of the packager-supplied control system.
• A 17 cu in. (279 cu cm) line volume limit exists on For these parameters, the packager is responsible for
the PS3 and P48 sensors. Changes to the tubing sensor leads and readout devices.
should not be made without consultation with the
Other critical parameters are measured at locations off
packager.
the gas turbine. Gas supply pressures GP1, GP2A,
• The P48 sensing lines for flowpath pressure GP2B, and GP23 (figure 5-4) are critical to the
measurement must include provision for controlling of the low emissions combustor system
preventing water accumulation in the line. Contact properly. P0, which is located in the inlet to the gas
your packager for the correct configuration. turbine, is critical to the scheduling of the VIGV
system and load limiting. The sensor reads slightly less
The engine includes an LPT inlet gas total pressure than ambient when functioning properly in a clean
(P48) probe located on the right side of the LPT stator inlet. Failure to calibrate this reference using a
case. calibrated ambient pressure gauge will result in
performance loss. It is critical that proper attention is
5-7.5.4 Additional Pressure Parameters given to a process that calibrates and maintains
calibration of all pressure transducers. Incorrect
Additionally, the LM6000 PF+ model includes calibration of pressure transducers can lead to
provisions for measurement of the following pressure performance loss, poor emission characteristics, and
parameters: potentially damaged gas turbine components.
NOTE 5-7.6 Chip Detectors

• A 17 cu in. (279 cu cm) line volume limit exists on
The engine is equipped with electrical/ magnetic
the PS3 and P48 sensors. Changes to the tubing
remote-reading chip detectors in the TGB/A-sump,
should not be made without consultation with the
B-sump, and common scavenge return lines. Optional
packager.
chip detectors are available for use on the C-, D-, and
• The PS3 sensing lines for flowpath pressure E-sump scavenge lines.
measurement must include provision for
Each standard or optional chip detector indicates chip
preventing water accumulation in the line. Contact
collection when resistance across the detector drops.
your packager for the correct configuration
Chip detector leads are connected to the No. 2
• HPC inlet static pressure (PS25) electrical panel.
• HPC discharge static pressure (PS3); two locations 5-7.7 Variable-Geometry Position
• Thrust balance cavity pressure (PTB) The positions of the LPC variable inlet guide vanes, the
LPC variable bypass valves, and the HPC VSV are
• Balance piston pressure reference (PBPV) provided to the control and monitoring systems by
independent pairs of linear variable differential
transformers. Two actuators in each VG system are
equipped with LVDTs.
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5-7.8 Flame Sensors lead sensors or on-engine harnesses, which are

terminated at five electrical connector panels and the
An ultraviolet flame detector indicates the presence or two staging valve mounting brackets mounted on the
loss of flame in the engine combustion system for engine. See figure 5-14 for electrical panel locations.
engine control system logic use in sequencing and
monitoring. The flame detector hardware consists of 5-8.1 Ignition System
two ultraviolet sensor assemblies and two flame
viewing window assemblies mounted on two holes in The ignition system consists of a high-energy igniter, a
the compressor rear frame. The flame sensors come high-energy capacitor-discharge ignition exciter, and
equipped with cooling cans and integral leads, which an interconnecting cable. A redundant ignition system
are connected directly to the packager-supplied signal that replaces a plug in the compressor rear frame is also
conditioner. Cooling air for the system is packager- available. The ignition cables interconnect directly
supplied and must be kept on for a minimum of between the package-mounted exciters and the igniters,
30 minutes following a normal shutdown. which are mounted on the engine compressor rear
frame.
5-7.9 Bleed Air Control System
During the start sequence, fuel is ignited by the igniter,
The bleed air control system consists of the on-engine which is energized by the ignition exciter. Once
VG hydraulic pump and two off-engine HPC bleed combustion becomes self-sustaining, the igniter is
valves (stage 8 and CDP) and valve actuators. The deenergized. The maximum duty cycle is a maximum
bleed valves each house a torque-motor positioned of 90 seconds ON and two start cycles within a
hydraulic servo for porting fluid at regulated pressure. 30 minute period.
The purchaser is required to supply hydraulic piping
between the supply and return connections to the HCU 5-8.2 Cabling
and the servos on the two off-gas turbine bleed air
control valve actuators. Positioning of the bleed air The LM6000 PF+ model is optionally supplied with
control valves is scheduled by purchaser-supplied electrical cables for interconnection between the
control system electrical inputs to the servo valves. package-mounted junction boxes and the engine. Each
Position feedback is provided by LVDTs integral with of the cables connect to the engine at one of five
the actuators. electrical panels (figure 5-14). Instrumentation leads
must be shielded, isolated from power leads, and run in
5-8 Electrical System conduits carrying only other very low level leads.
Figure 5-14 provides the identification and panel
The engine electrical system consists of the ignition designation for the cables supplied as standard.
system and the cabling for the control and Table 5-2 defines the abbreviated nomenclature used in
instrumentation. The system is designed for high figure 5-14.
reliability and ease of maintenance by utilizing integral
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GEK 119319 LM6000 PF+
Figure 5-14. LM6000 PF+ Model Electrical Panel Locations
5-24 Change 1
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LM6000 PF+ GEK 119319
Table 5-2. LM6000 PF+ Electrical Cable Panel Nomenclature

Abbreviation Nomenclature
AGB Accessory Gearbox
CRF Compressor Rear Frame
LVDT Linear Variable Differential Transformer
RTD Resistance Temperature Detector
TC Thermocouple
T/M Torque Motor
TGB Transfer Gearbox
TRF Turbine Rear Frame
T48 Low Pressure Turbine Inlet Temperature
T2 Low Pressure Compressor Inlet Temperature
T25 High Pressure Compressor Inlet Temperature
T3 High Pressure Compressor Discharge Temperature
VBV Variable Bypass Valve
VIGV Inlet Guide Vane
VSV Variable Stator Vane
XNSD Low Pressure Turbine Rotor Speed
XN25 High Pressure Rotor Speed
5-8.3 Electrical Panels 5-9 Bleed System

The LM6000 PF+ model is equipped with five Stage 8 and HPC discharge air (CDP) are used for
electrical panels mounted on the engine. These panels combustor flame temperature control. Extraction of
provide a convenient intermediate interface point HPC bleed air affects the performance, component life,
between the engine instrumentation sensors and the and available power output of the engine. Bleed air is
enclosure interface. Figure 5-14 illustrates the five not available for use by the customer.
panel locations. The advantages of these interface
panels are listed as follows: 5-10 High Pressure and Low
• Simplified installation and removal of the engine Pressure Recoup System
• Keyed or sized connectors to prevent incorrect The compressor rear frame B- and C-sump
mating pressurization system is isolated from the HPC by the
CDP and vent labyrinth seals. These seals serve to form
• The positive-lock threaded connectors specified HP recoup and LP recoup chambers. The HP recoup
eliminate the need for safety wiring the connectors. airflow results from compressor discharge air leaking
across the CDP seal. The LP recoup airflow develops
from the HP recoup air leaking across the vent seal.
Change 1 5-25
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GEK 119319 LM6000 PF+
5-11 Engine Control Unit 5-15 Air System Tubing and Frame
Strut Functions
The ECU, supplied by the packager, performs the fuel,
bleed, VG and scheduling, engine start and stop The LM6000 PF+ model has 11 major external
sequencing, and data acquisition for support of the pneumatic tubing designs and three strut locations. The
engine monitoring system. Alarm and shutdown logic struts are located in the front frame, CRF, and turbine
is included in Chapter 10, Troubleshooting. rear frame. See figure 5-16 and figure 5-17 for tubing
locations and figure 5-18 for strut functions.
5-12 Low Pressure Rotor Balance
Piston System 5-15.1 A-, B-, C-, D-, and E-Sump Vents
A balance piston system has been included in the aft Two interfaces are provided to the customer for
end of the engine. See figure 5-15. The system is venting the three bearing sumps. These vents direct the
designed to provide the required thrust load on the No. sump air/oil mixtures overboard so the customer can
1B bearing. reclaim lubrication oil.
The balance piston system consists of the balance 5-15.2 B- and C-Sump Pressurization
piston disk, the balance piston casing, their associated
seals, and the dome-shaped cavity formed by these LPC discharge air from the front frame is directed
parts. This cavity is pressurized by stage 8 and CDP through a single manifold to the CRF where it supplies
bleed air, mixed in an ejector, and controlled by an pressurization air for the B- and C-sump.
orifice in the supply line downstream of the ejector.
5-15.3 Balance Piston
The balance piston casing is attached to the aft inner
hub of the TRF; the balance piston disk is attached to This cavity is pressurized by stage 8 and CDP bleed air,
the LPT shaft. mixed in an ejector, and controlled by an orifice in the
supply line downstream of the ejector. This air is
5-13 Water-Wash System directed aft into the TRF at struts 3, 9, and 13 for
supplying the balance piston system cavity.
A water-wash system can be provided by the packager
to remove contaminants that accumulate in the LPC 5-15.4 HPC Stage 8 Bleed
and HPC, resulting in a loss of performance.
Stage 8 bleed air is extracted through holes bored in the
There are two methods of water-washing available: stator casing aft of the stage 8 vane dovetails. The
crank-soak and on-line cleaning. Technique associated bleed air is available at two interface ports on the HPC
with a working water-wash system that maintains case. One is used for the pressure balance piston air
compressor efficiency is very much dependent on site supply through an ejector driven by 11th stage air; the
conditions. Each operator should, by testing, choose other is used for SPRINT® air and DLE combustion
the proper fluid and wash frequency based on their temperature control. The purchaser is required to
plant economics. Water-wash recommendations and provide the interconnecting piping between this
procedures are covered in WP 4014 00. interface for both SPRINT® and stage 8 bleed valve.
5-14 Engine Airflow

A schematic representation of the internal and external
gas turbine air flows is shown in Chapter 4, figure 4-1.
5-26 Change 1
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LM6000 PF+ GEK 119319
Figure 5-15. Low Pressure Rotor Balance Piston System
Change 1 5-27
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GEK 119319 LM6000 PF+
Figure 5-16. LM6000 PF+ Model Gas Turbine - Left Side View
5-28 Change 1
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LM6000 PF+ GEK 119319
Figure 5-17. LM6000 PF+ Gas Turbine - Right Side View
Change 1 5-29
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GEK 119319 LM6000 PF+
Figure 5-18. LM6000 PF+ Model Gas Turbine - Strut Functions
5-30 Change 1
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LM6000 PF+ GEK 119319
5-15.5 Compressor Discharge Pressure SPRINT® water injection is automatically initiated

Bleed only at Ps3 values within 50 psi (344.7 kPa) of the dry
Ps3 schedule. Reference Chapter 8 on operation of the
The CDP bleed manifold combines two compressor SPRINT® System.
case bleed ports into a single interface. The purchaser
is required to provide the interconnecting piping Injection nozzles are installed in the radial inlet volute
between this interface and the CDP bleed valve. to enable LPC inlet injection which provides
evaporative cooling benefits during hot-day operation.
5-15.6 High Pressure and Low Pressure The inlet mist injection is disabled during potential
Recoup below-icing conditions (T2 <45°F [7.2°C]).
The HP recoup air is connected by manifolds from the 5-16.1 SPRINT® Systems with LP Inlet
compressor rear frame struts 4 and 10 to the LPT stage Injection
1 nozzle area on the LPT case. HP recoup air is used
for cooling of the aft position of the LPT stage 1 nozzle The on-engine system is comprised of:
vanes. LP recoup air is bled overboard from CRF struts
6 through 8. • 17 injector nozzles mounted in the inlet volute
• Two manifolds (air and water) mounted forward of

5-15.7 HPT Cooling the air collector
Stage 11 HPC bleed air is used for cooling the stage 2 • 34 feeder tubes which deliver the air and water to
HPT nozzle. Four external tubes extract stage 11 air the nozzles
from the compressor and are branched into eight ports
on the HPT case. • Atomizing air supply line from the compressor to
the atomizing air manifold
5-15.8 LPT Cooling
The off-engine part of the system includes:
Stage 8 HPC air is routed through two manifolds to the
stage 1 LPT nozzle for cooling its leading edge cavity. • Water supply pump, metering device flow
measuring, and air and water control on-off valves
5-15.9 Passive Clearance Control
• Air supply lines from compressor extraction to
LPC discharge air is extracted at the front frame and SPRINT® air manifold
discharged through small holes in tubing that surrounds
the LPT case. The cooling air reduces LPT clearance • Pressure taps to sense manifold pressures and send
resulting in increased turbine efficiency. to the control
• 17 inlet volute mounted nozzles

5-16 SPRINT® System
• An atomizing air manifold and supply piping
SPRINT® is an optional equipment system which
allows higher power operation for inlet temperatures • An inlet volute mounted water manifold
above 30°F (-1.1°C). SPRINT® operates as an
intercooler by injecting a fine water mist into the
compressor airflow and reduces the temperature of the
air as it evaporates in the front compression system.
The water is atomized to a fine aerosol mist using

atomizing air extracted from stage 8 of the HPC.
Change 1 5-31/(5-32 Blank)
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/03) *(.

Chapter 6
Service and Support Requirements
6-1 Purpose and Scope 6-2.1 Engine Shipment
CAUTION
This chapter defines the following service and support
requirements associated with the LM6000 PF+ gas ENSURE CRANE IS OF SUFFICIENT LIFTING
turbine. CAPACITY WHEN MOVING SHIPPING CON-
TAINER WITH ENGINE INSTALLED, INTO AND
• Shipping OUT OF TRUCK.
• Storage NOTE
• Installation/removal Both the engine and LPT module containers can be
air-shipped on the 747F, L1011, or C130. The LPT
• Auxiliary systems module can also be air-shipped on DC10CF, C130,
A300C, and A310C/F aircraft.
• Support services
a. The engine assembly is shipped in a metal con-
• Maintenance tainer, equipped with shock mounts to avoid dam-
age to the engine bearings during shipment. The
The information provided is general but not all- container has a pressure relief valve for controlled
inclusive. References are made to other sections of this breathing, humidity indicators, and a desiccant
manual and to specific maintenance work packages container for a controlled environment.
(WP) that cover these topics in detail.
b. Weights and dimensions of the container are
6-2 Shipping shown in table 6-1. Maximum gross weight
(MGW) is the combined weight of the engine and
The engine is shipped from the factory as a complete container. Tare is the weight of an empty container
assembly, including the engine, fuel manifold, engine- and Net is the weight of the engine.
mounted accessories, external configuration hardware,
and engine mounted sensors. The engine is shipped on c. The installation of the air ride (Soft Ride) kit
an air-ride tractor trailer or a conventional tractor trailer SWP 3014 01 adds approximately 2000 lb (907
can be used if an air ride (soft ride) kit is installed onto kg) to the weight, and 48 inches (122 cm) to the
the shipping container per SWP 3014 01. The air ride length, of the container.
(soft ride) kit is designed to reduce the possibility of
bearing damage in engines installed in shipping d. In the event that the engine requires repair at a
containers in areas where tractor trailers with air-ride designated repair facility, it should be shipped to
suspensions may not be available. the facility in the shipping container. Installation
of the engine in the shipping container is covered
If the gas turbine and fuel system are removed from the in WP 3014 00.
enclosure in preparation for shipment, the fuel system
must be properly drained and purged of gas or liquid
fuel prior to removal as covered in WP 3010 00.

*(. /03)

Table 6-1. Weights and Dimensions of the LM6000 Shipping Containers

LM6000 LM6000 LM6000 LM6000 LM6000 LM6000
PA PA, PB PA, PB *PA, *PB, PC, *PA, *PB, PC *PA, *PB, PC,
PD, PF, PF+, PD, PF, PG,
PG, PH PH
106C7154P01 106C7154P02 106C7154P03 106C7154P04 106C7154P05 106C7154P07
MGW 24,790 lb 27,910 lb 27,660 lb 30,619 lb 30,619 lb 30,819 lb
11,245 kg 12,660 kg 12,546 kg 13,892 kg 13,892 kg 13,983 kg
TARE 10,220 lb 10,619 lb 10,369 lb 10,619 lb 10,619 lb 10,819 lb
4,636 kg 4,817 kg 4,703 kg 4,817 kg 4,817 kg 4,907 kg
NET 14,570 lb 17,291 lb 17,291 lb 20,000 lb 20,000 lb 20,000 lb
6,609 kg 7,843 kg 7,843 kg 9,072 kg 9,072 kg 9,072 kg
CUBE 1224 cu ft 1274 cu ft 1224 cu ft 1274 cu ft 1274 cu ft 1274 cu ft
35 cu m 36 cu m 35 cu m 36 cu m 36 cu m 36 cu m
WIDTH 8.5 ft 8.5 ft 8.5 ft 8.5 ft 8.5 ft 8.5 ft
2.6 m 2.6 m 2.6 m 2.6 m 2.6 m 2.6 m
HEIGHT 8.3 ft 8.3 ft 8.3 ft 8.3 ft 8.3 ft 8.3 ft
2.5 m 2.5 m 2.5 m 2.5 m 2.5 m 2.5 m
LENGTH **17.5 ft ***18.2 ft **17.5 ft ***18.2 ft ***18.2 ft ***18.2 ft
5.3 m 5.6 m 5.3 m 5.6 m 5.6 m 5.6 m
* Uprate Engines **210.0 inches (533 cm) ***220.0 inches (559 cm)
Note: The installation of an air ride (soft ride) kit adds approximately 2000 lb (907 kg) to the weight, and 48
inches (122 cm) to the length, of a container.

/03) *(.

6-2.2 Low Pressure Turbine Module Notify GE of any unusual engine/container ship-
Shipping ping event such as dropped container (with engine
installed) or tractor trailer accident. All special
NOTE events require a report to your GE representative
Both the engine and LPT module containers can be for disposition of the gas turbine/gas generator.
air-shipped on the 747F, L1011, or C130. The LPT
module can also be air-shipped on DC10CF, C130, 6-2.4 Container and Engine Lifting
A300C, and A310C/F aircraft.
GE recommends the following prior to lifting a
a. The low pressure turbine (LPT) module, LM6000 shipping container:
consisting of the LPT rotor, LPT stator, turbine
rear frame, and aft drive adapter, can be a. Visually inspect lifting features for cracks.
transported in a unique reusable metal shipping
b. If cracks noted, document and report findings
container. This container is 95 inches (241.3 cm)
to GE.
long by 88 inches (223.5 cm) wide by 80 inches
(203.2 cm) high. Similar to the engine assembly c. If cracks noted, local weld repair is authorized.
container, it is equipped with shock mounts to Weld procedure is provided in LM6000 Service
avoid damage to the No. 6R and No. 7R bearings Letter No. 6000-04-08.
during shipment. It has a pressure relief valve for
controlled breathing, humidity indicators, and a d. Utilize a Quad Sling of 144 inches (3658 mm)
desiccant container for a controlled environment. minimum length (45 degrees standard practice)
for lifting as indicated in figure 6-1, sheet 2.
b. The weight of the container is approximately
5200 pounds (2359 kg) empty and 11,600 pounds
6-2.5 Enclosure Shipping
(5262 kg) loaded. Installation of the LPT module
in the shipping container is covered in In the event that the engine is to be shipped already
WP 3017 00. mounted in the enclosure (package), the design of that
enclosure shall meet the requirements listed above for
6-2.3 Engine Shipping Container the shipping container.
a. The shipping container described in

6-2.6 Highway Shipping
paragraph 6-2.1 and shown in figure 6-1 is
equipped with a vibration-attenuation support CAUTION
system. It protects the engine from damage when
subjected to repetitive or nonrepetitive loads at the SHIPMENT BY RAIL TRANSPORTATION IS NOT
container mount interface locations during ACCEPTABLE.
transportation and handling.
b. All aero engines (gas turbines and gas generators)

are to be transported on air ride tractor trailer or
conventional tractor trailer with air ride (Soft
Ride) kit installed (SWP 3014 01) for the specific
engine and shipping container. Aero engines are
not approved for transportation by rail type
systems.

*(. /03)

CAUTION 6-2.7 On-Site Transportation

SHIPPING OF THE ENGINE/CONTAINER
CAUTION
SYSTEM REQUIRES THE USE OF A PNEUMATIC
SUSPENSION TRACTOR TRAILER FOR IF THE ENGINE IS REMOVED FROM THE
HIGHWAY SHIPMENT. A CONVENTIONAL CONTAINER OR ENCLOSURE AND
TRACTOR TRAILER CAN BE USED IF AN AIR TRANSPORTED USING THE LM6000 PF+
RIDE (SOFT RIDE) KIT IS INSTALLED ONTO MAINTENANCE DOLLY, SPEED DURING THAT
THE SHIPPING CONTAINER. WHEN USING A MOVEMENT SHOULD BE LIMITED TO A
PNEUMATIC SUSPENSION TRACTOR AND MAXIMUM OF 2 MPH. FAILURE TO COMPLY
TRAILER, THE ENGINE CONTAINER SHALL BE WITH THIS REQUIREMENT MAY RESULT IN
SECURED TO THE TRAILER IN SUCH A DAMAGE TO THE ENGINE BEARINGS.
MANNER THAT THE SHOCK-ABSORBING
CAPABILITY OF THE CONTAINER IS NOT Figure 6-2 illustrates the LM6000 PF+ maintenance
DISABLED. TIE-DOWN POINTS ARE PROVIDED dolly. Use of the maintenance dolly is covered in
ON BOTH SIDES OF THE LOWER PORTION OF WP 3012 00. A ground handling dolly is available for
THE CONTAINER, FORE AND AFT. FAILURE TO transportation on-site. Contact GE M&IAD for details
COMPLY WITH THIS REQUIREMENT MAY of use.
RESULT IN DAMAGE TO THE ENGINE
BEARINGS. WHEN USING A CONVENTIONAL
TRACTOR TRAILER WITH AN AIR RIDE (SOFT
RIDE) KIT INSTALLED ONTO THE SHIPPING
CONTAINER, THE AIR RIDE (SOFT RIDE)
BOXES ON EACH CORNER OF GAS TURBINE
SHIPPING CONTAINER SHALL BE SECURED TO
TRUCK TRAILER BED, USING CHAINS
BETWEEN TRAILER AND TIE-DOWN RINGS ON
AIR RIDE (SOFT RIDE) BOX. MAKE SURE
SHIPPING CONTAINER IS NOT DIRECTLY
CHAINED TO OR IN DIRECT CONTACT WITH
TRAILER BED, OR DAMAGE TO THE ENGINE
BEARINGS MAY RESULT.

/03) *(.

Figure 6-1. Engine Shipping Container (Sheet 1 of 2)

*(. /03)

Figure 6-1. Engine Shipping Container (Sheet 2 of 2)

/03) *(.

6-3 Storage If the fuel manifolds or other fuel system components

are shipped with the engine, the system must be
The engine is prepared for long-term storage when properly drained and purged of gas or liquid fuel
shipped from the factory or from a repair facility. consistent with regulatory requirements for hazardous
Long-term storage includes the following elements: materials prior to installation in the shipping container.
Separate fuel system drain and purge requirements for
• Lubrication system is flushed with rust both ground and air shipment are included in
preventative WP 3010 00.
• Inlet is covered • Overhead installation/removal through an opening

in the top of the enclosure requires the use of an
• Air collector is covered on-site or mobile crane and an adjustable beam.
• Exhaust is covered • Side installation/removal requires the engine to be
lifted using an adjustable beam and the ground
• Lines are connected or capped handling points, so it can be moved laterally
into/from the enclosure.
• Container is hermetically sealed and provided with
desiccant for humidity control
6-4.2 Size/Weight
Should temperature, pressure, and/or humidity
conditions be such that the desiccant seen through the The following information is provided for installation,
container inspection port is pink, then the container removal, and on-site movement planning.
must be serviced in accordance with WP 3014 00.
• Engine Length: 193.5 inches (491.5 cm), Variable
When an LM6000 gas turbine is to be stored for an Inlet Guide Vane (VIGV) forward flange to aft
extended period of time, precautions must be taken to drive adapter
preserve the gas turbine in order to minimize exposure
• Engine Width: 84.7 inches (215.1 cm), air collector
to atmospheric corrosion. Details of preservation
upper flange
depend on the duration of nonoperation and whether
the gas turbine is being stored in an engine enclosure or • Engine Height: 83.0 inches (210.8 cm), LPT
in a shipping container. Table 6-2 provides a summary piping to Accessory Gearbox (AGB) low point
of these details. Refer to WP 3011 00 for details of
precautions and preservation procedures. The estimated weight and center of gravity of the
engine with VIGV installed offered are 16,827 lbs
6-4 Installation/Removal (7633 kg) and axial station 233 inches (5.9 m),
respectively, without the fuel system. The fuel system
This section provides general descriptions of weight is 1702 lbs (772 kg). See table 6-3 for weights
procedures and elements requiring consideration and centers of gravity of the major components.
during installation and removal of the engine. Centers of gravity are axial station numbers; for
reference, the VIGV forward flange (or inlet frame)
6-4.1 Installation/Removal Methods station is 140.44 inches (3.567 m). All dimensions are
measured in the aft direction from the VIGV forward
Installation of the engine into, or removal from, the flange (or inlet frame).
enclosure will normally be accomplished by one of two
methods listed below. Installation and removal
procedures are covered in WP 3010 00.

*(. /03)

Figure 6-2. Maintenance Dolly

/03) *(.

Table 6-2. Engine Preservation Summary (Refer to WP 3011 00)

Timing: Less Than 30 Days Greater Than 30 Days
Inspection Requirement Inspection Requirement
Engine installed in package Inspect inlet Inspect inlet
Inspect exhaust Inspect exhaust
Inspect VBV duct (if accessible) Inspect VBV duct (if accessible)
Oil wet bearings (BRAYCO 599, or Oil wet bearings (BRAYCO 599, or
equivalent, required if preservation equivalent, required)
period greater than 15 days) Cover inlet (optional)
Cover inlet (optional) Cover exhaust (optional)
Cover exhaust (optional) Cover VBV (optional)
Cover VBV (optional) Oil wet bearings every 30 days
(BRAYCO 599, or equivalent,
required)
Engine installed in container Oil wet bearings (BRAYCO 599, or Oil wet bearings (BRAYCO 599, or
equivalent, required if preservation equivalent, required)
period greater than 15 days) Install desiccant
Install desiccant Inspect desiccant every 30 days
Inspect desiccant every 30 days If blue:
If blue: No action required
No action required If pink:
If pink: Oil wet bearings within 14 days
Oil wet bearings within 14 days Install new desiccant
Install new desiccant
Engine installed in Oil wet bearings (BRAYCO 599, or Oil wet bearings (BRAYCO 599, or
maintenance dolly or pedestal equivalent, required if preservation equivalent, required)
period greater than 15 days) Cover inlet
Cover inlet Cover exhaust
Cover exhaust Cover VBV
Cover VBV Oil wet bearings every 30 days
(BRAYCO 599, or equivalent,
required)

*(. /03)

Table 6-3. LM6000 PF+ and Major Component Weight and Center of Gravity
Center of Gravity Engine
Weight Station
Component lb (kg) in. (m)
Engine without Fuel System 16,827 (7633) 233 (5.9)
Engine with Gas Fuel System (Note 1) 18,529 (8405) 233 (5.9)
VIGV Module (Note 2) 575 (261) 145 (3.7)
LPC Module (Note 2) 2700 (1225) 159 (4.0)
Air Collector (Note 2) 1000 (454) 190 (4.8)
Accessory Gearbox (Note 2) 580 (263) 190 (4.8)
NOTES:
(1) Weight with fuel system includes weight of manifold support tool as shipped. When installed in the
enclosure, manifolds are supported off-gas turbine with support tool removed.
(2) This component may be removable inside the enclosure.
6-4.3 Engine Mount Attachments 6-4.4 Engine Power Output Shafts
Mounting attachments are provided in five places on The engine is equipped with flanged drive adapters at
the engine. The forward two mount points are located both the forward and aft ends to accommodate forward
aft of the low pressure compressor (LPC) bypass air or aft drive arrangements. The packager-supplied
collector at the 3:00 and 9:00 o’clock positions. coupling shaft, which mates with the engine drive
adapter, incorporates a close-tolerance rabbet-fit and
a. The forward mount connections are accomplished must be dynamically balanced and aligned in
by uniballs and pillow blocks supported by accordance with packager-supplied instructions. This
stanchions or a similar design, as shown in must be done during initial installation and subsequent
figure 6-3. These mounts are designed to provide to any removal or replacement of the engine.
support in all directions and are sized to
accommodate axial thrust, operating torque, and
vibratory loads. The two engine-mounted
trunnions are not to be removed from the engine;
all hardware is packager-supplied.
b. The turbine rear frame is equipped with three

mount attachments, as shown in figure 6-3. These
mounts are designed to provide for vertical and
lateral support of the engine.

/03) *(.

Figure 6-3. Engine Mount Diagram

*(. /03)

6-4.5 Flange Interfaces 6-5.1 Inlet System
a. The VIGV case forward outer flange mates with There are two basic inlet system designs for the engine.
the outer flowpath structure of the packager's inlet A radial inlet is required for a front drive application
system. and may be used with a rear drive configuration. An
axial inlet with a bellmouth and centerbody can only be
b. The VIGV forward inner flange mates with either used with a rear drive configuration. These two
the packager-supplied radial air inlet system or the arrangements are shown schematically in figure 6-4,
centerbody (bullet nose) supplied with the engine figure 6-5, and figure 6-6.
for axial air inlet system. Refer to the appropriate
section of the packager's manual for details. CAUTION
ENSURE THE CLEARANCE BETWEEN THE
c. For installations with an axial inlet, a packager-
INLET BAFFLES AND THE VIGV FORWARD
supplied air inlet bellmouth is independently
FLANGE IS CORRECT OR ENGINE DAMAGE
supported at the forward enclosure bulkhead. The
COULD RESULT. REFER TO THE PACKAGER'S
flowpath between the bellmouth and the engine is
MANUAL FOR THE PROPER CLEARANCE
formed by a liner following the contour of the
DIMENSION.
bellmouth. Any gap outboard of this liner must be
sealed to prevent inflow of ambient air. • The air inlet system provides for the following:
d. The aft or exhaust interface flanges are on the • Clean airflow with minimum pressure loss in order
turbine rear frame. The outer and inner flanges to minimize any effect on engine performance.
mate with the packager's exhaust outer and inner
flowpath diffuser. These joints normally • An inlet screen forward of the VIGV and LPC to
incorporate a piston ring assembly to protect compressor flowpath components from
accommodate thermal growth of the engine. ingesting foreign objects.
6-5 Auxiliary Systems • Mounting of a nylon mesh screen (on the inlet
described above) with openings that do not exceed
Provision is made in the packager’s design to 800 micrometers and a porosity rating of
accommodate the following conditions and auxiliary 55-60 percent open area.
requirements.
• After 1000 hours of operation in which no debris is
found in the inlet plenum or captured by the screen,
the operator/user may find it advantageous to
replace the 800-micrometer screen with a coarser
1200-micrometer mesh to reduce the rate of screen
fouling. A 55-60 porosity rating is recommended.

/03) *(.

Figure 6-4. Radial Inlet Duct Interface

*(. /03)

Figure 6-5. Radial Inlet Duct
Figure 6-6. Axial Inlet Duct Interface

/03) *(.

6-5.1.1 Air Filtration The anti-icing system, whether installed by the

operator/user or the packager, must ensure that the
a. The air entering the inlet of the engine must meet humidity and temperature measured at the engine inlet
the following conditions: are within the limits shown in figure 6-7.
• 95 percent of the time: must not contain solid An alternate method, which eliminates the need for a
particles exceeding 0.004 grains/1,000 ft3 humidity sensor, is to heat the inlet air 10°F (5.6°C)
(0.0097 grams/1,000 m3) above ambient temperature when ambient temperatures
are less than 30°F (-1.1°C) and to heat the inlet air to
• 5 percent of the time: must not contain solid 40°F (4.4°C) when ambient temperatures are between
particles exceeding 0.04 grains/1,000 ft3 30°F and 40°F (-1.1°C and 4.4°C). No heating is
(0.097 grams/1,000 m3) required for ambient temperatures above 40°F (4.4°C).
b. For operation in marine environments, sodium
6-5.2 Exhaust System
entering the engine should not exceed
0.00045 ppm average or 0.003 ppm maximum. To recover the greatest amount of exhaust total
These limits apply to both air entering the engine pressure, a rear diffuser is used to decelerate the flow.
and to the cooling air supply. Depending on fuel Figure 6-8 shows a radial diffuser arrangement. An
characteristics, inlet air contamination may axial design diffuser is shown in figure 6-9. The inner
require restriction below the levels stated above. and outer diffuser walls connect to the turbine rear
The combination of entrained sodium entering the frame through piston ring seals. Figure 6-10 shows the
engine through inlet air and fuel contamination diffuser/piston ring interface.
must not exceed 0.2 ppm. See Appendix A1.
c. The maximum allowable liquid water content in 6-5.3 Secondary Cooling Air
the inlet air is 0.5 percent of the inlet airflow
During operation, heat is released by the engine
weight (approximately 350 lb/s [159 kg/s]) at air
through radiation and convection from hot surfaces, by
inlet temperatures of 42°F (5.6°C) and above. At
hot air leakage, and by vent air. In order to maintain
temperatures below 42°F (5.6°C), no liquid water
enclosure and engine component temperatures at
content is allowed due to the potential for icing.
acceptable limits, secondary cooling air must be
provided.
6-5.1.2 Anti-Icing
Secondary cooling air must be filtered so that solid
Under certain conditions, as a function of temperature material in the air does not exceed 0.2 grains per
and humidity, ice can form at the engine inlet, be 1000 ft3 (0.013 grams per 28.32 m3) of air and the size
ingested into the flow path, and cause foreign object and density distribution should be such that no more
damage (FOD). The engine is not equipped with an than 5 percent (by weight) of the solid particles are
integral anti-icing protection system. GE does 10 micrometers or greater in size. Air containing salts,
recommend, however, that such a system be installed or other corrosive elements, have a harmful effect on
and operational for any installation operating in a the engine and must be filtered or washed from
climate where the temperature can fall below 40°F secondary cooling air circuits.
(4.4°C).

*(. /03)

Figure 6-7. Temperature/Humidity Limits
Figure 6-8. Radial Exhaust Diffuser

/03) *(.

Figure 6-9. Axial Exhaust Diffuser
6-6 Support Services • Water supply and control system for water-washing
of the engine
The following packager/operator-supplied support
services are required for operation of the engine as part • Engine cooling and post-shutdown frame cooling
of the overall system.
• Anti-icing system (as applicable)
• Unloading and installation of all equipment
• Vent and drain systems
• Fuel supply to the engine in accordance with the
applicable GE specification • Electric power supply
• Verification of site conditions, including inlet air • Control and instrument panel, including all
quality and fuel quality interconnecting wiring and piping
• Lubrication system external to the engine • Air, natural gas, or hydraulic supply to the starter
and discharge ducting or piping from the starter
• Fuel metering and control systems; engine speed-
governing and protection systems • Personnel safety protection features
• Engine base, mounting structure, sound enclosure, • Condition-monitoring systems

inlet system, exhaust system, and front or rear
flexible drive coupling
• Fire detection and protection system

*(. /03)

6-7 Maintenance
The engine is designed and mounted in the enclosure
with consideration of site maintenance requirements.
Maintenance activity on the engine falls into the three
following categories:
Level 1: Any maintenance activity associated with the

exterior of the engine, up to, and including, removal
and reinstallation of the complete engine assembly.
Level 2: Any maintenance activity associated with the

interior or flowpath of the engine. This includes
removal and replacement of complete module
assemblies, such as, the VIGV, LPC, AGB, High
Pressure Compressor (HPT), and other components.
Depot: Any activity that requires detailed teardown

and/or test verification that can only be accomplished
in a designated repair facility.
All level 1 and 2 maintenance activities are detailed in
individual work packages contained in Volume II of
this manual.

/03) *(.

Figure 6-10. Diffuser/Piston Ring Interface
%ODQN
/03) *(.

Chapter 7
Installation and Startup
7-1 Purpose and Scope 7-4 Pre-Startup Inspections
This chapter covers the installation procedure The engine and package should undergo a thorough
references, pre-startup inspections, and verification pre-startup inspection, during installation or after
tests for the engine following initial installation and/or maintenance, to ensure a trouble-free transition from
subsequent removal, and replacement or maintenance installation to full operation. This inspection will help
of the engine, major components, or supporting to detect potential installation problems. Record the
systems. results of the prestartup inspection checklists provided
in figure 7-1 through figure 7-4 to ensure a complete
7-2 General prestart inspection was performed. The following
inspections should be performed during installation of
The following procedures are intended to provide the engine in the enclosure:
operating personnel with the information required to
operate the engine safely and reliably. Some of the a. Perform an external inspection per WP 4012 00.
information contained in this chapter is also provided, Ensure that all air tube, hose, and electrical
in whole or part, in other chapters. Redundancy is used harness and cable connections are tight and that no
to provide as much specific detail as required. Some binding or chafing is evident. Shake all air tubes
material is generic in nature and may not apply to a and hard leads to ensure that they are secure and
specific engine model or installation. It is also likely clamps are tight. Ensure that gas turbine
that the information may not provide for every components do not contact package components
variation in installation equipment, or contingency to (at noninterface locations). Failure to do so will
be found in conjunction with engine operation. result in accelerated component wear.
Customer's should comply with that which is
b. Ensure all electrical harnesses, cables, and leads
applicable to their model or configuration. Additional
are properly routed and connected. Verify
information can be provided by the packager or by GE.
interfaces are correct.
The material provided in Chapter 8 on Safety
Equipment and Engine Protection should be previewed
prior to proceeding.
7-3 Installation
If not already installed in the package, the engine
should be installed according to the packager's
requirements and specifications. For specific details on
installation, refer to WP 3010 00 and WP 3014 00 and
to the packager's manual.

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Figure 7-1. Site Information Checklist (Sheet 1 of 5)

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Figure 7-2. Prestart-up and Operability Review Checklist (Sheet 1 of 13)

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Figure 7-3. Distillate Fuel Systems (Including D/F Systems) Checklist (Sheet 1 of 7)

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Figure 7-4. Gaseous Fuel Systems Checklist (Sheet 1 of 3)

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c. Inspect the engine inlet area per WP 4010 00. i. Ensure that the air/oil separator system and all
Thoroughly clean inlet plenum of dirt and foreign vents and drains are free and clear. Remove any
objects. Vacuum and/or wash the area as restrictions, and clean as required.
necessary. In addition, GE strongly recommends
that all inlet areas upstream of the engine interface j. Ensure that the gas turbine fuel meets GE
be thoroughly inspected and cleaned. No specification requirements. Based on experience,
fasteners, loose or trapped material, or weld GE strongly urges customers to regularly check
slag/spatter is allowed. Weld splatter that is fuel samples, particularly given the damaging
attached to or trapped behind the inlet plenum effects of noncompliant fuel on gas turbine
perforated plate must be completely removed. components. GE also recommends that particular
Remove weld splatter by mechanical means, as attention be given to the Fuel Forwarding
required. Failure to remove all loose or weakly Recommendations provided in the Liquid Fuel
constrained material will likely result in gas Specification and Chapter 5 to assure that fuel
turbine damage from material ingested through remains continuously free of contamination.
the gas turbine inlet.
k. Verify packager fuel and hydraulic system for
d. Inspect bleed air ducting to ensure the system is correct installation. Reference the appropriate
free of blockage and the exhaust area is clear as packager's manual.
specified in Chapter 8. Inspect bleed air ducting
including potential traps for debris. No weld l. Verify bleed valve operation. Calibrate eighth and
slag/splatter or loose material is allowed. Clean compressor discharge pressure (CDP) bleed
using mechanical means as required. valves per appropriate packager's manual.
Visually confirm that valve opens (100 percent
e. Perform an exhaust system inspection per stroke). A slot on the end of the valve shaft should
WP 4013 00. Ensure that exhaust components are be parallel to the air flow when open. Visually
aligned with the turbine rear frame, that there are confirm that the valve closes (zero percent stroke).
no obstructions, and that the flowpath is smooth. The shaft slot should be perpendicular to air flow
when closed.
f. Ensure that lube, fuel, and purge systems are
properly routed and connected. Assure that gas m. Calibrate the acoustic sensor signal conditioning
manifolds are aligned properly per WP 3015 00. system per WP 1611 00.
g. Ensure that the lube system is properly serviced. n. Verify natural gas properties input to control.
Engine oil should be MIL-PRF-23699F per the Obtain recent gas properties from the fuel supplier
requirements of Chapter 5. GE recommends that and compare to the site gas properties device
the lube system be flushed prior to gas turbine output. The device must be calibrated. Specific
installation for a new plant, prior to installation of gravity (SG), lower heating valve (LHV), and
engine or module replacement due to lube or sump ratio of specific heats (K) are required. Some fuel
component failure, or on-site repair of the gas systems require mole percent of N2; mole percent
turbine lube supply system (reference Chapter 8). CO2. Unstable gas properties can present
difficulties for controlling the gas turbine. Contact
h. Inspect lube and scavenge pump screens, and GE M&I if gas supply properties are unstable.
remove and clean or replace all system filters to
avoid engine contamination. GE also recommends
that an oil sample be taken per WP 4016 00 to
verify oil quality, and that it is free of
contamination.

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o. Verify high pressure compressor (HPC) discharge 7-5 Operational Checkout

temperature (T3) and low pressure turbine (LPT)
inlet temperature (T48) thermocouples. Confirm CAUTION
proper thermocouple wiring. All gas turbine
IF A QUESTIONABLE CONDITION EXISTS, DO
thermocouples are type K and can be verified by
NOT ATTEMPT TO MOTOR OR OPERATE THE
wire color. Input the proper type K voltage at the
ENGINE UNTIL A THOROUGH INVESTIGATION
gas turbine electrical panel for T3 and T48 and
OF THE CONDITION HAS BEEN MADE. DO NOT
readout on the engine control to confirm proper
REPEAT HOT STARTS, COMPRESSOR STALLS,
system setup.
LOAD–SHEDDING, OR OTHER PROBLEMS
p. Verify pressure measurement systems. Calibrate THAT INITIATE EMERGENCY SHUTDOWNS OR
the gas turbine pressure sensors and check gas ABORTED OPERATION WITHOUT THOROUGH
turbine to transducers to verify no leaks. Verify INVESTIGATION. FAILURE TO DO SO CAN
proper control wiring by reading out control RESULT IN UNDUE STRESS ON ENGINE
output during calibration. Hook up the sense lines COMPONENTS THAT MAY RESULT IN
to their proper interfaces per the packager's DAMAGE OR SUBSEQUENT DESTRUCTIVE
appropriate manual. Confirm HPC discharge static FAILURE OF THE ENGINE.
pressure (PS3) and LPT inlet pressure (P48) are
The initial startup procedures described in this section
not switched. Assure that inlet pressure (P0) is
should be followed after any LM6000 PF+ gas turbine
accurately calibrated using an absolute pressure
installation or internal maintenance.
reference.
a. Inspect the enclosure per the packager's
q. Verify variable-geometry. Calibrate variable inlet
instructions.
guide vanes (VIGVs), variable bypass vanes
(VBVs), and variable stator vanes (VSVs). b. Perform normal prestart checks (Chapter 8).
Visually verify that variable-geometry slews to the
proper position during calibration. c. Perform an ignition system functional check per
WP 4023 00. Verify that proper igniter is selected
r. Verify emissions equipment per appropriate by the control. Verify that adjacent staging valve
packager's manual. Measurement of NOx, CO, opens on ignition.
and O2 is required for combustor mapping. NOx
provides a check on average flame temperature. If d. Dry motor the engine for 2 minutes per the
NO and NO2 are measured, then the ratio of NO to packager's instructions and per dry motoring in
NO2 should be a range of 80:20. Troubleshoot the Chapter 8 and Chapter 12 of this manual. During
emissions equipment if ratios of 60:40 or lower motoring, check for the following:
are obtained. CO is used to determine combustor
blowout. Unburned hydrocarbons can also be • Oil supply and scavenge pressure indication
used. A value of 20 lb/min or greater indicates the
blowout point. O2 is required to correct NOx and • Lube oil leaks
CO to 15 percent O2.
• Unusual noise during coastdown
WARNING
WHEN WORKING INSIDE OR NEAR THE
ENGINE ENCLOSURE DURING OPERATION,
OBSERVE THE SAFETY PRECAUTIONS
DESCRIBED IN Chapter 8.

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e. Make a start (Chapter 8) and set power at idle. b. For mechanical drive applications, the sump
When the engine is stabilized at idle, do the pressurization system (SPS) and sump evacuation
following: system (SES) are activated during the starting
sequence. Verify the SPS and SES are operating
• Check engine and supply systems for leaks. within the parameters listed in Chapter 5, table 5-
1.
• Check for loose parts, tubing, cabling, etc.
c. Slowly advance to full power. If the accel follows
• Observe and record all results. a cold start, it should be at a rate not to exceed
zero to maximum load in less than 5 minutes
f. If any discrepancies are noted, make a normal or
(approximately 8 mW/minute, or less). A ramped
emergency shutdown, as required, (Chapter 8).
(constant rate) load increase should be maintained
Otherwise, proceed to the verification test
during the accel.
paragraph 7-6, if required.
d. Stabilize at full power for at least 3 minutes, then
g. Correct any discrepancies noted during the initial
observe and record the data specified in Chapter 8.
startup.
e. Reduce power to idle, if required.
7-6 Verification Test
f. Perform a normal shutdown, if required
If no verification test is specified by the packager, the (Chapter 8).
verification test, described below, should be performed
after the initial startup procedure has been completed. g. Inspect for leakage and loose parts and take any
corrective action required.
NOTE
h. Check lube and scavenge pump screens for
Combustor mapping is required prior to increasing load
evidence of contamination per WP 4020 00.
beyond idle. Combustor mapping is the process of
measuring operational boundaries such as acoustic i. Check inlet/fine mesh screen for any debris per
zones, blowout regions, and emission requirements, WP 4020 00. If any debris is found, its source
and translating the data into control schedules. Each must be identified and eliminated.
burner mode must be mapped from idle to base load.
Mapping is required at initial engine installation,
following installation of a new engine, or after
combustor or premixer hardware changes. Contact GE
M&I for mapping assistance.
a. Make a start (Chapter 8), if required.

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Chapter 8
Engine Operation
8-1 Purpose and Scope The LM6000 PF+ is a high-speed machine. In the
remote case of parts failure, the casing may not
This chapter covers general operating procedures for contain major compressor or turbine disk failures.
the LM6000 PF+. The procedures discussed are typical Personnel should not be permanently stationed in,
of any LM6000 PF+-powered package but should not or near, the plane of the rotating parts.
be considered totally comprehensive for any specific
installation. Configuration and system procedures may Rotating parts of the starter operate at a very high
vary from package to package and with the packager- speed. In the remote case of a parts failure,
supplied control system. Prior to operation of the personnel should not be stationed near the starter
engine, the site operators should be thoroughly during start, motoring, or purge cycles.
schooled in both normal and abnormal (emergency)
operation and the control system action/reaction to The low pressure (LP), high-velocity airflow
these conditions. created by the compressor in the LM6000 PF+ can
draw objects and personnel into the engine. The
use of an inlet screen or other protective measure
8-2 General is mandatory.
The following procedures are intended to provide In the event that the fire extinguishing system is
operating personnel with the information required to activated, care must be taken to ensure that all
operate the engine safely and reliably. Some of the personnel are clear of the enclosure prior to
information contained in this chapter is also provided, activation. Due to lack of oxygen, failure to
in whole or part, in other chapters. Redundancy is used comply may result in injury or death to personnel
to provide as much specific detail as required. It is also remaining inside the enclosure.
possible that the information may not provide for every
variation in installation, equipment, or contingency to Suitable fire protection equipment should be
be found in conjunction with engine operation. provided for the installation. Carbon dioxide,
Additional information can be provided by the halides, fog, water, or chemical fire extinguishing
packager or by GE. systems may be used. Discharge of fine chemical
or water mists directly on engine casings is
8-3 Safety permissible. The use of chemical fire
extinguishing media will require the disassembly
General safety precautions are defined in Chapter 1. of the engine for cleaning.
The following safety considerations should be
observed by operators and support personnel working Suitable explosive mixture sensing devices should
on the engine: be provided to sense any leakage of fuel (both into
the enclosure and into the fuel manifold) and to
The outside surfaces of the engine are not shut down the engine if leakage is present.
insulated. Adequate precautions should be taken
to prevent personnel from inadvertently coming in
contact with hot surfaces.
The engine is a source of considerable noise. It

will be necessary for personnel working on it, or
in its vicinity, to wear proper ear protection
equipment when the engine is operating.

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WARNING • SECONDARY AIR TO THE ENCLOSURE

WHEN ENTERING THE GAS TURBINE SHALL BE SHUT OFF, SINCE HIGH
ENCLOSURE, THE FOLLOWING SECONDARY AIRFLOW MAY PREVENT
REQUIREMENTS SHALL BE MET: OPENING OR CLOSING THE ENCLOSURE
DOOR.
• THE GAS TURBINE SHALL BE SHUT DOWN.
• THE ENCLOSURE DOOR SHOULD BE KEPT
• MODULE ENTRY DURING ENGINE OPEN. IF THE GAS TURBINE IS
OPERATION IS PROHIBITED IN GENERAL. OPERATING, AN OBSERVER SHOULD BE
IF ENTRY SHOULD BE REQUIRED DURING STATIONED AT THE ENCLOSURE DOOR
ENGINE OPERATION, CONTACT GE FIELD AND CONFINED SPACE ENTRY
SERVICE FOR A REPRESENTATIVE WHO IS PROCEDURES SHALL BE FOLLOWED.
TRAINED TO ENTER THE MODULE UNDER
SUCH CONDITIONS. • ALLOW GAS TURBINE TO COOL DOWN.
AVOID CONTACT WITH HOT PARTS, AND
Personnel entry into the engine enclosure during WEAR THERMALLY INSULATED GLOVES
operation at engine speeds above core idle should AS NECESSARY.
be prohibited. This prohibition should include
operation at synchronous idle. Signs or placards • EAR PROTECTION SHALL BE WORN IF GAS
should be posted at the enclosure access doors and TURBINE IS OPERATING.
should clearly state the hazardous conditions that
• DO NOT REMAIN IN THE ENCLOSURE OR
exist in the enclosure during operating above core
IN THE PLANE OF ROTATION OF THE
idle.
STARTER WHEN STARTING OR MOTORING
THE GAS TURBINE.
8-3.1 Gas Turbine Maintenance/
Inspection Precautions • WHEN PERFORMING MAINTENANCE ON
ELECTRICAL COMPONENTS, AVOID
WARNING SHOCKS AND BURNS BY TURNING OFF
WHEN ENTERING THE GAS TURBINE ELECTRICAL POWER TO THOSE
ENCLOSURE, THE FOLLOWING COMPONENTS, EXCEPT WHEN POWER IS
REQUIREMENTS SHALL BE MET: REQUIRED TO TAKE VOLTAGE
MEASUREMENTS.
• THE GAS TURBINE SHALL BE SHUT DOWN.
• LOCK OUT ALL CONTROLS AND
• MODULE ENTRY DURING ENGINE SWITCHES, IF POSSIBLE; OTHERWISE, TAG
OPERATION IS PROHIBITED IN GENERAL. ELECTRICAL SWITCHES OUT OF SERVICE
IF ENTRY SHOULD BE REQUIRED DURING TO PREVENT INADVERTENT ACTIVATION.
ENGINE OPERATION, CONTACT GE FIELD TAG THE ENGINE OPERATING CONTROLS
SERVICE FOR A REPRESENTATIVE WHO IS DO NOT OPERATE TO PREVENT STARTING
TRAINED TO ENTER THE MODULE UNDER DURING A DESIRED SHUTDOWN
SUCH CONDITIONS. CONDITION.
• THE FIRE EXTINGUISHING SYSTEM SHALL

BE MADE INACTIVE ACCORDING TO THE
CUSTOMER'S PROCEDURES.

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• THE COMPONENT LIFE/REPAIR Similar to the inlet cover, this cover should also be
INTERVALS SECTION OF THIS CHAPTER retained by the operator and installed under the
PROVIDES MAINTENANCE GUIDELINES following conditions:
FOR CERTAIN COMPONENTS, BASED ON
TOTAL EQUIVALENT BASE LOAD AND • When maintenance activity dictates that this
PEAK LOAD HOURS. FOR CONTINUED connection be broken.
SAFE OPERATION, IT IS ESSENTIAL THAT
THESE GUIDELINES BE FOLLOWED. • When maintenance activity is performed in the
bleed air ducting. In this case, the cover should be
• DO NOT USE ENGINE PIPING, CABLES, installed and left in place until the ductwork has
INSTRUMENTATION LEADS, OR OTHER been blown down or otherwise cleaned of all
EXTERNAL HARDWARE AS HAND OR debris.
FOOTHOLDS WHEN PERFORMING
MAINTENANCE ACTIVITY ON THE 8-4.3 Exhaust Cover
ENGINE. THESE HARDWARE ITEMS ARE
NOT DESIGNED TO SUPPORT LOADS The engine is shipped with an exhaust cover which
OTHER THAN THOSE ASSOCIATED WITH should be left in place until the engine is mated with
ENGINE OPERATION. the exhaust duct.
Similar to the inlet and bleed air collector covers, this

8-4 Equipment Protection cover should also be retained by the operator and
installed any time the engine is disconnected from the
The engine is provided with covers that protect various
enclosure/site exhaust duct.
operational interfaces during shipping, handling,
installation, and maintenance activity. These covers are
used to protect the engine from potential foreign object 8-4.4 Electrical, Fluid, and System
damage (FOD) caused by handling and objects such as Interface Covers
dirt, weld beads, tools, and rags. Should an object be
dropped during maintenance it should be found at once The engine is shipped with protective covers over all
to preclude having objects inadvertently dropped into electrical, fluid, and system interfaces. These covers
the gas turbine. are in place to prevent handling damage (threads, pins,
etc.) and fluid or system piping contamination.
8-4.1 Inlet Cover A supply of these covers should be maintained by the
operator for use during maintenance activities that
The engine is shipped with an inlet cover that should
require electrical leads, fluid piping, or system piping
only be removed when the variable inlet guide vane
to be disconnected.
(VIGV) forward flange is to be mated with the radial
inlet or bellmouth. This cover should be retained by the
operator and installed for engine protection any time 8-5 Engine Protection
the VIGV flange to inlet or bellmouth connection is
broken. The LM6000 PF+ is a reliable, durable engine designed
to operate in an industrial atmosphere for extended
periods of time. However, the operator needs to follow
8-4.2 Bleed Air Collector Cover
certain basic procedures in order to enhance the
The bleed air collector discharge is covered during engine's operational capability.
shipment. This cover should not be removed until a
clean, uncontaminated environment downstream of this
flange can be assured.

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In other portions of this manual, specifically Chapter 5, CAUTION

Chapter 6, and Chapter 7, information is included on FAILURE TO PROPERLY MAINTAIN A CLEAN
safety, equipment, protection, records, inlet/enclosure LUBE SYSTEM WILL LIKELY RESULT IN
inspections, pre-start checks, and operations. These FAILURE OF THE GAS TURBINE OR
topics are all directed at ensuring that the operating, COMPONENTS.
maintenance, and support personnel have a source of
technical information associated with the engine and its d. Flushing of the off-engine lube oil system should
operation as installed in an enclosure. It provides the be performed prior to connecting the off-engine
operator with specific requirements concerning the air, lubrication system to the LM6000 or any time that
oil, and fuel used during normal operation. The particulate contamination is suspected (including
guidelines are designed to ensure that the engine is lube system maintenance). The flush system uses
operating in the environment, and under conditions, for an off-engine flush pump and filter to clean
which it was designed. particulate contaminates from the oil system prior
to connecting it to an engine. The flush system
8-5.1 Lubricating Oil should consist of a pump which can produce
approximately 30 gpm (113.6 lpm) flow. Flow
Lubricating oil is used to lubricate bearings, sumps, should be filtered using a 3 micron cleanup filter.
and gearboxes. Additionally, lube oil actuates the
variable geometry control system, and bleed valves. (1) Inspect the inside of supply oil tank for
Lubricating oil flows at a rate of 11 to 19 gal/min (42 to contamination. Wipe all tank surfaces clean
72 l/min). The oil must be temperature-controlled and and then install tank cover.
kept clean per the following requirements in order to
adequately perform its function. (2) Connect a flush cart (see note on figure 8-1)
to the lube system supply and return interface
NOTE connections (see figure 8-1 for typical
Typical lube oil pressure is affected by lube oil supply system). Each supply and return may be
temperature. flushed separately or a manifold arrangement
can be used to flush all circuits
At the full power settings, typical maximum oil supply simultaneously (include stator and hydraulic
pressures are shown, in figure 8-1 for an oil supply pump circuits if applicable).
temperature as low as 100°F (37.8°C). Oil supply
pressures outside the bounds of figure 8-1 may indicate (3) Start flush pump and monitor system
a problem. Refer to Chapter 10, Troubleshooting, for cleanliness. Oil should be sampled
corrective action. periodically.
a. Minimum temperature at start is 20°F (-6.7°C) for (4) Actual required flush time will vary
type II (MIL-PRF-23699) oil. depending on the initial system
contamination level and the actual system
b. Minimum allowable temperature for operation at volume. It is expected that a minimum of
synchronous idle or above is 90°F (32.2°C). 8 hours of continuous flushing will be
required to clean-up a typical facility oil
c. Mixing of MIL-PRF-23699 oils from different system.
supply sources should be done by topping off the
lube tank rather than complete replacement. (5) When oil sample meets cleanliness standards
Reference the lube oil supplier for additional outlined in WP 4016 00, the engine may be
recommendations. Refer to Chapter 5 for installed.
additional information.

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Figure 8-1. Typical LM6000 PF+ Gas Turbine Lube Oil Supply Pressure

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NOTE Liquid hydrocarbons in gas fuel can cause surges in

Following this flushing, the system filters should be operation or engine damage. Therefore, gas fuel
removed and cleaned or replaced to avoid engine mixtures must be maintained at temperatures well
contamination. above their dewpoint at the engine fuel manifold inlet.
e. In the event of a failure during site operation that 8-5.4 Water

involves the engine lube system, the system
should be disconnected, drained, and cleaned as Water used for SPRINT® water injection shall not
described in step 8-5.1.d. This procedure should contain particles larger than 20 micrometers absolute
be followed whether the engine is removed and and total matter shall not exceed 5.0 lb/min
replaced or repaired on-site. (2.3 kg/min). Additionally, pH shall be between 6.0
and 8.0 and conductivity at 77°F (25.0°C), between 0.5
f. Engine oil is recommended filtered to and 1.0 micro-ohms/cm (measured when the water is
3 micrometers, absolute. free of carbon dioxide).
8-5.2 Air 8-6 Records and Running Log

Maximum airflow through the LM6000 PF+ engine is A log should be kept of all engine operation and/or
approximately 360 lb/sec (163 kg/sec) and is filtered running time. It is recommended that, as a suggested
by the inlet system to meet the following requirements: minimum, site operators should record the following:
• 95 percent of the time: must not contain solid • Time of all starts and shutdowns
particles exceeding 0.004 grains/1,000 ft3
(0.0097 grams/1,000 m3). • Total time for engine and site
• 5 percent of the time: must not contain solid • Reading of all engine instrument recordings, taken
particles exceeding 0.04 grains/1,000 ft3 twice daily at the set-load point
(0.097 grams/1,000 m3).
• All changes of engine speed and load
• When operating in a marine environment, sodium
(from air or water) entering the engine should not • Brief statement of action taken in response to
exceed 0.00045 lb/sec (0.00020 kg/min) average, alarms or emergencies
or 0.003 lb/sec (0.001 kg/min), maximum.
• Any system modifications, adjustments, or parts
• The maximum allowable liquid water content in removal/replacement
the inlet air is 0.5 percent of the inlet airflow
weight at inlet air temperatures of 42°F (5.6°C) and • Preventive or corrective maintenance activity
above. Below 42°F (5.6°C), no liquid water
• Lease pool, running time, change dates
content is allowed.
8-5.3 Gas Fuel 8-7 Inlet/Enclosure Inspection
Gas fuel should be what is known in industry as dry Ensure that the inlet and enclosure have been inspected
gas. That is, the gasoline vapor in 1,000 ft3 of gas at and cleaned in accordance with instructions in the
standard conditions (60°F and 30 in. Hg abs) should packager's manual. Refer to Chapter 7 of this volume
not exceed 0.1 gallon of liquid. and Volume II, WP 4010 00, WP 4012 00, and
WP 4013 00.

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8-8 Prestart Checks Although not required as part of normal starting

procedures, dry motoring is frequently used following
Consult the packager's manual for mandatory prestart maintenance to check the engine prior to making a
procedures specifying that the packager-furnished lube start. Dry motoring is performed with the fuel shutoff
supply subsystem is activated and operational. valves closed.
Prior to any motoring or start sequence, GE suggests 8-9 Motoring Procedures

the following checks as a minimum:
• All maintenance requirements or discrepancies 8-9.1 Dry Motoring

cleared and signed off
Any dry motoring check should be made with the
• Fuel shutoff valves closed ignition system deenergized.
• Fuel boost pump on CAUTION

BE CERTAIN THAT CHECKLISTS HAVE BEEN
• Lube tank level full ESTABLISHED FOR PACKAGER-FURNISHED
EQUIPMENT. CONSULT THE PACKAGER'S
• Lube supply valves open MANUAL FOR MANDATORY PRESTART
PROCEDURES AND MAKE CERTAIN THAT THE
• Water-wash solenoid (if applicable) deenergized
PACKAGER-FURNISHED LUBE SUPPLY
• All switches and interlocks set for proper sequence SUBSYSTEM IS ACTIVATED AND
to allow motoring OPERATIONAL PRIOR TO ANY MOTORING OR
START SEQUENCE.
• Fuel valve at start position
a. Check all switches and interlocks for proper
• High pressure compressor (HPC) rotor speed motoring settings.
(XN25) and low pressure turbine (LPT) rotor speed
(XNSD) governor references at lowest point b. With the fuel shutoff valves closed, activate the
motoring or start sequence and allow the engine to
• VIGVs, variable bypass vanes (VBVs), and motor to maximum motoring speed for
variable stator vanes (VSVs) on schedule 30 seconds. Observe and record the following:
• 8th stage and compressor discharge pressure • Engine high pressure rotor speed
(CDP) bleed valves on schedule
• Starter air or hydraulic inlet pressure
• Fuel drain valve closed (if applicable)
• Inlet air temperature
• Flameout detection circuit OK
• Lube supply and scavenge pressure
• Flame detection cooling air on
c. After 30 seconds, deenergize the starter.
• Gas lower heating value within range
• Gas vent valves set for gas startup
• Staging valves in proper position

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8-10 Starting and Operation c. At a minimum, record the levels for the
compressor rear frame (CRF) and turbine rear
8-10.1 Normal Starting Sequence frame (TRF) accelerometers, acoustic sensors, the
operating parameters designated in table 8-1, and
CAUTION the additional fuel system parameter in table 8-2.
A sample data sheet is shown in figure 8-2. If all
IT IS CRITICAL THAT THE COLD RESTART parameters shown in table 8-1 are normal, engine
PROCEDURE BE FOLLOWED; OTHERWISE, operation to load may continue. If engine
MAJOR ENGINE DAMAGE CAN RESULT. parameters are outside the normal operating limits
shown in table 8-1, table 8-2 and table 8-3,
a. Ensure that all prestart checks have been
troubleshoot and correct the problem per
completed.
Chapter 10 before continuing
b. Open the starter shutoff valve or initiate the start
sequence. The following should occur: d. A typical power generation start-to-load sequence
is shown in figure 8-3. Upon reaching the desired
• The engine will begin to rotate for a load condition, record the data indicated in
predetermined period to purge the exhaust paragraph 8-14.
system.
8-10.1.1 Hot Starts
• The starter will rollback the core speed to
approximately 1,700 rpm or maintain the a. Hot starts are normally the result of insufficient
core speed at approximately 2,400 rpm starter power, excess starting fuel flow,
(recommended), depending on packager excessively high acceleration fuel flow rate, or
setting. open VSVs.
• The ignition system will be energized and the b. Starts indicating a T48 value in excess of 1,300°F
fuel shutoff valves will open. (704.4°C) are considered to be hot starts. Normal
starts are 1,000° to 1,200°F (538° to 648°C).
• Lightoff should occur in approximately
10-12 seconds. c. If a hot start occurs, the startup procedure should
not be repeated without investigating the cause of
• The engine will accelerate to core idle
the hot start. For troubleshooting procedures, refer
(starter-assisted to 4,600 rpm, where starter-
to Chapter 10.
cutout occurs).
• In power generation applications, after a brief

pause of no more than 1 minute at core idle,
during which rotation of the LP system must
be indicated, the engine will continue to
accelerate to synchronous idle.
• Finish 5 minute warmup prior to loading

(5 minutes total time at idle speed).
• Maintain a constant rate of load increase

during acceleration (13.2 mW/minute at ISO,
or approximately 0.75 rpm/sec). Stepped
accel rate should be avoided. If the packager-
supplied control requires a stepped accel rate,
the rate shall not exceed specified limits.

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Table 8-1. Typical Operating Levels Base Load Inlet Loss = 4" H2O; Exhaust Loss = 6" H2O
Max
Max Dry Base Max Base Power Operating
Parameter Core Idle Synchronous Idle Power SPRINT® Limit
MW 0 0 53.2 57.3 N/A
WF (Fuel Flow), lb/hr (kg/hr) 4141 (1878) 5386 (2443) 22,550 (10,229) 24,493 (11,110) 38,000
(17,237)
T2 (Inlet Temperature), °F (°C) 59 (15) 59 (15) 59 (15) 59 (15) N/A (N/A)
P0 (Ambient Inlet Pressure), 14.7 (101.4) 14.7 (101.4) 14.7 (101.4) 14.7 (101.4) N/A (N/A)
psia (kPa)
T25 (HPC Inlet Temperature), 162 (72.2) 196 (91.1) 252 (122.2) 249 (120.6) N/A (N/A)
°F (°C)
XN25 (HPC rpm) 8263 8664 10,483 10,534 10,810
XNSD (LPT rpm) 3378 3930 3930 3930 3960
PS3 (HPC Discharge Pressure), 125 (862) 156 (1076) 470 (3241) 497 (3427) 530 (3654)
psia (kPa)**
T3 (HPC Discharge Temp), 583 (306.1) 673 (356.1) 1038 (558.9) 1006 (541.1) 1080 (582.2)
°F (°C) **
P48 (LPT Inlet Pressure), 35.0 (241) 42.0 (290) 114 (786) 121 (834) N/A (N/A)
psia (kPa)
T48 (LPT Inlet Temp) 1081 (582.8) 1193 (645) 1738 (947.8) 1728 (942.2) 1740 (948.9)
°F (°C) **
PTB (Thrust Balance Pressure), 16-20 (111-137) 34-38 (235-262) 95-105 (656-723) 95-105 (656-723) See
psia (kPa) ** figure 8-4
Lube System Oil Supply 30-55 (207-379) 53-60 (366-413) 65-75 (449-517) 65-75 (449-517) 15 (103)
Pressure, psig (kPa) minimum
Lube System Oil Supply Temp, 130-150 (55-65) 130-150 (55-65) 130-150 (55-65) 130-150 (55-65) 170 (76.7)
°F (°C)
Lube Scavenge Pressure, 17-21 (118-144) 18-22 (125-151) 18-23 (125-158) 18-23 (125-158) 100 (689)
psig (kPa)
Lube Scavenge Temp 175-220 205-245 230-265 230-265 310
(A/TGB-Scav), °F (°C) (80-104) (97-118) (111-129) (111-129) (154.4)
(B-Scav), °F (°C) (88-107) (99-118) (108-143) (108-143) (165.6)
(C-Scav), °F (°C) (94-123) (113-137) (144-160) (144-160) (171.1)
Lube Scavenge Temp (D-Scav), 190-260 215-275 230-290 230-290 315
°F (°C) (88-126) (102-135) (111-143) (111-143) (157.2)
Lube Scavenge Temp (E-Scav), 150-200 175-220 185-240 185-240 340
°F (°C) (66-93) (80-104) (86-115) (86-115) (171.1)

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Table 8-1. Typical Operating Levels Base Load Inlet Loss = 4" H2O; Exhaust Loss = 6" H2O (Continued)
Max
Max Dry Base Max Base Power Operating
Parameter Core Idle Synchronous Idle Power SPRINT® Limit
(TGB-Scav), °F (°C) (66-93) (80-104) (86-115) (86-115) (171.1)
VIGV Position 28.6 28.6 85.7 97.1 102
(percent of stroke)
VSV Position 39.9 43.3 83.3 85 102
(percent of stroke)
VBV Position 85 78.3 1.32 1.32 102
(percent of stroke)
** Record all sensors.
Table 8-2. Fuel System Parameters

Parameter Description
TH Total hours, all operation
TFS Total fired starts
TT Total trips (emergency shutdowns and step decels to idle)
T3 Measured HP compressor discharge temperature
T3BH Total hours for which (T3B-30°F) < T3 < T3B (base region)
T3CH Total hours for which T3 < (T3B-30°F) (sub-base region)
T3B T3 base load limit (set-point only; log not required)
BRNDMD Burner Demand
TFLAMEPCT Percent zero
TFLMAX Maximum bulk flame temperature schedule
TFLCYCS Calculated bulk flame temperature
TFLMIN Minimum bulk flame temperature schedule
TFODFS Calculated outer (A-ring) flame temperature
TFLOREF Demanded (control) outer flame temperature
TFLPDFS Calculated pilot (B-ring) flame temperature
TFLIDFS Calculated inner (C-ring) flame temperature
TFLIREF Demanded (control) inner flame temperature
WPQPERRCOR Blowout parameter
GP1PSEL Fuel metering valve supply pressure

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Table 8-2. Fuel System Parameters (Continued)

Parameter Description
GP2OSEL Outer ring metering valve downstream pressure
GP2PSEL Pilot ring metering valve downstream pressure
GP2ISEL Inner ring metering valve downstream pressure
TFUEL Fuel temperature
LHVSEL Fuel lower heating valve
SGSEL Fuel specific gravity
Table 8-3. Limits and Operating Requirements

Event/Item Max Limits/Requirements
Max Time Allowed for Ignition XN25 > 1,700 rpm at t 20 sec (gas fuel)
Max Time to Reach Starter Cutout XN25 > 4,600 rpm at t 90 sec
Max Time to Reach Core Idle XN25 6,050 rpm and XN25R 6,400 rpm at t 120 sec
LP Rotor Vibrations • 1.40 in./sec (3.6 cm/sec) peak at XN25 Sel XN25 Max
or
• 1.75 in./sec (4.5 cm/sec) peak at XN25 Sel < XN25 Max
Wideband Rotor Vibrations < 3.00 in./sec (7.6 cm/sec)
HP Rotor Vibrations 2.0 in./sec (5.1 cm/sec)
Fuel Supply Temperature (Gas) < Tsv + 20°F (11°C) min; > 300°F (149°C)
Air Inlet Screen Differential Pressure Commissioning pressure + 1.0 in. H2O (0.249 kPa)

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Figure 8-2. LM6000 Performance Data Sheet (Sheet 1 of 5)

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Figure 8-3. Typical LM6000 PF+ Gas Turbine Start-to-Load Time Sequence
Figure 8-4. Thrust Balance Pressure Limits

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8-10.2 Special Operating Requirements If power is reduced during SPRINT® operation, the
water injection will automatically shut off when PS3
The information in the following paragraph is drops t60 psi (414 kPa) below the PS3 dry schedule.
presented as generic information only. Refer to the During shutdown a drain valve is opened to air purge
packager’s manual for specific control system water out of the SPRINT® water supply line to prevent
sequencing modes and site operation information. freezing.
8-10.2.1 SPRINT® Injection Requirements Water injection flow to the SPRINT® system is
scheduled as a function of T2. The water flow is set to
LM6000 PF+ model engines equipped with SPRINT® 22 gpm (83.3 lpm) for T2 45°F (4.4°C) and
include provision to inject a very fine water mist in the T2 80°F (26.7°C)
LPC inlet flow, creating an evaporative, cooling effect
and enabling higher engine output than would 8-11 Shutdown
otherwise be achieved with a standard LM6000 PF+.
The percent increase in power due to SPRINT® is The following types of engine shutdowns may occur:
greater for warmer inlet temperatures than for cooler
temperatures. Expected output increase at T2=59°F Normal shutdown: engine is taken off line for a
(15.0°C) is about 7.7 percent and for T2=90°F (32.2°C) specific reason not necessarily related to the engine.
is about 15.8 percent.
Emergency shutdown: engine is taken off line by the
The SPRINT® system will automatically sequence if operator or the control system due to an engine or
the operator selects SPRINT® operating mode before system fault.
(or during) load ramp (see packager’s appropriate
manual). Other: annunciated fault or other indication of
problem which operator interprets as a reason for
When the following conditions are met: taking the engine off line.
• T2 t30° (-1.1°C), 8-11.1 Normal Shutdown

• Other site permissives are satisfied, and Under normal operating conditions, the LM6000 PF+
is shut down in the sequence described below.
• PS3 reaches a level with 50 psid (345 kPa) of the
baseload dry PS3 schedule, a. Power is retarded to minimum load or the control
sequencer is activated to accomplish the
SPRINT® is activated, T3 will decrease, and power shutdown. The following should occur:
will automatically ramp increase by the ratio of the
SPRINT® maximum power limiter to the dry • High pressure rotor speed decreases to
maximum power limiter to achieve greater power. The approximately 8,700 rpm over a 2-3 minute
LP speed reference throttle can then be manually (i.e., period.
by the operator) advanced further or until the SPRINT®
MW limiter is achieved or otherwise limited by T3, • T48 decreases.
T48, or XN25R3 regulators for the case when the
power turbine droop reference is set to maximum. b. The engine should then decelerate to core idle
speed, approximately 8,000 rpm, where it should
SPRINT® system can also be manually activated while be allowed to cool for 5 minutes. After 5 minutes,
at baseload operating conditions (see packager’s the fuel shutoff valves should be closed and the
appropriate manual). For specific details of how to drain valves opened.
activate the SPRINT® system, refer to the Original
Equipment Manufacturer (OEM) operations manual.

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NOTE a. The fuel shutoff valves and metering valve are

After shutdown, natural circulation of air through the closed.
engine must not be interrupted. This includes site air
b. The 8th stage and CDP bleed valves are closed.
supply to the compressor rear frame and turbine rear
frame lube lines/sump walls to avoid coking. Also, c. The staging valves are closed.
flame detector cooling can air circuit airflow is
required for a period of at least 30 minutes d. The VBVs are opened (closed later during
(temperature must be 175°F [79.4°C] or lower). coastdown).
8-11.2 Emergency Shutdown e. Underspeed and oil pressure alarms are bypassed.
In an emergency, the engine can be shut down from any f. Drain and vent valves are opened per control
power setting. This action can be initiated by the sequencing.
operator or by the packager-supplied control system.
An emergency shutdown automatically initiates the g. Alarms, interlocks, sequence timers, and operating
following actions: timers are reset.
NOTE The emergency shutdown will not allow reset until core
speed (XN25) is less than 300 rpm. Table 8-4 outlines
The information presented herein describes a typical the protection functions that require root cause
sequence of events. However, for specific control resolution prior to engine motoring.
sequencing modes, and site operation information, see
the packager's manual.

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Table 8-4. Protective Function Causes Requiring Resolution Prior to Restart or Motoring
N25 Reset
Description of Event Parameter Event Speed, RPM Comments
No Start Fault ST8FAIL ST8 Bleed Valve Sensors Failed 500 SPAM
No Start Fault ST8NSFLT ST8 Null-Shift Failure 500 SPAM
No Start Fault ST8POSFAIL ST8POSFAIL Fault 500 SPAM
No Start Fault ST8TMFAIL ST8 Torque Motor Current 500 SPAM
Failure
No Start Fault CDPFAIL CDP Bleed Valve Sensors Failed 500 SPAM
No Start Fault CDPNSFLT CDP Null-Shift Failure 500 SPAM
No Start Fault CDPPOSFAIL CDPPOSFAIL Fault 500 SPAM
No Start Fault CDPTMFAIL CDP Torque Motor Current 500 SPAM
Failure
No Start Fault T48FAIL T48 Sensor Failure 500 SPAM
No Start Fault VBVDIF_NST VBV Difference No-Start Flag 500 SPAM
Step-to-Idle, SVFSI Staging valve failure then 4600 SPAM
Then Rolling Restart step-to-idle
Shutdown
Step-to-Idle, PX36FAIL PX36 sensor system failure 1100 SPAM
Then No Rolling
Restart Shutdown
Step-to-Idle, PX36HFAIL High Frequency PX36 sensor 1100 SPAM
Then No Rolling system failure
Restart Shutdown
Step-to-Idle, IGVPOSFAIL IGVPOSFAIL FAULT 1100 SPAM
Then Shutdown
With No Motor
Step-to-Idle, IGVFAIL Inlet guide vane sensors failed 1100 SPAM
Then Shutdown
With No Motor
Step-to-Idle, IGVTMFAIL IGV torque motor current failure 1100 SPAM
Then Shutdown
With No Motor
Step-to-Idle, VSVFAIL Variable stator vane sensors 1100 SPAM
Then Shutdown failed
With No Motor
Step-to-Idle, VSVTMFAIL VSV torque motor current failure 1100 SPAM
Then Shutdown
With No Motor

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Table 8-4. Protective Function Causes Requiring Resolution Prior to Restart or Motoring (Continued)
N25 Reset
Step-to-Idle, VSVPOSFAIL VSV position failure 1100 SPAM
Then Shutdown
With No Motor
Emergency SISDNM Step-to-Idle, then shutdown with 1100 SPAM
Shutdown With no motor
No Motor
Emergency STALLDET Compressor stall detection 1100 SPAM
Shutdown With
No Motor
Emergency LPSHAFTFAIL Low pressure system shaft 1100 SPAM
Shutdown With failure detection
No Motor
Emergency NSDOVSPD Low pressure system shaft 1100 SPAM
Shutdown With overspeed
No Motor
Emergency N2LOCKOUT Low pressure system shaft 1100 SPAM
Shutdown With lockout (over 5000 rpm)
No Motor
Emergency NSDFAIL NSD sensors failed 1100 SPAM
Shutdown With
No Motor
Emergency N25FAIL N25 sensors failed 1100 SPAM
Shutdown With
No Motor
Emergency N25OVSPD N25 overspeed 1100 SPAM
Shutdown With
No Motor
Shutdown With FLMFALHI Flame detectors failed high 1100 SPAM
No Rolling Restart
Shutdown With FLAMEFAIL Flame detectors failed off 1100 SPAM
No Rolling Restart
Shutdown With FLMDTMODE Flame detectors difference 1100 SPAM
No Rolling Restart failure
Shutdown With SISDNR Step-to-Idle, then no rolling 1100 SPAM
No Rolling Restart restart shutdown
Shutdown With T3FAIL T3 sensors faulted flag 1100 SPAM
No Rolling Restart

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N25 Reset
Shutdown With GP2OM1FAIL GP2OM1 sensor failed 1100 SPAM
No Rolling Restart
Shutdown With GP2OM2FAIL GP2OM2 sensor failed 1100 SPAM
No Rolling Restart
Shutdown With GP2OPFAIL GP2OP sensor failed 1100 SPAM
No Rolling Restart
Shutdown With GP2IPFAIL GP2IP sensor failed 1100 SPAM
No Rolling Restart
Shutdown With GP2IMFAIL GP2IM sensor failed 1100 SPAM
No Rolling Restart
Shutdown With Z_SHUTDOWN Facility shutdown command 4600 SPAM
Rolling Restart
Shutdown With PSUMPLO Low PSUMP pressure shutdown 4600 SPAM
Rolling Restart
Shutdown With SISDRR Step-to-Idle, then rolling restart 4600 SPAM
Rolling Restart shutdown
Shutdown With SVFSD Staging valve failure shutdown 4600 SPAM
Rolling Restart
Shutdown With PX36HHISD PX36_HI high shutdown signal 4600 SPAM
Rolling Restart
Shutdown With PX36HHDLSD PX36_HI high at idle shutdown 4600 SPAM
Rolling Restart signal
Shutdown With PX36HISD PX36 high shutdown signal 4600 SPAM
Rolling Restart
Shutdown With PX36HIDLSD PX36 high at idle shutdown 4600 SPAM
Rolling Restart signal
Shutdown With T48OVRTEMP T48 over temperature shutdown 4600 SPAM
Rolling Restart
Shutdown With T48LOWSD T48 low temperature during start 4600 SPAM
Rolling Restart
Shutdown With FLAMEOUT Combustor flameout detected 4600 SPAM
Rolling Restart

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N25 Reset
Excessive vibration step decel to Requires
idle resolution prior
to restart or
motoring; SPAM
Fire system shutdown and/or Requires
Halon release resolution prior
to restart or
motoring; SPAM
GT lube oil supply pressure low Requires
decel to idle resolution prior
to restart or
motoring; SPAM
Enclosure high combustion gas Requires
level shutdown resolution prior
to restart or
motoring; SPAM
Starter system failure Requires
resolution prior
to restart or
motoring; SPAM
Fail to crank indication Requires
resolution prior
to restart or
motoring; SPAM
High liquid fuel manifold Requires
temperature shutdown or step resolution prior
decel to idle to restart or
motoring; SPAM
Air inlet screen delta pressure Requires
high limit resolution prior
to restart or
motoring; SPAM

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8-11.3 Post-Shutdown Fire 8-12.1 Hot Restarts
During a normal shutdown, exhaust gas temperature A restart following an emergency shutdown or step
should decrease following closure of the fuel shutoff decel to idle action from a power level where T48 is
valves. Under both normal and emergency shutdowns, higher than 1,200°F (648.9°C) is considered a hot
a temperature increase (T48) may occur while the restart sequence and should not be attempted until the
engine is coasting down. This indicates that fault or circumstance triggering the shutdown is
combustion is continuing, due to either a leaking fuel resolved. It is critical that the hot restart procedure
valve or residual fuel trapped in the engine fuel system. follows a specific sequence to avoid major engine
To correct this problem, follow the procedures damage.
described in paragraph 8-9.1 and Chapter 9.
An emergency shutdown must be followed by a restart
In the case of a post-shutdown fire caused by fuel or motoring cycle, if possible, to commence no more
leaking through the lower air/gas premixers, a rise in than 10 minutes after gas turbine high pressure rotor
T48 will be noticed. With fuel valves closed, the engine speed decreases below 300 rpm. Conditions may not
should be motored on the starter (refer to allow restarting or motoring in some situations,
paragraph 8-9.1 and Chapter 10) until T48 starts to depending on the cause of the emergency shutdown or
drop, at which point the operator can discontinue the status of the starting system. Reasons for not
motoring. restarting or motoring the gas turbine following an
emergency shutdown are listed in table 8-4. If restart or
8-12 Restart motoring cannot be accomplished within 5 minutes, a
mandatory lockout of 4 hours is enacted by the control
CAUTION system to allow sufficient component cooling to
prevent possible damage to the engine.
IF A QUESTIONABLE CONDITION EXISTS, DO
NOT ATTEMPT TO MOTOR OR OPERATE THE If the fault causing the emergency shutdown is fully
ENGINE UNTIL A THOROUGH INVESTIGATION understood, resolved, and cleared, and it has been
OF THE CONDITION HAS BEEN MADE. DO NOT verified that no damage to the engine has occurred, a
REPEAT HOT STARTS, COMPRESSOR STALLS, restart or motoring sequence can be initiated if the
LOAD-SHEDDING, OR OTHER PROBLEMS THAT 10 minute limit has not been exceeded.
INITIATE EMERGENCY SHUTDOWNS OR
ABORTED OPERATION WITHOUT THOROUGH
8-12.1.1 Restart Within 10 Minutes After
INVESTIGATION. FAILURE TO DO SO CAN
Shutdown
RESULT IN UNDUE STRESS ON ENGINE
COMPONENTS THAT MAY RESULT IN If circumstances permit the shutdown problem to be
DAMAGE OR SUBSEQUENT DESTRUCTIVE cleared within 10 minutes or less and the high pressure
FAILURE OF THE ENGINE. (HP) rotor speed is less than 300 rpm, the restart
procedure is as follows:
This section addresses requirements for restarts after
operation at power. Restarts may be initiated at any a. Start the restart timer and initiate a manual restart
time if the prior shutdown sequence included a cool- purge. Reset all other timers as required.
down period of 5 minutes or more at idle speed, or if
cool-down motoring has been initiated or completed. b. Energize the starter to crank the HP rotor to a
speed not to exceed 2,400 rpm. If the HP rotor
Restarts following an emergency shutdown or step rotates freely, make a normal start.
decel to idle action from operation at power may be
restricted, depending on cause and if motoring has been
initiated within 10 minutes of HP rotor coastdown.
Refer to paragraph 8-12.1.

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c. If circumstances allow the HP rotor to be cranked • Both engine rotors may windmill for periods of up
within 10 minutes after shutdown, a manual to 20 minutes at speeds between 100 rpm and
purge, if available, will enable a restart purge 1,000 rpm, provided each period is preceded by
cycle to be initiated. The restart purge cycle normal engine operation.
motors the engine high pressure rotor to prevent
thermal bowing of the HP rotor. Starter use for • Unlimited windmilling of the engine rotors is
motoring the engine HP rotor must be consistent allowed at HP rotor speeds above 1,000 rpm,
with limitations specified in Chapter 10. provided supply oil temperature is maintained
above 90°F (32.2°C) and scavenge oil temperature
d. By selecting the restart purge option, the operator is kept below 340°F (171.1°C). At this speed, the
preserves capability to restart the engine any time lube supply and scavenge system operates
after the fault or system problem has been cleared. normally, provided positive oil pressure is
maintained and oil cooling is provided.
8-12.1.2 Restart More Than 10 Minutes
After Shutdown 8-14 Engine Performance
CAUTION Following installation and checkout, the engine should
BYPASSING THIS LOGIC AND CRANKING THE be operated at various speed/load conditions in order to
HP ROTOR MAY RESULT IN SEVERE HP establish baseline performance for the specific
COMPRESSOR RUBS AND MAY DAMAGE THE installation. Refer to step 8-10.1.c, table 8-1, and
COMPRESSOR BLADES AND VANES. table 8-3.
If it is not possible, or desirable, to initiate the restart 8-14.1 Performance Measurement

purge cycle or a cool-down motoring cycle within
10 minutes after the HP rotor has coasted to below A log of all LM6000 PF+ running time should be kept.
300 rpm, the control system will then lock out any The following minimum data should be recorded:
further attempts to restart or motor the engine for a
period of 4 hours. • Time of all fired and unfired starts and shutdowns
After 4 hours, a normal start sequence may be initiated. • Total time since installation for all engines
installed
8-13 Windmilling • Twice daily log of all instrument readings, taken at
Windmilling is generally caused by air forced through the set-load point
the inlet, causing the rotors to turn at relatively low
Daily log data is invaluable for engine trending and
speeds of less than 100 rpm. Windmilling also occurs
troubleshooting:
during shutdown as the kinetic energy of the rotor is
dissipated by the pumping and rolling-element friction. • All changes in speed or load
The windmilling limits below should be observed to
avoid rolling element life reduction. • Adjustments and part changes, including those
done at a repair facility
• There is no provision for unrestricted windmilling
operation. However, the flow of air through the • Preventive maintenance action
engine must not be restricted during the engine
cool-down period. • Lease pool gas turbine installation, removal, run
time
• Both engine rotors may windmill for up to 7 days
at speeds up to 100 rpm, provided each period is
preceded by normal engine operation.

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8-14.2 Performance Data Recording 8-14.3 Component Life/Repair Intervals
For diagnosing performance or emissions issues, best Safe operation of the LM6000 PF+ is dependent on
results are obtained when all the parameters in the properly scheduled maintenance, repairs, and
Performance Data Sheet, figure 8-2, are recorded and component replacement. In order to properly track
the data is recorded to the indicated level of precision. these conditions, packager-supplied time and event
Also for best accuracy in the analysis, the engine counters provide data for the parameters listed in
should be stabilized for at least 5 minutes prior to data table 8-2.
recording and several (3-5) readings should be taken at
a given power level. The operator is responsible for maintaining a log of the
operating data parameters for gas turbine components.
The Performance Data Sheet shows typical parameters This will require that the operator track components
and precision levels which would normally be required that are removed during field or depot maintenance.
for a performance evaluation by GE.
Other considerations for best accuracy:
• Instrumentation should be recently calibrated
• VG systems should be rig checked and calibrated
• Crank soak washing should be performed prior to

test
• Fuel sample should be collected and analyzed for

lower heating value (LHV) and specific gravity
(SG) to assist in expedited analysis of performance
data. Liquid fuels are to be analyzed for
contaminants and compliance with fuel
specification
• High power data readings should be taken with

VBV closed
The same data should be used for periodic trending of

engine performance.

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Chapter 9
Abnormal Operation
9-1 Purpose and Scope 9-3.1 Alarms
This chapter covers abnormal operating conditions and Alarms are used to alert the operator to a condition that
procedures, and control-provided auto-protective requires operator intervention. Some alarms may
features. It provides definitions, descriptions, and simply indicate that a condition has been reached that
operator actions required for abnormal conditions will require maintenance in a short time. Other alarms
resulting in alarms or protective action. It also covers indicate that a condition has been reached that may
other conditions that do not trigger alarms or protective lead to the initiation of a protective function if positive
action, but which require special action by the operator. corrective action is not taken immediately. Reference
the Troubleshooting Reference Table in Chapter 10 for
9-2 General Definitions the problem events and system conditions that trigger
alarms and protective functions.
Abnormal operation is defined as any type of LM6000
PF+ operating condition that: 9-3.2 Power Cutback
• Deviates from normal operating limits A power cutback is accompanied by an alarm. There is
one power cutback function that can be initiated by the
• Exceeds normal operating limits control:
• Causes an alarm or other protective action to be • Slow decel to minimum load

initiated
9-3.2.1 Slow Decel to Minimum Load
A protective function is defined as any action initiated
automatically by the packager's control in order to: A slow decel to minimum load (min-load) is a
controlled deceleration at a rate that allows all engine
• Prevent damage to the LM6000 PF+ engine or schedules and engine cooling to be maintained at a
installation controlled rate.
• Prevent injury to personnel The decel rate for a slow decel is approximately
100 rpm/s (XN25). Rather than decel all the way to
9-3 Control Actions core idle, the engine decels to the min-load point. This
allows the condition to be investigated without
There are three levels of protection initiated by the requiring a shutdown. There is no time limitation for
LM6000 PF+ packager-supplied control system when remaining at min-load, unless the condition requiring
abnormal conditions are sensed: this decel still persists, in which case a normal
shutdown sequence is initiated.
• Alarms (alarm-only conditions)
• Power cutbacks
• Shutdowns

*(. /03)

9-3.3 Shutdowns • Drain and vent valves are opened per control
sequencing
All shutdowns are accompanied by an alarm. There are
four shutdown functions that can be initiated by the • Alarms, interlocks, sequence timers, and operating
control: timers are reset
• Emergency shutdown (gas turbine motoring The emergency shutdown will not allow reset until core
allowed) speed (XN25) is less than the values listed in table 8-4.
Table 8-4 outlines the protection functions that may
• Emergency shutdown (gas turbine motoring not require root cause resolution prior to engine motoring.
allowed)
9-3.3.3 Step-Decel to Idle/Shutdown
• Step decel to idle
A step-decel to idle is an immediate rapid (max decel
• Abort start
rate) deceleration to idle followed by a 10 second
All alarm and protective function setpoints are based pause, and then by a shutdown. A step-decel provides a
on typical applications with driven equipment rated for more controlled and orderly way of shutting down the
continuous duty operation at 3930 rpm (XNSD). engine than does an immediate shutdown at power. The
10 second pause at core idle allows various scheduled
engine systems, such as variable inlet guide vanes
9-3.3.1 Shutdown
(VIGVs), to reach a stabilized condition before
A control initiated shutdown is a controlled decel to shutdown occurs.
idle, a 5 minute stabilization period, and a shutoff of When a step-decel occurs, the control initiates the
the fuel valves and opening of the fuel staging valves. following sequence of events:
9-3.3.2 Emergency Shutdown a. Power is immediately reduced to core idle, causing

the engine to decel as rapidly as possible.
An emergency shutdown is initiated by the control
when the engine must be shut down immediately in b. When the engine reaches core idle speed, the
order to prevent severe damage to the engine or control holds it at idle for 10 seconds and then
installation. initiates a shutdown. The hold at core idle allows
the engine to be shut down from an on-schedule,
When an emergency shutdown occurs, the control stabilized condition.
initiates the following events:
c. When the control initiates the shutdown after the
• The fuel shutoff valves and metering valve are 10 second idle hold, the following events occur:
closed
• The fuel shutoff valves are closed
• The 8th stage and compressor discharge pressure
(CDP) bleed valves are closed • The VIGVs are closed during coastdown
• The staging valves are closed • Underspeed and oil pressure alarms are
bypassed
• If a gas blowoff valve is in the fuel system, it is
opened • Drain and vent valves are opened per control
sequencing
• The variable bypass valves (VBVs) are opened
(closed later during coastdown) • Alarms, interlocks, sequence timers, and
operating timers are reset
• Underspeed and oil pressure alarms are bypassed

/03) *(.

9-3.3.4 Aborted Start e. After a power cutback, correct the problem before
resuming operation at power. If recovery is not
An abort is initiated at any time during the start possible, shut down and correct the problem.
sequence when certain parameters exceed limits.
During an aborted start, the control initiates the f. After a shutdown, correct the problem before
following events: attempting a restart.
• The fuel shutoff valves are closed CAUTION
• The ignition system and starter are de-energized IF MOTORING WITHIN 10 MINUTES AFTER THE
HP ROTOR (XN25) IS ROTATING AT LESS THAN
• The VIGVs are closed during coastdown 300 RPM IS NOT POSSIBLE, DO NOT ATTEMPT
• Underspeed and oil pressure alarms are bypassed TO MOTOR THE ENGINE FOR AT LEAST
4 HOURS. ANY ATTEMPT TO MOTOR THE
• Drain and vent valves are opened per control ENGINE SOONER MAY RESULT IN SEVERE
sequencing DAMAGE TO THE ENGINE.
• Alarms, interlocks, sequence timers, and operating g. If possible without causing damage, motor the
times are reset engine for cooling within 10 minutes of the time
• A purge cycle is initiated by the control, if the high pressure (HP) rotor (XN25) is rotating at
applicable less than 300 rpm. Refer to Chapter 8.
h. Enter appropriate comments in the engine run log

9-4 Operator Action (Chapter 8) concerning any problems and
In order to avoid more severe protective action, the corrective action.
operator must address the causes of all alarms and
determine corrective actions necessary to clear 9-5 Hot Restarts
abnormal conditions. Before resuming normal engine
operation after a power cutback or shutdown, positive A hot restart is defined as any attempt to start the
action to correct the cause is necessary. For any alarm engine immediately following emergency shutdown or
or protective action, the following general procedures a trip-from-power shutdown. A hot restart should not
should be followed: be attempted until the fault or circumstance triggering
the shutdown is resolved. It is critical that
a. Acknowledge the alarm in the manner specified in the hot restart procedure follows a specific sequence
the packager's manual. to avoid major engine damage. Refer to Chapter 8 for
hot restart procedures. Refer to Chapter 10 for
b. Reduce power, if necessary, and take whatever
Troubleshooting Procedures.
steps possible to prevent further alarms or more
severe protective action. Reducing power to
eliminate an alarm without investigation of alarm 9-6 Post-Shutdown Fire
root cause is unacceptable. Significant damage to
the engine can occur if alarms are bypassed. During a normal shutdown, T48 should decrease. An
increasing T48 during coastdown is an indication of
c. Consult the Troubleshooting Procedures in continued combustion, possibly due to a leaking fuel
Chapter 10 of this manual. valve. To correct this condition, shut off the fuel supply
and motor the engine to blow out the fire. When T48
d. During an alarm-only condition, correct the
returns to normal, discontinue motoring. Refer to
problem, if possible, and resume normal operation.
Chapter 8 and Troubleshooting Procedures in
If recovery is not possible, shut down and correct
Chapter 10.
the problem; refer to the packager's manual for
more specific information.

*(. /03)

9-7 Special Inspections • Thermal quench by water or other agent, local

overheating by fuel system failure
a. The maintenance of the gas turbine requires that
inspection checks be made periodically. The • Exposure to corrosive chemicals, fire-fighting
inspection requirements and limits throughout this agents, salt water, or sewage
manual are based on operation within specified
limits. In addition to the regular inspections, there These events are highly variable and the exposure and
are special inspections necessary when the gas associated damage which a gas turbine experiences is
turbine has been operated outside of the specified unpredictable. This prevents establishing a single, all-
limits, for example, off-schedule variable- inclusive inspection and repair procedure. Depending
geometry operation, overspeed, or upon the circumstances of the event, instances of
overtemperature. There also may be special localized, limited damage can often be dispositioned by
inspections necessary if the gas turbine has been normal channels. For abnormal events, such as the
exposed to abnormal conditions. These events events listed above, execution of a special inspection
include failures with significant damage and other workscope is necessary for proper restoration of
abnormal exposure such as an installation fire or serviceability. In some extreme cases, repair may not
mishap during transportation, handling, or storage. be possible or economical, and, therefore, further repair
Some of the abnormal conditions to which an effort may not be advisable. Before proceeding with
engine may be exposed are: inspection or repair action to restore serviceability after
a mishap, contact the following for guidance:
• Shock loading, collision impact, exposure to
explosion, handling or transportation mishap GE Aircraft Engines
Marine & Industrial Customer Service
• Structural overstress, mounting system Mail Drop S-155
overload to gas turbine interface (e.g., 1 Neumann Way
earthquake, installation error) Cincinnati, Ohio 45215-1988 USA
• Any equipment failure where parts are not Assurance of a part's serviceability is derived from
contained within the gas turbine, or where a control of material processing and manufacturing,
major rotating component separates operation within defined limits, and maintenance
within defined limits and processes, as well as by
• Sudden seizure or stoppage of the gas turbine inspection. Parts exposed to abnormal conditions may
rotor(s) or driven equipment rotors appear to be serviceable when, in fact, the actual state
of the material cannot be ascertained even by the most
• Excess G-loading during operation in excess of advanced non-destructive testing and inspection
packager manual limits methods. Parts which have been involved in an
abnormal event must be formally reviewed for severity
• Significant inlet ingestion events (e.g., foreign of operation beyond the normal working environment
objects causing significant flowpath damage, and dispositioned as to the necessity for a special
ice ingestion, inlet system failure) inspection workscope. The operator has the
responsibility for the continued safe operating
• Exposure to external fire, involving inlet condition of the gas turbine. Since used replacement
system, exhaust system, base enclosure, and parts may be available which have operated in
equivalent abnormal events, the operator should verify that the
service histories of these parts are known and that,
• Exposure to external fire in storage or transport
when applicable, the required special inspections and
• Internal fire part disposition following exposure to abnormal
conditions have been completed and the part is
serviceable.

/03) *(.

b. Similarly, many components or assemblies from (1) Rotating components

aircraft engines which have experienced previous
flight service are not usable in LM engines. In (2) Stator cases and stator vanes
addition, gas turbine components which have
experienced an extremely high number of start/stop (3) Frame assemblies, including sump
cycles may not be usable. Specifically, use of used- components
serviceable flight or high-cycle engine parts in the
(4) Main shaft bearings
following categories is prohibited:
Prior to use of other components, contact Marine &
Industrial Engines Customer Service about usability.
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Chapter 11
Maintenance Considerations
11-1 Purpose and Scope Top - the side of the engine that is up when the engine
is in the normal operating position
This chapter covers basic maintenance and inspection
practices and procedures to be followed during Bottom - the side of the engine on which the gearboxes
maintenance operations. are mounted
Clock Positions - the positions of the numbers on a

11-2 Levels of Maintenance clock face as seen from aft, looking forward. The 12:00
o’clock position is at the top, 3:00 o’clock is on the
The workscope for level 1 corrective maintenance
right side, 6:00 o’clock is at the bottom, and 9:00
allows replacement of external parts, adjustments, and
o’clock is on the left side.
other work (preventive and corrective) up to and
including removal and replacement of the entire
engine. 11-3.2 Maintenance Within an Enclosure
The workscope for level 2 corrective maintenance WARNING

permits the replacement of major engine sections WHEN ENTERING THE GAS TURBINE
(modules) and the replacement or repair of certain ENCLOSURE, THE FOLLOWING
internal parts. Level 2 maintenance is performed on- REQUIREMENTS SHALL BE MET:
site on a noninstalled engine or on an installed engine
in the enclosure, as permitted by the enclosure design. • THE GAS TURBINE SHALL BE SHUT DOWN.
Maintenance is performed with the engine horizontal.
See Volume II. • MODULE ENTRY DURING ENGINE
OPERATION IS PROHIBITED IN GENERAL.
IF ENTRY SHOULD BE REQUIRED DURING
11-3 Standard Maintenance ENGINE OPERATION, CONTACT GE FIELD
Practices SERVICE FOR A REPRESENTATIVE WHO IS
TRAINED TO ENTER THE MODULE UNDER
11-3.1 Points of Reference SUCH CONDITIONS.
The following points of reference are used throughout • THE FIRE EXTINGUISHING SYSTEM MUST
this manual: forward, aft, right, left, top, bottom, and BE DEACTIVATED BEFORE PERSONNEL
clock position. These points of reference are defined as ENTER THE ENCLOSURE. SUFFOCATION
follows: CAN OCCUR IF THE FIRE EXTINGUISHING
SYSTEM IS ACTIVATED.
Forward - the air intake end of the engine
WARNING
Aft - the turbine end of the engine
THE FOLLOWING STEPS MUST BE PERFORMED
Right - the right side of the engine when viewed from BEFORE ENTERING THE ENCLOSURE. THESE
the aft end and when the engine is in the normal CONDITIONS MUST BE MAINTAINED WHILE
operating position (gearbox down) INSIDE THE ENCLOSURE TO PREVENT INJURY
TO PERSONNEL.
Left - the side opposite the right side

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CAUTION d. Turn off all electrical power, liquid, and air service
ALL HARDWARE ITEMS HAVE BEEN to system on which maintenance is to be
MANUFACTURED TO ENGLISH performed. Allow the engine to cool.
MEASUREMENT UNITS. USE OF SUBSTITUTE
e. The following steps must be performed upon
METRIC SIZES IS NOT RECOMMENDED AND
exiting the enclosure after completion of
WILL VOID THE WARRANTY FOR
maintenance:
INTERFACING PARTS. TOOLS IN METRIC SIZES
SHOULD BE FURNISHED WITH SUITABLE (1) Ensure no personnel are inside the enclosure.
ADAPTERS TO MATE WITH ENGLISH
MEASUREMENT UNIT SIZES GIVEN. LIMITS, (2) Close the enclosure door.
FITS, AND CLEARANCES MAY BE
INTERPRETED IN EITHER ENGLISH OR METRIC (3) Remove tag and turn on electrical power, and
UNITS, AS SHOWN IN THE TABLES. liquid and air services.
NOTE 11-3.3 Electrical Bonding Straps

Most of the tasks outlined can be done within the
enclosure if the horizontal maintenance option is Electrical bonding strap contact surfaces shall be
selected, provided that tooling is available. Deviations prepared by removing all anoxic film, grease, paint,
from the procedures in the Volume II work packages lacquer, or other high-resistance material from an area
are permitted as necessary to adapt to the needs at least one and one-half times the bonding surface
dictated by the enclosure design, provided that these contact area. Bonds shall be installed and contact
deviations do not compromise the intent of the surfaces sealed within 4 hours of cleaning. The area
instruction. Some modular change-out may be done shall then be painted to match the surrounding area.
within the enclosure and some outside, whichever is
more convenient. Consult the packager for planning 11-3.4 Torque
assistance when questions arise.
In these maintenance procedures, it is assumed that all
Observe all safety precautions listed below, as well as threaded parts on the engine will be tightened to a
those listed in Chapter 1 and Chapter 8. specific torque value. Special torque values, if
required, will be stated in the text; otherwise, standard
a. Wear protective clothing, gloves, safety glasses, torque values should be used.
etc. as required by the maintenance to be
performed. a. Torque values are expressed in lb in. (pound-
inches) or lb ft. (pound-feet). One pound-inch (or
b. Ensure the engine will not be started while one pound-foot) is the twisting force of one pound
personnel are inside the enclosure. applied to a twist-type fastener (such as a bolt or
nut) with 1 inch (or one foot) of leverage. This
c. Post an observer at the exit while maintenance is twisting force is applied to the fastener to secure
being performed inside the enclosure. the components.
WARNING b. It is important to use the correct torque wrench for
ELECTRICAL POWER TO SYSTEM ON WHICH the amount of torque being applied. See table 11-1
MAINTENANCE IS BEING PERFORMED MUST for torque wrench ranges and requirements.
BE TURNED OFF TO PREVENT ARCING AND
POSSIBLE INJURY TO PERSONNEL OR
DAMAGE TO COMPONENTS. TAG THE SWITCH,
OUT OF SERVICE FOR MAINTENANCE, TO
PREVENT INADVERTENT ACTIVATION.

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CAUTION c. Never over-torque any fastener. Torque limits are

IF TORQUE SHOULD INCREASE provided in the text and in table 11-2 through
SIGNIFICANTLY PRIOR TO FINAL SEATING OF table 11-5; these limits must be observed. Refer to
ANY THREADED FASTENER, REMOVE AND paragraph 11-3.4 for application information.
INSPECT THE FASTENER FOR THE CAUSE OF
d. Do not use lubricant on bolt threads unless
THE TORQUE INCREASE.
specified in assembly procedures. Start threads at
least two turns by hand to ensure proper
engagement.
Table 11-1. Torque Wrench Requirements
NOTE
The ANSI Standard allows for a 4 percent reading error between 20 percent and 100 percent of wrench capacity,
while below 20 percent, ANSI allows for a reading error equal to 0.8 percent of wrench capacity (which can
result in as much as a 16 percent error in reading). Further, the accuracy of torque wrenches typically differs
when using the wrench in a clockwise (CW) direction versus a counter-clockwise (CCW) direction.
Every torque wrench has a specific range of effectiveness and accuracy, with the most accurate reading
occurring at the midpoint of the range. It is, therefore, very important to choose the correct torque wrench for
each operation.
Typical minimum and maximum torque values used on engine hardware are shown in table 11-2 through
table 11-5. Additional torque values may be specified in the text of procedures as necessary.
CAUTION
MAKE SURE THE WRENCH YOU USE IS ACCURATE AND SIZED APPROPRIATELY FOR THE
TORQUE REQUIREMENT. FAILURE TO DO SO CAN RESULT IN DAMAGE TO ENGINE HARDWARE
OR HARDWARE FAILURE.
When choosing a torque wrench to obtain a particular torque value, make sure the minimum and maximum
values of the desired torque are within the torque range - and that the nominal torque value is closest to the
midpoint of the torque range - of the wrench you choose.
For example: The torque required for a 1.3125-12 engine plug (see table 11-5) is 60-70 lb ft (82-94 N·m). The
minimum and maximum torque values are within the range of four of the torque wrenches shown below (5-75,
20-100, 30-150, and 50-250 lb ft); the nominal torque value of 65 lb ft (88 N·m) is closest to the midpoint of the
torque wrench with a torque range of 20-100 lb ft (27-136 N·m).
Below, is a list of torque ranges provided by various sizes of typical torque wrenches (shown for example only),
along with the midpoint for each torque range.

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Table 11-1. Torque Wrench Requirements (Continued)
Torque Ranges of Typical Torque Wrenches Midpoint of Torque Wrench/Range

lb in. (N·m) lb in. (N·m)
10 - 50 (1.1 - 5.6) 30 (3.4)
40 - 200 (4.5 - 22.6) 120 (13.6)
20 - 1000 (22.6 - 113.0) 600 (67.8)
lb ft (N·n( lb ft (N·m)
5 - 75 (7 - 102) 40 (54)
20 - 100 (27 - 136) 60 (81)
30 - 150 (41 - 203) 90 (122)
50 - 250 (68 - 339) 150 (203)
80 - 400 (108 - 542) 325 (441)
Table 11-2. Torque Values for Steel Bolts, Nuts, and Self-Locking Nuts
Torque Value
Thread Size (in.) Threads per Inch lb in. (N·m)
0.1640 32 14 - 16 (1.6 - 1.8)
0.1900 24 22 - 24 (2.5 - 2.7)
0.2500 20 46 - 54 (5.2 - 6.1)
0.3125 18 83 - 97 (9.4 - 10.9)
0.3750 16 171 - 199 (19.4 - 22.4)
0.4375 14 263 - 307 (29.8 - 34.6)
0.5000 13 428 - 502 (48.4 - 56.7)
0.1640 36 17 - 19 (2.0 - 2.1)
0.1900 32 33 - 37 (3.8 - 4.1)
0.2500 28 58 - 66 (6.6 - 7.4)
0.3125 24 106 - 124 (12.0 - 14.0)
0.3750 24 194 - 226 (22.0 - 25.5)
0.4375 20 304 - 356 (34.4 - 40.2)
0.5000 20 483 - 567 (54.6 - 64.0)

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Table 11-3. Torque Values for Engine Plugs and Unions
Torque Value
Fitting
Thread Size Dash No. lb in. (N·m)
0.3125-24 2 42 - 48 (4.8 - 5.4)
0.3750-24 3 88 - 102 (10.0 - 11.5)
0.4375-20 4 134 - 156 (15.2 - 17.6)
0.5000-20 5 152 - 178 (17.2 - 20.1)
0.5625-18 6 175 - 205 (19.8 - 23.1)
0.7500-16 8 236 - 307 (39.8 - 34.6)
0.8750-14 10 350 - 410 (39.6 - 46.3)
lb ft (N·m)
1.0625-12 12 46 - 54 (63 - 73)
1.3125-12 16 60 - 70 (82 - 94)
1.6250-12 20 74 - 86 (101 - 116)
1.8750 - 12 24 83 - 97 (113 - 131)
Table 11-4. Torque Values for Tubing Nuts and Hose Fittings
Fitting Torque Value Torque Value

Thread Size Dash No. (See Note 1) See Note 2)
lb in. (N·m) lb in. (N·m)
0.3125-24 2 - - 42 - 48 (4.8 - 5.4)
0.3750-24 3 37 - 43 (4.2 - 4.8) 88 - 102 (10.0 - 11.5)
0.4375-20 4 49 - 57 (5.6 - 6.4) 134 - 156 (15.2 - 17.6)
0.5000-20 5 65 - 75 (7.4 - 8.4) 175 - 205 (19.8 - 23.1)
0.5625-18 6 92 - 108 (10.4 - 12.2) 263 - 307 (29.8 - 34.6)
0.7500-16 8 161 - 189 (18.2 - 21.3) 460 - 540 (52.0 - 61.0)
0.8750-14 10 230 - 270 (25.0 - 30.5) - -

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Table 11-4. Torque Values for Tubing Nuts and Hose Fittings (Continued)
Fitting Torque Value Torque Value

Thread Size Dash No. (See Note 1) See Note 2)
lb ft (N·m) lb ft (N·m)
0.8750-14 10 - - 56 - 64 (76 - 86)
1.0625-12 12 28 - 32 (38 - 43) 79 - 91 (108 - 123)
1.3125-12 16 46 - 54 (63 - 73) 111 - 129 (151 - 174)
1.6250-12 20 60 - 70 (82 - 94) 129 - 151 (175 - 204)
1.8750-12 24 60 - 70 (82 - 94) 157 - 183 (213 - 248)
NOTES:
(1) These values apply when either sealing surface is aluminum. Nut may be steel or aluminum.
(2) These values apply when flared tube, ferrule, and connector are steel, nickel-base alloy, or titanium. Nut
may be steel, nickel-base alloy, titanium, or aluminum.
Table 11-5. Torque Values for Plugs and Unions Used in Bosses and for Universal Bulkhead Fitting Locknuts
Torque Value
Thread Threads
Dash No. Size Per Inch lb in. lb ft (N·m)
2 0.3125 24 42 - 48 - (4.8 - 5.4)
3 0.3750 24 88 - 102 - (10.0-11.5)
4 0.4375 20 134 - 156 - (15.2 - 17.6)
5 0.5000 20 152 - 178 - (17.2 - 20.1)
6 0.5625 18 175 - 205 - (19.8 - 23.1)
8 0.7500 16 263 - 307 - (29.8 - 34.6)
10 0.8750 14 350 - 410 - (39.6 - 46.3)
12 1.0625 12 - 46 - 54 (63 - 73)
16 1.3125 12 - 60 - 70 (82 - 94)
20 1.6350 12 - 74 - 86 (101 - 116)
24 1.8750 12 - 83 - 97 (113 - 131)

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11-3.4.1 Tightening Procedures This prevents shearing or breaking of tight bolts

due to force concentrations.
CAUTION
c. It is not desirable to tighten to the final torque
WHEN CHILLING OR HEATING AN ENGINE
value during the first drawdown; uneven tension
PART DURING ASSEMBLY, DO NOT TORQUE
can cause distortion or overstressing of parts.
SPANNER NUTS, LOCKNUTS, OR RETAINING
Torque mating parts by tightening the bolts or nuts
BOLTS UNTIL THE PART HAS RETURNED TO
gradually until the parts are firmly seated. Loosen
ROOM TEMPERATURE. THE FASTENER MAY
each fastener by one-quarter turn, then apply final
LOOSEN AS THE PART COOLS OR MAY BE
tightening. Tightening in a diametrically opposite
OVERSTRESSED AS THE PART WARMS AND
(staggered) sequence is desirable in most cases
EXPANDS.
(figure 11-1). Do not exceed listed maximum
a. If possible, tighten at a uniformly increasing rate torque values. All bolts are installed with heads
until the desired torque is obtained. In cases where forward and up with nuts aft and down, unless
gaskets or other parts cause a slow permanent set, otherwise specified.
be sure to hold the torque at the desired value until
d. Washers are installed beneath the part that turns
the material is seated.
when tightening, unless otherwise specified.
b. Apply uniform torque to a series of bolts that have
e. The torque wrenches listed in table 11-1 are
different diameters and are installed on one flange
recommended for use within the indicated ranges.
or in one area. Torque shall be less than the final
Larger wrenches have too great a tolerance and
torque required for the smallest diameter bolt.
can result in inaccuracies.
Figure 11-1. Tightening Sequence for Threaded Fasteners

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f. Torque values specified in this manual are actual

values to be applied to fasteners. Whenever an Table 11-6. Minimum Breakaway Torque for
adapter (crowfoot, spanner wrench, etc.) is used Self-Locking Nuts
with a torque wrench, torque must be calculated
per figure 11-2. Minimum Breakaway Torque
g. Inspect all nuts and bolts after tightening to make Threads/

sure they are seated. If any nut or bolt is not seated Size inch lb in. (N·m)
after the required torque has been applied, remove 0.1380 32/40 1.0 (0.1)
and inspect for thread damage.
0.1640 32/36 1.5 (0.2)
h. Lubricate tube/hose connector threads and
between the B-nut and ferrule of a connector. Run 0.1900 32 2.0 (0.2)
B-nuts onto fittings by hand to ensure that tubes 0.250 28 3.5 (0.4)
and hoses are aligned and threads are free of burrs.
Two wrenches must be used when loosening or 0.3125 24 6.5 (0.7)
tightening B-nuts, one on the fitting to which the
0.3750 24 9.5 (1.1)
tube or hose is being connected to hold it
stationary and one on the B-nut for torquing. This 0.4375 20 14.0 (1.6)
not only prevents twisting the tube, but also
prevents loosening or overtightening the fitting. 0.5000 20 18.0 (2.0)
When using an extension on a torque wrench, 0.5625 18 24.0 (2.7)
calculate the correct torque input before applying
torque per figure 11-2. 0.6250 16 32.0 (3.6)
0.7500 16 50.0 (5.6)
11-3.4.2 Breakaway Torque
Refer to table 11-6 for minimum breakaway torque on

self-locking nuts. This table applies to silver-plated,
lubricated, and nonlubricated self-locking nuts. Values
given are for nuts with no axial load. To check
minimum breakaway torque, screw the nut onto a bolt
until two to five threads are exposed beyond the nut.
Measure the amount of torque required to just start the
nut moving off the bolt. Nuts that do not meet these
minimum frictional requirements should be replaced.

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Figure 11-2. Torque Wrench Correction Factor Determination

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11-3.4.3 Loose Fasteners 11-3.5 Tri-Wing Fasteners
Prior to retightening, examine the fastener for the cause Tri-wing recessed-head fasteners are available in a
of the looseness. If safety wire is missing, tighten to the wide range of sizes, and each size requires the use of a
required torque and safety-wire the fastener. If the matched driver (figure 11-4). When properly used, the
fastener has a self-locking feature, check breakaway tri-wing design permits a higher ratio of torque to end-
torque per the preceding step. Replace defective pressure than is possible with slotted-head or cross-
fasteners as required. head designs, minimizing burring and mutilation. The
following procedures should be used for tri-wing
11-3.4.4 Standard Torque fasteners.
Use the following standard torque tables, unless 11-3.5.1 Installation

otherwise directed in the text.
a. Select the correct driver. The driver number
a. Use the torque values given in table 11-2 for steel should match the recess number of the fastener
bolts and nuts (including self-locking nuts). head as shown in figure 11-4. Table 11-7 lists a
Values given are for clean bolts and nuts that are range of standard fastener sizes with their
free of nicks and burrs. corresponding tri-wing recess identification
numbers.
b. Use half the value given in table 11-2 for the
following applications: b. Ensure the axis of the drive is aligned with the
axis of the fastener when installing or removing
(1) Thin steel hex nuts - These nuts have a height the fastener. If the head of the fastener has been
of less than 0.60 inch (15.2 mm) of the inside coated with paint or other material, use a driver
diameter for plain nuts and less than 0.80 one size smaller than that indicated, to
inch (20.3 mm) of the inside diameter for compensate for the thickness of material on the
self-locking nuts. walls of the recess.
(2) Nonsteel nuts and bolts except titanium.
(3) All bolts threaded directly into aluminum,

magnesium, or other non-steel parts.
c. Use the torque values given in table 11-3 and

table 11-4 for gasketed fittings. Install fittings as
illustrated in figure 11-3. Torque values given in
table 11-3 and table 11-4 are for packing made of
synthetic material, asbestos compounds, or soft
metal (copper, aluminum, etc.). These values do
not apply to steel gaskets or special boss seals.

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Figure 11-3. Universal Fittings Installation

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Figure 11-4. Tri-Wing Fastener Drive
11-3.5.2 Extraction b. If corrosion or other factors have caused the

fastener to seize so that failure of the recess
a. There is no slope to the walls of mating surfaces occurs, select the proper drill and screw extractor
of either fastener or driver, so that the tendency of for the size of fastener involved. The bottom of
the driver to slip out of the recess is minimized. the fastener recess is shaped so that the drill
Normal extraction by applying counterclockwise centers itself naturally and no special drilling
torque is usually successful. procedure is required. Drill into the fastener deep
enough to provide sufficient working depth for the
screw extractor. Tap the extractor to seat it firmly,
then apply counterclockwise torque to remove the
fastener.

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CAUTION
Table 11-7. Tri-Wing Drivers and Standard-Thread WHENEVER IT IS NECESSARY TO MARK ANY
Fasteners ENGINE PARTS, ONLY APPROVED MARKING
COMPOUNDS SHALL BE USED. USE OF
Screw Thread Size Tension Head Shear Head
UNAUTHORIZED MARKING COMPOUNDS CAN
0 - 80 0 - CAUSE DAMAGE TO ENGINE PARTS.
2 - 56 1 - b. Permanent marking of parts should be done in the

area of lowest stress, as specified on the
4 - 40 2 1
applicable drawing. Methods are listed below in
6 - 32 3 2 order of preference (unless otherwise specified).
Electric etch is not approved.
8 - 32 4 3
c. Marking methods are:
10 - 32 5 4
1/4 - 28 6 5 (1) Dot peen - preferred - optical character
recognition (OCR) is DM3. The OCR
5/16 - 24 7 6 requirement defines the character height,
width, and spacing.
3/8 - 24 8 7
7/16 - 20 9 8 (2) Vibropeen - acceptable
1/2 - 20 10 9 (3) Metal stamp - special use only

9/16 - 18 11 10 CAUTION
5/8 - 18 12 11 GREASE OR LEAD (GRAPHITE) PENCILS MUST
NOT BE USED TO MARK COMBUSTION-
3/4 - 16 13 12 SECTION OR HOT-SECTION PARTS. THESE
7/8 - 14 14 13 MATERIALS PLUS HEAT CAN CAUSE PARTS
MATERIAL DAMAGE.
1 - 12 15 14
d. Lead- and sulfur-containing materials should not
11-3.6 Marking of Parts be used for marking any parts. Preferred materials
are listed below:
a. Parts or assemblies designated as matched sets
must be maintained as matched sets throughout • Sharpie T.E.C.
maintenance activity. Set numbers, part numbers,
and serial numbers shall be protected during • Chalk
cleaning or rework to prevent removal. When
• Dykem - red, yellow, black
identification markings are removed or are no
longer legible, the item must be re-marked per the • Ink - Justrite Slink Black; Marco S-1141,
original marking method and at the location black
specified on the applicable drawing. Do not use
electrochemical etch method to re-mark part. • March Stencil Ink
• Carters Marks-A-Lot - black
• Carters Marks-A-Lot - blue

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• Dixon - black • In all cases, safety-wiring must be done through

the holes provided. If no wire hole is provided,
• Dixon - yellow safety-wiring shall be to a neighboring part in a
manner not to interfere with the function of the
• Dykem Steel Blue DX100 parts and in accordance with the basic principles
described.
• Soapstone
• The maximum span of safety wire between tension
11-3.7 Safety-Wiring points shall be 6 inches (152 mm), unless
otherwise specified. Where multiple groups are
Safety-wiring is the securing of two or more parts with safety-wired either by the double-twist or the
a wire installed in such a manner that any tendency for single-strand method, the maximum number in a
a part to loosen will be counteracted by additional series shall be determined by the number of units
tightening of the wire. This is not a means for obtaining that can be safety-wired with a 24-inch-inch (610
or maintaining torque, but rather a safety device used to mm) length of wire. When safety-wiring widely
prevent the disengagement of parts. See figure 11-5 for spaced multiple groups with the double-twist
general safety-wiring practices. method, the maximum number in a series shall be
three units.
NOTE
• Although not every possible combination of safety- • Both 0.020-inch (0.51 mm) and 0.032-inch (0.81
wiring is shown in figure 11-5, all safety-wiring mm) safety wires are used throughout the engine.
must, in general, correspond to the examples The application is determined by the size of the
shown. hole in the unit to be safety-wired. Whenever
possible, use the 0.032 inch (0.81 mm) safety wire.
• GE gas turbines use special locking cables at some Only new safety wire shall be used in each
locations. When removed for maintenance, these application.
should be replaced with equivalent cables or safety
wire using standard safety-wiring procedures in • The safety wire shall be pulled taut while being
this chapter. twisted, and shall have 9 to 12 twists per inch (25
mm) for 0.020 inch (0.51 mm) diameter wire and 7
11-3.7.1 Safety-Wiring General Practices to 10 twists per inch for 0.032 inch (0.81 mm)
diameter wire.
The following rules for safety-wiring shall be
observed, unless specific instructions to the contrary • Hose and electrical coupling nuts shall be safety-
are given in the text. wired in the same manner as tube coupling nuts.
• Safety wire shall consist of two strands of wire • Caution must be exercised while twisting to keep
twisted together (so called double-twist method), the wire tight without overstressing it or allowing it
where one twist is defined as being produced by to become nicked, kinked, or otherwise mutilated.
twisting the strands through an arc of 180°,
equivalent to half a complete turn. Use the single- • Only existing safety wire should be replaced; do
strand method only when specified. not add safety wire which was not previously in
place or specified in text.
• Safety wire shall not be installed in a manner to
cause the wire to be subjected to chafing, fatigue • When removing safety wire, identify safety-wiring
through vibration, or additional tension other than holes on parts.
the tension imposed on the wire to prevent
loosening.

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Figure 11-5. Safety Wiring Practices (Sheet 1 of 2)

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Figure 11-5. Safety-Wiring Practices (Sheet 2 of 2)

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11-3.7.2 Safety Wire Installation

Table 11-8. Installed Safety Wire Flex Limit
The following safety-wiring procedures are to be used
throughout the engine: Length of Safety Wire
Between Parts Total Flexing at Center
a. Insert the safety wire through the first part and
bend the upper end either over the head of the part Inches (mm) Inches (mm)
or around it. If bent around it, the direction of
wrap and twist of the strands shall be such that the 0.50 (12.7) 0.13 (3.3)
loop around the part comes under the strand 1.00 (25.4) 0.25 (6.3)
protruding from the hole. Done this way, the loop
will not tend to slip upward and become slack. 2.00 (50.8) 0.37 (9.3)
b. Twist the strands while taut until the twisted 3.00 (76.2) 0.50 (12.7)
portion is just short of the nearest hole in the next 4.00 (101.6) 0.75 (19.0)
part. The twisted portion should be within 1/8 inch
(3.2 mm) of the hole in each part. 5.00 (127.0) 0.75 (19.0)
c. If the free strand is to be bent around the head of 6.00 (152.4) 0.75 (19.0)
the second part, insert the upper strand through the
hole in this part, then repeat the previous step. If g. Always cut, rather than break, safety wire so that
the free strand is to be bent over the unit, the safety wire holes are not torn or pulled out.
direction of twist is unimportant. If there are more Instructions for dismantling and disassembly do
than two units in the series, repeat the preceding not include safety wire removal because of the
steps. obvious necessity for removing safety wire.
d. After wiring the last part, continue twisting the WARNING

wire to form a pigtail of three to eight twists (1/4- USE EXTREME CAUTION IN MONITORING THE
1/2 inch [6-13 mm] long) and cut off the excess SAFE AND COMPLETE REMOVAL OF ALL
wire. Bend the pigtail inward toward the part in EXCESS SAFETY WIRE. CARE MUST BE TAKEN
such a manner as to prevent it from becoming a WHEN CUTTING OFF THE ENDS OF INSTALLED
hazard to personnel. WIRE TO ENSURE COMPLETE RETRIEVAL IN
ORDER TO PREVENT INJURY TO PERSONNEL
NOTE AND/OR SUBSEQUENT ENGINE DAMAGE.
Apply light finger pressure at the midpoint of the safety
wire span, and flex the wire in both directions to check h. When removing safety wire, ensure that all pieces
for tautness. are removed to prevent them from entering engine
parts or otherwise causing damage.
e. If the safety wire is not taut after safety-wiring per
the preceding instructions, use the limits shown in 11-3.8 Safety Cable
table 11-8 to determine its acceptability.
Safety cable is an alternative to safety wire. Safety
f. If the safety wire fails to meet the limits shown in cable is installed through two or more parts in such a
table 11-8, remove it and install new safety wire. way that as the fastener or part loosens the safety cable
will tighten. When the safety cable tightens, it will not
permit the fastener to part or turn.

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11-3.8.1 Safety Cable General Practices requirements. GE Aircraft Engines recommends the
pulloff load test be done at the beginning, middle, and
The safety cable system has three components: safety end of each shift. Refer to manufacturer's instructions
cable, ferrules, and crimping tool. for pulloff load test procedure.
• The safety cable is available in one size, 0.032 inch 11-3.8.3 Safety Cable Installation
(0.81 mm). One end of the cable will have a cable
end fitting swaged to it. The strands of the cable on a. Do a visual inspection of the holes to be safety
the opposite end of the cable are fused together to cabled to find all damage. If the hole is damaged,
prevent the cable from fraying. replace the part, or if possible, use another hole to
safety cable.
• The ferrules have spring-loaded, disposable
magazine. When the safety cable is installed, the NOTE
ferrule will be crimped on the open end of the
Keep the safety cable as straight as possible when you
cable.
safety cable the fasteners or parts together.
• The hand operated crimping tool operates in one
direction only and has a cycle end dead stop to tell b. Put the end of the cable without the cable end
the operator when the ferrule is fully crimped. The fitting into the hole in the part. Pull the cable
crimping pressure of the tool is set by the through the hole until the cable end fitting is
manufacturer. If necessary, the crimping pressure against the part.
can be adjusted with standard hand tools. The c. Insert the end of the cable through the second part.
Snap-On tool has a spring-loaded crimp rod to hold Choose the hole in the part that permits the cable
the ferrule in place during the crimping procedure. to be as straight as possible. Pull the cable through
Cable tension is done automatically by the internal the second part. If three parts must be safety
retraction mechanism. cabled, do the same procedure for the third part.
• Where possible, install the safety cable so it does NOTE
not touch other parts.
On a two bolt pattern, do not cable in a negative pull
• Make sure the cable is not damaged or bent when direction. Make sure the cable has a positive or neutral
installing safety cable through the holes in the pull.
fastener or part. Frayed cable assemblies are not
permitted. d. Put the end of the safety cable coming out of the
last part to be safety cabled through a ferrule in the
• Install the safety cable through existing holes only. ferrule magazine. Pull the safety cable through the
• Unless specified differently in the packager's ferrule and use the safety cable to pull the ferrule
manual: out of the ferrule magazine.
The maximum length of the safety cable between e. Put the end of the safety cable through the
safety cabled parts is 6.0 inches (152.4 mm). crimping head of the crimping tool. Make sure the
large hole in the crimping head is on the same side
No more than three bolts can be safely tied with as the ferrule. Move the crimping tool along the
one safety cable. safety cable until the crimping head is against the
ferrule. Pull back on the retraction knob. Put the
Safety cable can not be used on titanium fasteners.
ferrule in the crimping head and release the
retraction knob. Make sure the ferrule is fully in
11-3.8.2 Crimping Tool Verification the crimping head.
Do a pulloff load test as necessary to make sure the
crimp done by the crimping tool meets the necessary

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CAUTION as dimension A. If three parts are safety

DO NOT PUT TOO MUCH TENSION ON THE cabled together, measure the distance
SAFETY CABLE. THE CRIMPING TOOL WILL between each of the parts and add the two
AUTOMATICALLY SET THE TENSION. TOO measurements together to get dimension A.
MUCH TENSION WILL BREAK THE SAFETY
(2) Push against the safety cable with light finger
CABLE.
pressure halfway between two safety cabled
f. Pull the safety cable to the tension post on the parts. Measure the distance the safety cable
crimping tool. Wrap the cable completely around moves laterally. Write this measurement
the post. Make sure the cable is in the groove at down as dimension C.
the top of the post. Pull the cable toward the drive
handle until the cable goes behind the locking (3) Compare the dimensions that were written
ball. down to the limits given in figure 11-6.
g. Hold the crimping tool perpendicular to the cable CAUTION

in the bolt head. Make sure the ferrule is tightly DO NOT TRY TO BREAK THE SAFETY CABLE.
against the bolt head. Lightly pull on the end of IF THE SAFETY CABLE MUST BE REMOVED,
the safety cable to remove slack. CUT THE SAFETY CABLE TO AVOID DAMAGE
TO THE HOLES IN THE PARTS.
h. Push the start cycle button and turn the drive
handle clockwise. At the start of the cycle, the n. If the safety cable is not in the limits given in
tension block will move backwards. This figure 11-6, cut the safety cable with wire cutters
movement backwards provides the cable tension. and remove the installed safety cable. Install new
When the drive handle is turned, release the start safety cable.
cycle button. Turn the drive handle until it stops
(approximately two full turns).
11-3.9 Correction of Leaks
i. Pull up on the safety cable end to remove it from
the tension block. CAUTION
DO NOT OVER-TORQUE THREADED
j. Pull back on the retraction knob and remove the FASTENERS AS A METHOD OF CORRECTING
crimping tool from the crimped ferrule and the LEAKING CONNECTIONS. OVER-TORQUING
remaining safety cable. COULD RESULT IN PART FAILURE.
k. Cut the unused safety cable even with the crimped
a. Disassemble the connection.
ferrule. Use the side cushioned cutters. Discard
the unused safety cable. b. Discard the seal, gasket, or packing, if present.
l. Visually inspect safety cable for kinks, frayed
c. Inspect mating surfaces for contamination,
wires, or improper crimps. Remove and replace
scratches, dents, or other surface defects.
safety cable if a problem exists.
m. Push against the safety cable with light finger d. Inspect threaded fasteners for thread damage and
pressure halfway between the safety cabled parts. ensure that fasteners seat properly when torqued
If the cable feels loose, do a dimensional check to to specified values.
make sure the safety cable is serviceable as
e. Replace nonserviceable parts and assemble the
follows (figure 11-6):
connection, using new seals, gaskets, or packing
(1) Measure the distance between the safety as required.
cabled parts. Write this measurement down

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Figure 11-6. Safety Cable Flex Limits

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11-3.10 Unpacking and Repacking engage and the threads in the flange are likely to
strip.
The following general instructions apply during
unpacking and repacking to minimize possible part c. Jackscrews, frequently designed as special tools
damage and contamination. and identified as such, are not chamfered and full
thread engagement will occur. If specially
a. Initially, remove only that portion of the packing manufactured jackscrews are not available and
material necessary to mount the part. Where must be manufactured locally, be sure that the
possible, remove the remainder of the packing ends are ground to remove the chamfer and the
material, including protective caps and plugs, one incomplete thread so that the maximum number of
at a time as each connection (fluid, air, or threads may be engaged.
electrical) is made.
b. Retain protective caps and plugs and reusable 11-3.12 Protective Closures and Caps
packing components for repacking purposes. a. Preventing foreign material from lodging in
c. Install a cap or plug on each connection (fluid, air, drilled passages, fuel lines, oil lines, air lines, and
or electrical) as it is disconnected. open engine ports is extremely important.
Machined surfaces must be properly protected to
d. When possible, repack the part for storage or prevent damage.
shipment, using the same packing material in
which the replacement part was received. b. Wrap precision parts and cap or plug all openings
and connections. It is most important that all
e. When original packing components are not engine parts be kept clean and free of corrosion.
available, use locally available packing materials All instructions that specify special handling of
and containers to pack the part. Make sure all parts must be followed without exception.
ports, openings, connections, and mating surfaces
are capped or covered, and that the part is c. Accessories, tubes, and hoses may contain fuel or
protected from potential handling or oil at the time of removal. Drain these fluids from
environmental damage. the accessory being removed and cap all
connecting hoses or tubes. Do not use tape.
f. Bearings shall be handled per paragraph 11-3.20.
d. Do not remove plugs, caps, etc., until the part is
11-3.11 Jackscrews ready for assembly. Check both seating surfaces
for removal of plugs, etc. prior to assembly.
a. When using jackscrews to remove components, do
not bend flanges or strip threads. Lubricate 11-3.13 Universal Fittings
jackscrews with engine lube oil before installing.
Turn jackscrews inward evenly and in small Universal fittings should be installed according to the
increments. Always check for and remove burrs or procedures described below (figure 11-3).
rough edges before using jackscrews. If regular Pipe fitting
bolts are used as jackscrews, the tips must be blunt
and polished. Do not allow components to fall free a. Inspect the fitting visually.
as jackscrews are tightened.
b. Clean if necessary.
b. Jackscrew holes are often in flanges that are only
c. Lubricate mating fittings.
thick enough for three or four threads. The ends of
most standard bolts are chamfered, and the first d. Install the fitting, screwing it down to within one-
couple of threads are missing or incomplete. half turn of final position.
These should not be used as jackscrews without
modification, since only one or two threads will e. Remove the fitting, clean, inspect, and lubricate
the male thread.

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f. Reinstall the fitting and screw it down to its final f. Screw the fitting and nut simultaneously into the
position. boss until the packing contacts the chamfer at the
face of the boss.
Union
g. Hold the nut and turn the fitting one-and-a-half
a. Lubricate the packing and roll it over the threads turns into the boss. The fitting may be positioned
into the groove in the union. further by one additional turn.
b. Screw the union into the boss until the packing h. Attach the line to the fitting and check the
contacts the surface of the boss. alignment of the fitting.
c. Tighten the union to the proper torque value. i. Hold the fitting and tighten the nut to the proper
Bulkhead fitting torque.
a. Lubricate the fitting end. Screw the nut onto the 11-3.14 Cleanliness
fitting until the washer face of the nut is aligned
with the upper corner of the seal groove. Cleanliness is important for equipment life and proper
operation. The major cause of premature engine
b. Lubricate the packing and roll it over the threads removal is foreign object damage (FOD).
into the groove in the fitting so that it contacts the
nut. a. The enclosure must be kept clean and free of dirt
and loose objects. It is recommended that small
c. Screw the fitting and nut simultaneously into the FOD containers be kept in the work area or in tool
boss until the seal contacts the chamfer at the face boxes.
of the boss and the nut contacts the boss.
b. All parts shall be inspected for cleanliness before
d. Position the fitting either by turning in as much as being installed.
three-quarters of a turn (270° clockwise) or
turning out as much as one-quarter turn (90° c. Gaskets and packing shall be free from dirt, lint,
counterclockwise). Attach the line to the fitting and/or grit.
and check the alignment of the fitting. Tighten the d. Mating flanges, tube flanges, and couplings shall
nut to the proper torque. be wiped clean to make sure that a good seal will
Fittings with backup rings be obtained.
a. Lubricate the male threads of the fitting, the e. Hands and gloves must be clean when handling
backup ring, and the packing. machined surfaces.
b. Screw the nut onto the fitting, with the f. The engine shall not be used as a shelf for holding
counterbore side facing the fitting end. tools or parts while maintenance is being
performed.
c. Put the backup ring on the fitting and seat it in the
counterbore of the nut, with its convex side facing g. After performing any maintenance, the work area
the fitting end. shall be thoroughly inspected for loose parts, rags,
tools, and other materials. The area shall be
d. Roll the packing over the threads into the groove cleaned to remove grit, dust, chips, safety wire,
in the fitting. and other small objects.
e. Adjust the nut so the backup ring forces the 11-3.15 Gaskets and Packing
packing firmly against the lower threaded portion
of the fitting. a. Gaskets, packing, key washers, and cotter pins
shall not be reused, unless otherwise specified.

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b. Gaskets and packing shall be lightly lubricated 11-3.17 Hoses

with engine lube oil prior to installation, unless
otherwise specified. Ensure parts are properly a. No hose should be bent more than the bend radius
seated. When a fitting with a jamnut and packing specified in table 11-9, especially when parts are
is used, see figure 11-3 for the proper installation cold, because of possible damage to Teflon liners.
procedure. See figure 11-7 for packing used with Kinked hoses must not be used. During
flexible sleeve type fittings. installation, be sure that no hose is twisted or
stretched. Never over-torque connectors. When
11-3.16 Tubes hoses are removed, cap the open ends. Do not use
tape to cover open ends.
When installing tubes, the following precautions and
instructions apply (figure 11-7). CAUTION
NATURAL GAS FUEL HOSES AND FUEL
a. As tubes are installed, tighten all end fittings and NOZZLE STEAM HOSES HAVE DIFFERENT AND
clamps finger-tight. After a complete system is MORE RESTRICTIVE REQUIREMENTS. REFER
installed, torque end-fittings first and then clamps. TO THE APPROPRIATE WORK PACKAGE IN
• Maintain a minimum clearance of 0.125 inch VOLUME II FOR DETAILS.
(3.17 mm) between tubes and adjacent parts.
b. Fluid fittings shall be tightened gradually to the
• Tubes and manifolds must fit within required torque value, backed off one-quarter turn,
0.063 inch (1.6 mm) radius in a free state and then tightened again. Do not attempt to
during assembly or be replaced. correct leaks by excessive tightening. Always use
two wrenches when tightening swivel coupling
• Coupling nuts shall thread freely by hand. nuts on hoses, tubes, or fittings. Hold the
• Mating flanges on tubes shall seal flush stationary part with one wrench while applying
within 0.005 inch (0.13 mm). torque with second wrench. Apply engine lube oil
between the tube/hose coupling nut and the ferrule
• The distance between faces of mating prior to tightening (figure 11-8).
surfaces or flanges shall not exceed
0.063 inch (1.6 mm). c. Preformed hoses or hoses of large diameter shall
not be bent or straightened (figure 11-9). When
• If tubes are reworked, the bend radii shall not hoses are removed, cap the open ends. Do not use
be less than twice the tube diameter and the tape to cover open ends.
bend angle shall not be changed by more than
3 degrees. No kinks or wrinkles are d. Before installing preformed hoses, visually
permitted. inspect the hose interior to assure that the Teflon
lining has not been damaged. If damaged, replace
• Do not bend tubes at fitting or weld areas.
the hose.
• Original bends in a tube may be bent in the
same direction, but reverse bending is not
allowed.
• Bend tubes in existing straight sections, if
possible.
Use bending tools on any tube 1 inch or more in

diameter to prevent the tube from collapsing.

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Table 11-9. Hose Minimum-Bend Radii
Minimum Brnd Radii

Dash Size Inches (mm)
3 1.50 (38.1)
4 2.00 (50.8)
5 2.00 (50.8)
6 4.00 (101.6)
8 4.62 (117.4)
10 5.50 (139.7)
12 6.50 (165.1)
16 7.38 (187.5)
20 11.00 (279.4)
24 14.00 (355.6)
32 22.00 (558.8)

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Figure 11-7. Flexible Coupling Assembly

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Figure 11-8. Hose Assemblies Installation

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Figure 11-9. Factory Preformed Hoses
11-3.18 Clamps present and serviceable before attaching the connector.

Replace unserviceable seals as follows:
a. Chafing of hoses and tubes must be avoided.
Clamp parts loosely in place, shift the hoses until a. Remove the unserviceable seal.
the best clearance is obtained, and then tighten the
clamps (figure 11-10). b. Engage the new seal over the barrel of the
connector.
b. Clamps must be of the proper size for the piping to
permit slippage during engine thermal growth. CAUTION
The cushion clamp liner position should also be DO NOT ALLOW THE SEAL TO TIP AND
checked before tightening the clamp FLATTEN. AN INCORRECTLY INSTALLED SEAL
(figure 11-11). Clamps must be positioned over COULD AFFECT THE USEFULNESS OF THE
the wear sleeves on the tube. SEAL AND/OR CONNECTOR.
11-3.19 Electrical Cables and Connectors c. Push the seal to its seated position against the
internal shoulder in the connector using a mating
During electrical cable installation, adjust the cable connector or blunt screwdriver.
through the clamps to get the smoothest and largest
radius. Sharp bends, twists, and kinks must be avoided.
Minimum clearance between the electrical cable and
any component other than hoses or other electrical
cables is 0.125 inch (3.17 mm).
A seal ring is located in the coupling nut of each

electrical connector. Inspect to ensure the seal is

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Figure 11-10. Routing and Clamping Techniques
Figure 11-11. Cushion Clamps Installation

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CAUTION 11-3.20.1 Preservation

DO NOT FORCE THE CONNECTORS TOGETHER.
WARNING
IF THE PINS ARE NOT ALIGNED, THEY WILL BE
BENT OR DISTORTED AND WILL NOT MAKE LUBRICATING OIL, MIL-L-6085, IS
CONTACT. FLAMMABLE AND TOXIC TO SKIN, EYES, AND
RESPIRATORY TRACT. SKIN, EYE, AND
d. Inspect electrical connector pins for straightness RESPIRATORY PROTECTION IS REQUIRED.
before connecting. Insert the mating cable
connector, hand-tighten the retaining nut, push the At the point where bearings are accessible in the
mating parts together until seated, and tighten the disassembly cycle, the bearings shall be thoroughly
retaining nut as required. covered with lubricating oil, MIL-C-6085.
e. If the connector is a locking connector, engage the Use of engine lubricating oil as a lubricant or
connector and wiggle the backshell while preservative is specifically prohibited.
tightening the coupling ring hand-tight. A clicking
sound is produced during tightening of the Personnel handling bearings must wear either synthetic
connector. Ensure that the full coupling color band rubber or nylon-mesh gloves with polyethylene palms
on the receptacle is not visible and that the and fingers.
backshell has no movement.
WARNING
f. Electrical connectors on flexible harnesses and CORROSION PREVENTIVE, MIL-C-11796, IS
leads shall be hand-tightened beyond finger-tight FLAMMABLE AND TOXIC TO SKIN, EYES, AND
(20° maximum) until connecting parts are in solid RESPIRATORY TRACT. SKIN, EYE, AND
contact without damage. Safety-wire the RESPIRATORY PROTECTION IS REQUIRED.
connectors only when specified in the procedure.
Bearings returned to storage shall be preserved with
g. Do not sharply bend, kink, or twist rigid leads. corrosion preventive, MIL-C-11796, Class 3, and
When tightening the connection, always hold both wrapped in barrier paper, MIL-B-121, Grade A, Type
mating connectors to prevent damage to the leads. 2, Class 2, glossy side toward bearing.
11-3.20 Bearing Handling After installation, bearings shall be returned to room

temperature and be preserved with lubricating oil,
CAUTION MIL-C-6085.
BALL AND ROLLER BEARINGS REQUIRE
SPECIAL CARE TO PREVENT CORROSION. 11-3.20.2 Heating and Chilling
BEARINGS MUST NOT BE HANDLED WITH
BARE HANDS NOR WITH ANY DEVICE THAT WARNING
MIGHT CAUSE CONTAMINATION. CLEAN CORROSION PREVENTIVE, MIL-C-6529, IS
RUBBER OR NYLON GLOVES OR A TOXIC TO SKIN, EYES, AND RESPIRATORY
PROTECTIVE HAND CREAM SHALL BE USED TRACT. SKIN, EYE, AND RESPIRATORY
AT ALL TIMES WHEN HANDLING BEARINGS. PROTECTION IS REQUIRED.

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WARNING NOTE
DRY ICE, BB-C-104: DO NOT LET THIS Heating and chilling are defined as any temperature
MATERIAL TOUCH YOU. LOW-TEMPERATURE 10°F (6°C) or more above or below room temperature.
SKIN DAMAGE. CAN DECREASE AVAILABLE
AIR. ASPHYXIANT. PERSONAL PROTECTIVE a. When it is necessary to chill a bearing in dry ice,
EQUIPMENT REQUIRED, ESPECIALLY coat the bearing thoroughly with corrosion
INSULATED GLOVES AND EYE PROTECTION preventive, MIL-C-6529, Type III, and place in a
WHEN HANDLING MATERIAL. USE IN A WELL- plastic bag prior to chill.
VENTILATED AREA. b. Immediately after installation of a chilled bearing,
apply heat with a heat gun until bearing and
WARNING adjacent parts are brought to room temperature.
USE THERMAL GLOVES WHEN YOU MOVE OR Remove any moisture using clean, dry shop air,
TOUCH HOT OR COLD PARTS. HOT OR COLD and coat the bearing with corrosion preventive,
PARTS CAN CAUSE INJURY. MIL-C-6529, Type III.
WARNING c. Heat bearings using ovens or heat guns. No direct

heat source, such as a blow torch, may be used.
WHEN USING COMPRESSED AIR FOR When the bearing returns to room temperature,
CLEANING, COOLING, OR DRYING, DO NOT coat with corrosion preventive, MIL-C-6529,
EXCEED 30 PSIG (207 KPA). WEAR EYE Type III.
PROTECTION AND DO NOT DIRECT
COMPRESSED AIR AT SELF OR OTHERS.
11-3.21 Spray Shields
CAUTION
Spray shields shall be positioned on tubing so as to
IMMEDIATELY AFTER INSTALLING OR prevent fluid from spraying on the engine if a leak
REMOVING A CHILLED BEARING, USE A HEAT occurs at the shielded area of a tube.
GUN TO RESTORE THE BEARING AND ANY
ADJACENT COLD AREA TO ROOM 11-3.22 Blending
TEMPERATURE SO THAT CONDENSATION OF
MOISTURE WILL BE MINIMIZED. CHECK NOTE
CAREFULLY FOR EVIDENCE OF MOISTURE Refer to specific engine manual section or service
AND CONTINUE HEATING UNTIL THE bulletin for blend limits for the piece part under review.
BEARING IS COMPLETELY DRY. APPLY Use the limits in this procedure only when no specific
CORROSION PREVENTIVE, MIL-C-6529, TYPE limits are specified for the component in the engine
III, AT ONCE TO THE BEARING AFTER manual or appropriate service bulletin.
COMPLETE DRYING.
Blending is a repair procedure that is used to remove
CAUTION stress concentrations caused by nicks, scratches, or
WHEN HEAT IS REQUIRED TO RELIEVE other sharp-edged damage marks on critical parts.
SHRINK FITS OF BEARINGS, USE HEAT GUNS Removal of the material surrounding the stress
OR OVENS. DO NOT USE DIRECT-HEAT concentration, so that the sharp edges are blended into
SOURCES TO APPLY THE HEAT AND DO NOT smooth contour, relieves the stress concentration and
HEAT THE BEARINGS TO A TEMPERATURE permits further use of the part by lessening the danger
HIGHER THAN 350°F (175°C). APPLY of cracking.
CORROSION PREVENTIVE, MIL-C-6529, TYPE Blending is also used to remove sharp edges resulting
III, TO THE BEARINGS BEFORE HEATING AND from machining, drilling, etc., and to restore the
AFTER THEY HAVE COOLED TO ROOM original contour and/or surface finish to parts that have
TEMPERATURE. been repaired by welding, brazing, etc.

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11-3.22.1 Blending General Practices removing metal from leading and trailing edges of
airfoil sections in such a way that the edges
The following rules for blending shall be observed, become thin or sharp; blend so as to maintain
unless specific instructions to the contrary are given in approximately the original contour.
the text:
b. When blending a cylindrical part, blend in a
CAUTION circumferential direction, not along the axis of the
DO NOT REPAIR TITANIUM PARTS WITH part.
TOOLS, SUCH AS GRINDING WHEELS, FILES,
c. The finish on the blended area shall be as close to
STONES, OR EMERY CLOTH, THAT HAVE BEEN
the original finish as possible.
USED TO REPAIR OTHER TYPES OF METAL.
DAMAGE TO PARENT METAL COULD OCCUR. d. When blending on a part involving a radius, keep
the radius as specified in the repair section. If the
• Defects more than 0.25 inch (6.3 mm) apart shall
radius is not specified, keep it as close as possible
be blended separately. Those less than 0.25 inch
to the original contour. Refer to a similar part, if
(6.3 mm) apart (except splines) shall be blended
necessary, to determine original radius.
together. Splines that are closer together than
0.25 inch (6.3 mm) and defects shall be repaired e. Etch reworked area per paragraph 11-3.23 and
separately. inspect by spot fluorescent-penetrant method, per
paragraph 11-3.24, after blending.
• The finish on the blended area must be as close as
possible to the original finish of the part.
11-3.22.3 Power Blending
11-3.22.2 Hand Blending Blending on most parts may be done by using a power-
driven polishing wheel or rubber-bonded abrasive
Sharp edges can be blended out using abrasive stones
points, and any special instructions for the individual
or papers, files, or crocus cloth. Coarse grades of
part must be followed.
abrasives or files may be used for fast metal removal,
but the parts must then be given a smooth surface finish WARNING
with fine grades of abrasives or crocus cloth.
DO NOT BREATHE THE PARTICLES FROM
WARNING GRINDING OR LET THE PARTICLES TOUCH
YOU. THE PARTICLES CAN CAUSE DAMAGE,
DO NOT BREATHE THE PARTICLES FROM
INJURY, OR IRRITATION TO YOU. USE
GRINDING OR LET THE PARTICLES TOUCH
PERSONAL PROTECTION EQUIPMENT. USE
YOU. THE PARTICLES CAN CAUSE DAMAGE,
LOCAL MECHANICAL EXHAUST VENTILATION
INJURY, OR IRRITATION TO YOU. USE
OR AN APPROVED RESPIRATOR.
PERSONAL PROTECTION EQUIPMENT. USE
LOCAL MECHANICAL EXHAUST VENTILATION CAUTION
OR AN APPROVED RESPIRATOR.
POWER BLENDING OF AIRFOIL SECTIONS MAY
NOTE BE DONE ONLY WHEN SPECIFIED BY
INDIVIDUAL PART INSTRUCTIONS. WHEN
Refer to the inspection and repair limits for specific
DOING POWER BLENDING, BE SURE TO AVOID
instructions on blending limits applicable to each part
BUILDING UP EXCESSIVE HEAT AND
of the engine.
RESULTING THERMAL STRESSES IN THE PART.
a. When blending compressor rotor blades, stator
vanes, turbine blades, and similar parts, blend in a
radial direction in relation to the engine. Avoid

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NOTE (d) Dent - A smooth rounded depression in

After power blending of a titanium part is completed, the airfoil made by impact with a
hand-blend the same area approximately 0.002 inch rounded object. If there is any noticeable
(0.05 mm) deeper to remove any residual stresses in the sharp discontinuity in the depression, it
surface material. should be considered as a nick.
Waviness of leading or trailing edges is
a. Rough out defects using coarse grades of resilient to be treated as a dent.
flexible abrasive impregnated wheels, brushes, or
points. Use fine or extra fine grades to finish the (e) Erosion - A sand- or shot-blasting effect
blend areas. on the leading edges or the leading
portion of the concave side caused by
b. Follow the requirements described in sand or dust going through the engine.
paragraph 11-3.22.3 when doing power blending.
(f) Torn Metal - A separation or pulling
c. Etch reworked area per paragraph 11-3.23 and apart of material by force, leaving
inspect by spot fluorescent-penetrant method, per jagged edges.
paragraph 11-3.24, after blending.
(2) Hand-blending of airfoils may be done as
specified below:
11-3.22.4 Component Specific
Requirements (a) Blending is done to remove stress
caused by nicks, pits, and scratches to
NOTE prevent blade failure. Remove high
Requirements in specific engine manual section or metal and straighten dents (where
appropriate service bulletin take precedence over the permitted) to restore the airfoil shape as
following procedures. The requirements in this section closely as possible to its original
should be used with engine manual or service bulletin aerodynamic contour.
criteria or when no criteria are specified.
(b) Blending shall be finished with fine
a. Blending Airfoils. stone or crocus cloth. Coarser tools may
be used for initial removal of material.
(1) The types of airfoil damage described below Finish blending in a direction along the
may be repaired by hand blending or by length of the blade or vane and remove
power blending. Always refer to applicable all evidence of marks across the airfoil
part inspection paragraph for a description of that may have been made during initial
airfoil defect limits as follows: blending.
(a) Nick - A V-shaped depression in the (c) Defects more than 0.25 inch (6.3 mm)
airfoil made by a sharp-edge object apart shall be blended separately; those
pushing the metal inward. 0.25 inch (6.3 mm) or less apart may be
blended together. All blends must have a
(b) Pit - A round sharp-edged hole with a minimum radius of 0.25 inch (6.3 mm).
rounded bottom caused by corrosion. The total reduction in chord width may
be taken on either side or divided
(c) Scratch - A V-shaped line or furrow in
between the sides. The amount of
the airfoil such as would be made by
rework is controlled by the minimum
dragging a sharp object across the
chord width limit. The minimum
surface.
allowable chord is given for root and tip
of airfoil, the minimum chord at other

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points is proportional. To minimize the passages are present to prevent

possibility of an engine stall, keep the excessive penetrant entrapment.
shape of the blended airfoil leading edge
as close as possible to the original (3) Power-blending of rotor blades, variable
contour (figure 11-12). vanes, and vane segments may be done as
follows:
(d) Blending limits are given as depth
dimensions to make it easier to see how (a) To avoid damaging the airfoil, use
much can be repaired. Experience has masking tape and mask off the airfoil
shown that depth limits are used for next to the rework area.
most rework. However, the minimum
chord limit is the most important (b) Use coarse grade, silicon-carbide
dimension; it should be checked in impregnated rubber wheels and points
borderline cases or where previous for the initial benching of the blades and
rework is evident in the same area. For vanes.
convenience, the depth limits and
NOTE
minimum chord limits are given in both
decimals and fractions. In borderline During finish blending of defects, make a radius on
cases where depth limits and minimum both the leading and trailing edges of the airfoil. To do
chord limits conflict with one another, this, apply light pressure with the rubberized abrasive
use the decimal minimum chord wheel, and let the cushion action of the wheel do both
dimension to decide if the part is usable. the blending of the radius and the buffing of the defect.
(e) Defect limits are given as depth (c) Finish blending the defects, using the
dimensions since this is the dimension fine and extra fine grade of rubberized
that affects strength. However, accurate abrasive wheels. Remove only enough
depth measurements require special material to repair the defect.
equipment not normally available.
Comparing the depth of a defect with (d) Swab etch reworked areas per
the thickness of a leaf of thickness gage paragraph 11-3.23 and spot-fluorescent-
or with the thickness of a piece of safety penetrant inspect per paragraph 11-3.24.
wire is a reasonably accurate way of
measuring depth (figure 11-13). (e) Place the repaired blades and vanes in
separate containers to prevent damage
(f) Swab etch reworked area per during handling.
paragraph 11-3.23 and spot-fluorescent-
penetrant inspect per paragraph 11-3.24. (f) Carefully inspect the blades and vanes.
Brush or swab on penetrant where air

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Figure 11-12. Airfoil Leading Edge Blending
Figure 11-13. Airfoil Defect Measurement

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b. Blending Minor Indications in Tubing. a. All surfaces to be etched must be free from oil,
grease, scale, or other extraneous material.
(1) Use a fine abrasive stone, a small file, emery
cloth, or crocus cloth for blending. b. Pour a small quantity of stock solution into a clean
plastic beaker or dish. This quantity will be the
(2) Blend around the circumference of the working solution, and is not to be returned to the
tubing. The finished blend shall be as close as stock bottle.
practical to the original finish of the part.
c. Saturate a cotton swab with the working solution,
c. Removing High Metal. High metal is caused by and swab the surface to be etched for 60-90
the displacement of metal above a surface. It is seconds, all Classes, except Class G. Class G
found around defects like nicks and scratches. etching time is 3-4 minutes. (Refer to MSDS for
Remove high metal as follows: classification of etchant being used.) Keep the
etching solution within defined boundaries of the
(1) Use a fine abrasive stone, a small file, emery area to be etched. Masking may be required to
cloth, or crocus cloth to remove high metal. contain etchant to areas for etching.
(2) Remove only the material that is projecting NOTE
above the original surface contour
(figure 11-14). Keep fresh solution in contact with the metal surface at
all times by dipping the swab into the working solution
(3) Swab etch reworked area per periodically. Rub the swab continuously over the
paragraph 11-3.23 and spot-fluorescent- surface of the metal being etched, to prevent the
penetrant inspect per paragraph 11-3.24. formation of an inert sludge.
d. After etching, blot up etching solution from the

11-3.23 Swab Etching Procedure
metal surface with a clean paper towel or cloth.
This procedure describes the materials and process for
e. Gently wipe the etched area at least three times
swab etching used as a preliminary step before
with a cloth or paper towel saturated with clean
fluorescent-penetrant inspection. Etching solutions are
water. Blot dry with clean cloth or paper towel.
used as described herein or with exceptions as
specified for individual parts in the Shop Manual. CAUTION
WARNING DO NOT POUR WORKING SOLUTION BACK
INTO STOCK CONTAINER. ALTHOUGH THE
ETCHING SOLUTION CONTAINS ACID AND IS
SMALL QUANTITIES INVOLVED DO NOT
HIGHLY TOXIC TO SKIN, EYES, AND
ORDINARILY CONSTITUTE AN
RESPIRATORY TRACT. SKIN AND EYE
ENVIRONMENTAL HAZARD, FLUSH AWAY
PROTECTION, AND VAPOR CONTROL ARE
DISCARDED SOLUTIONS WITH SEVERAL
REQUIRED. AVOID ALL CONTACT.
VOLUMES OF WATER TO ENSURE ADEQUATE
CAUTION DILUTION.
REFER TO THE MATERIAL SAFETY DATA f. Discard used working solution, rinse, and dry
SHEETS (MSDS) FOR STORAGE AND plastic container for future use.
HANDLING INSTRUCTIONS FOR ETCHANT
SOLUTION. ETCHANT SOLUTIONS CAN
BECOME HAZARDOUS TO PERSONNEL IF NOT
HANDLED APPROPRIATELY.

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Figure 11-14. Blending and High Metal Removal
11-3.24 Spot-Fluorescent-Penetrant 11-3.24.1 Spot-Fluorescent-Penetrant

Inspection Inspection Equipment/Materials
The spot-fluorescent-penetrant inspection process is a. Equipment required:

intended for inspections at remote locations. It is a
localized process, limited to small specific areas for (1) Inspection booth, darkroom, or black cloth
inspection. It is not intended as a substitute for normal hood (for remote locations) to prevent
inspection. It is convenient to use for inspection of excessive admission of white light.
welded or other localized repair areas.
(2) Compressed air supply for drying parts. Air
Personnel performing this inspection must be certified supply must have filters to remove oil and
in accordance with MIL-STD-410, American Society moisture which can contaminate parts or
of Non-Destructive Testing (ASNT-TC-IA), Air inspection materials.
Transport Association Specification No. 105 (ATA
105), or locally approved certification program. (3) Ultraviolet lamp to detect fluorescent
indications. The ultraviolet (black) light
Any training which may be provided by GE for a source used for the detection of fluorescent
technique requiring the performance of this inspection indications shall have an intensity no less
method does not imply that the personnel who receive than 1,000 microwatts per sq. centimeter
that training have met the requirements for inspector when measured at 15 inches (381 mm). The
certification in accordance with MIL-STD-410, ASNT- black light should be checked on a weekly
TC-IA, or ATA 105. basis or before use, whichever is less
frequent.

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(4) White light lamp for visual inspection of NOTE

parts. • If visible color dye penetrant has been used on
parts which are to be subsequently inspected with
(5) Time piece for timing operations.
fluorescent penetrants, the contamination by the
(6) Tools for inspection personnel: dye may prevent reliable fluorescent penetrant
inspection. Any color dye indications evident by
(a) Three power and 10 power magnifying white light visual inspection shall be considered
lenses valid indications even if not detectable by
ultraviolet light.
(b) Cotton swabs or small fine hair art brush
to apply solvents for evaluating • Excessive white light may interfere with detection
questionable indications of a rejectable size indication. A test part having a
known defect can be used to evaluate effectiveness
b. Materials required: of white light shielding.
NOTE a. Parts must be cleaned of all traces of oil, grease,

Qualified Products listed in MIL-I-25135 QPL carbon, and rust scale prior to penetrant
(Qualified Products List) as Level 3, Method D, are application.
considered acceptable alternates to the products listed.
b. Apply penetrant oil with soft-bristle brush, cotton
(1) Post-Emulsification Fluorescent-Penetrant swab, or spray application. Allow a minimum of
Oils: ZL22A, B, or C, ZL27 or ZL27A 30 minutes for penetration.
(Magnaflux Corporation)
WARNING
(2) Hydrophilic Removers: ZR10A or ZR10B ACETONE, O-A-51: EXPLOSIVE. FLAMMABLE.
(Magnaflux Corporation) AVOID SOURCES OF IGNITION, SPARKS, OR
FLAMES. DO NOT INHALE, INGEST, OR LET
(3) Dry Powders: ZP4A or ZP4B (Magnaflux THIS MATERIAL TOUCH YOU. ASPHYXIANT.
Corporation) CENTRAL NERVOUS SYSTEM
DAMAGE/ADVERSE EFFECTS. LIVER AND
(4) Non-Aqueous Wet Developers (NAWD): KIDNEY DAMAGE. ALLERGEN. IRRITANT.
ZP9B, C, E, F, or D499C (Magnaflux PERSONAL PROTECTIVE EQUIPMENT
Corporation) REQUIRED. DO NOT USE IN AN ENCLOSED
SPACE. USE IN A WELL-VENTILATED AREA OR
(5) Halogen-free solvents: Isopropyl Alcohol
WITH LOCAL MECHANICAL EXHAUST
(TT-I-735) or Acetone (O-A-51)
VENTILATION - IF NOT AVAILABLE, USE AN
APPROVED RESPIRATOR.
11-3.24.2 Spot-Fluorescent-Penetrant
Inspection Procedure WARNING
This procedure is to be used wherever the shop manual ALCOHOL IS FLAMMABLE AND TOXIC TO
calls out specific classes using either waterwashable or SKIN, EYES, AND RESPIRATORY TRACT. SKIN
post-emulsifiable penetrant systems. AND EYE PROTECTION IS REQUIRED. AVOID
REPEATED OR PROLONGED CONTACT. USE IN
A WELL-VENTILATED AREA.

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CAUTION f. Remove all residues by spraying, wiping, or

TITANIUM ALLOY PARTS ARE SUBJECT TO soaking with approved solvents.
STRESS CORROSION CRACKING WHEN
RESIDUES OF HALOGEN CONTAINING 11-3.25 Miscellaneous Procedures
COMPOUNDS REMAIN ON A PART THAT IS
SUBSEQUENTLY SUBJECTED TO ELEVATED CAUTION
TEMPERATURES TYPICAL OF WELDING, HEAT USE OF MOTOR-DRIVEN HYDRAULIC PUMPS
TREATING, OR ENGINE OPERATION. THESE TO OPERATE HYDRAULICALLY ACTUATED
PARTS MUST BE THOROUGHLY CLEANED SPECIAL SUPPORT EQUIPMENT OTHER THAN
WITH NONHALOGEN COMPOUNDS AFTER TORQUE MULTIPLIERS IS NOT
EXPOSURE TO ANY HALOGEN CONTAINING RECOMMENDED. EQUIPMENT DAMAGE CAN
COMPOUND TO PREVENT THE CRACKING AND RESULT FROM IMPROPER POWER
POSSIBLE FAILURE OF PARTS. APPLICATION.
NOTE a. Use hand-operated hydraulic pumps to operate

Indications of defects can be lost by use of excessive hydraulically actuated special support equipment
solvent. such as pushers or pullers, unless otherwise
specified.
c. Wipe off excess penetrant with a clean cloth using
a solvent. b. Exercise extreme care during assembly or
disassembly operations to prevent entrance of
(1) Alternate. Remove excess penetrant with a pieces of safety wire, nuts, washers, or any other
hydrophilic remover, provided it belongs to objects into the engine or assembly. If anything is
the same family as the penetrant used. Do not dropped into the engine during assembly or
exceed 90 seconds contact time. If remover is disassembly, stop and remove the object before
applied manually, do not scrub the surface of proceeding.
the part with the applicator. Use applicator
only to deliver fluid to the part surface. c. Do not store tools or maintenance equipment on or
against the engine. Account for and properly store
WARNING all tools after use.
NONAQUEOUS DEVELOPER IS MIXED IN A d. Clean fittings of contamination before making or
SOLVENT BASE CONTAINING ACETONE OR breaking connections.
ISOPROPYL ALCOHOL. SOLVENTS ARE
FLAMMABLE AND TOXIC TO SKIN, EYES, AND WARNING
RESPIRATORY TRACT. SKIN, EYE, AND
DO NOT USE EXTERNAL ENGINE PIPING AS A
RESPIRATORY PROTECTION IS REQUIRED.
LADDER OR HAND-HOLD WHILE PERFORMING
AVOID REPEATED OR PROLONGED CONTACT.
MAINTENANCE. SERIOUS DAMAGE OR
AVOID BREATHING VAPORS AND USE IN A
PERSONAL INJURY COULD RESULT. USE ONLY
WELL-VENTILATED AREA.
AUTHORIZED WORK STANDS AND
d. Apply either dry powder or NAWD as a fine thin PLATFORMS.
coating at ambient temperature to a dry surface.
e. Handle all parts carefully. Lift heavy parts with
Allow a minimum of 10 minutes for developer to
proper lifting fixtures and a hoist to prevent
absorb penetrant before inspecting part.
damage to parts and physical harm to personnel.
e. Evaluate any indication to the required inspection
standards.

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f. Always use fiber or plastic blocks and hammers WARNING

with plastic, rawhide, or nylon heads for driving LUBRICATING OIL, MIL-PRF-23699F (C/I):
operations. COMBUSTIBLE. DO NOT INHALE, INGEST, OR
LET THIS MATERIAL TOUCH YOU. IRRITANT.
g. Tie related parts together when they are removed.
PERSONAL PROTECTIVE EQUIPMENT
Tag or mark parts for identification.
REQUIRED. USE MECHANICAL EXHAUST
h. Coat parts, that are to be stored for any length of VENTILATION - IF NOT AVAILABLE, USE AN
time, with an appropriate preservative. APPROVED RESPIRATOR.
i. When installing or removing body-bound bolts, CAUTION

tap them straight through the holes. Do not turn ENGINE LUBRICATING OIL MAY SOFTEN
them. PAINT OR STAIN CLOTHING. CLEAN SPILLED
OIL FROM PAINTED SURFACES.
j. Verify identification of all mating parts.
q. Accessories, tubes, and hoses may have oil or fuel
k. Observe tagged parts for proper location. in them at time of removal. Drain these fluids
from accessory being removed and cap all
l. During assembly, align matchmarks on all parts connecting hoses or tubes.
that were marked during disassembly.
r. Lubricate all gears and splines with engine lube
m. Keep all protectors, plugs, and caps installed until oil before installing them, unless otherwise
removal is required. specified.
n. Prior to final assembly, inspect all cavities and s. Prior to the installation of any part, a visual check
openings for foreign material. should be made and any obvious signs of handling
damage or abnormal wear should be noted and
o. Inspect all mating flanges for foreign material
reported so that corrective action can be taken.
prior to final assembly. Remove any high metal
with a fine stone. t. Always read the complete operation and be sure
you understand it fully. It is better to stop and ask
CAUTION
than to continue and cause unnecessary work
DO NOT MIX PLATED HARDWARE WITH and/or damage.
UNPLATED HARDWARE. DO NOT USE SILVER
OR CADMIUM-PLATED TOOLS OR HARDWARE u. Do not disassemble any component any further
ON TITANIUM PARTS. PLATING CONTAINS than necessary to perform the required
SMALL QUANTITIES OF CHLORINE SALTS maintenance, even though complete disassembly
THAT ARE HARMFUL TO TITANIUM. instructions may be given. Remove piping and
electrical leads only as required to perform
p. Three types of tools (common, improvised, and maintenance tasks.
special) are used to perform maintenance.
Common tools are identified only when used in v. Attaching hardware (bolts, nuts, plain washers,
special applications. Drawings for improvised brackets, clamps, etc.) is generally reusable. When
tools are incorporated in the text when such tools possible, it is recommended that attaching
are required. Special tools are identified both by hardware be left in place or temporarily reinstalled
name and part number when they are required. until the replacement component is installed.

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w. Parts or assemblies designated as matched sets removal of the cap is essential to continuing with
elsewhere in this manual or by the parts list shall the installation.
be maintained as a matched set throughout the
maintenance cycle. Set numbers, part numbers, d. Use care during the installation of ducts and tubes
and serial numbers shall be protected during to ensure mating and alignment of flanges. A
cleaning or repair to prevent removal. When poorly fitted joint requires excessive torque on the
identification is removed, or is no longer legible, T-bolt to close the joint and imposes structural
the item shall be re-marked per the original loads on the V-band clamp. Adjacent support
marking method and location for the part. clamps or brackets should remain loose until
installation of the coupling has been completed.
x. When discrepancies are found during When connections are by V-band couplings, the
maintenance, refer to inspection tables for limits weight of the components should be fully
and corrective action. supported during the fit-up and installation of the
couplings.
Petrolatum, Fed Specification VV-P-236, shall be used
as an assembly aid for tight-fitting parts, bearings, and e. When reinstalling a used coupling, check it for
packing, unless otherwise specified. twist or distortion. Visually check the V-section
for spreading at the open ends or other signs of
NOTE distortion. Check spot welds or rivets for
Mobile Assembly Fluid 403C may be used in place of condition and security. The corner radii should be
soft petrolatum. carefully checked for tool marks and cracks. V-
band couplings in poor condition should be
11-3.26 V-Band (Coupling) Clamps replaced.
f. Check the threads on the T-bolt for wear and

11-3.26.1 Preinstallation Checks condition. If there is any sign of wear, galling, or
deformation, install a new T-bolt or coupling
a. Check alignment of tube ends, unrestrained, to the
clamp.
following maximum limits prior to installing V-
band clamps: g. Check the T-bolt for straightness; however, if it is
bent it will be necessary to determine if the bend is
(1) Parallelism: no angle (centerlines of tubes or
intentional. Some small diameter couplings have
fittings parallel).
curved T-bolts. Check the applicable illustrated
(2) Offset between fittings or tube centerlines: no parts breakdown for part identification. If in
more than 0.060 inch (1.52 mm) doubt, install a new T-bolt or coupling clamp.
circumferential, axial, or combined.
h. Check the trunnion and latch for freedom of
(3) Gaps: no more than 0.060 inch (0.15 mm) movement or other overloading.
space between fitting seats.
i. Avoid twisting, spreading, or bending of the
(4) If tube ends do not align within the above coupling when positioning the coupling on the
limits, readjust mounting until proper joint.
alignment is attained.
b. Ensure flange faces are free of dirt, grease,

corrosion, distortion, deformation, and scratches.
c. Use protective flange caps on the ends of all ducts

until the installation progresses to the point where

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j. When gaskets are used in the joint, exercise care CAUTION

in handling to avoid nicks and burrs on the gasket COUPLING T-BOLT NUTS SHALL NOT BE
surfaces. Whenever a joint is disassembled after REUSED. DO NOT SUBSTITUTE ANY OTHER
service operations, a new gasket should be used COUPLING NUT FOR THE TYPE NUT SUPPLIED
when reassembling to ensure maximum sealing WITH THE COUPLING. THE CORRECT NUT
efficiency. Exercise care to ensure that the gasket (ESNA Z1200J SERIES) IS IDENTIFIED BY THE
is properly seated. LETTER J STAMPED ON A WRENCH FLAT.
FAILURE TO COMPLY MAY RESULT IN DUCT
11-3.26.2 Installation JOINT FAILURE.
The following procedures should be followed to ensure a. Place the V-band clamp over one of tube ends far
proper V-band clamp installation: enough to clear flange.
CAUTION b. Install gasket, if required, and mate both flanges.
DO NOT USE PLIERS ON V-BAND CLAMPS TO
FORCE ALIGNMENT OF TUBE ENDS WHILE c. Relocate clamp over both flanges and press clamp
ENGAGING V-BAND BOLTS AND NUTS. closed.
RESIDUAL STRESS IN THE TUBES AND NICKS,
d. Install nut. Ensure T-bolt is properly seated, and
SCRATCHES, OR DEFORMATION IN THE
tighten nut to approximately one-half of required
CLAMPS, CAN CAUSE PREMATURE FAILURE
torque marked on strap.
OF THESE PARTS.
e. Tap clamp lightly around circumference with a
rubber mallet to equally distribute load.
f. Alternate tightening and tapping until torque

stabilizes at the specified value. Avoid
overtorquing.
g. Inspect clamp for even seating.
h. See figure 11-15 for safety wiring the V-band

clamp. Use 0.041-0.051-inch (NOVN) (1.0-1.3
mm) safety wire.

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Figure 11-15. Band Clamps and Safety-Wiring Techniques

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MID-TD-0000-0
January 2016
5
APPENDIX A
GE Aero Derivative Gas Turbine Requirements
This appendix contains specifications for the following:
Appendix A1 – MID-TD-0000-1 Gaseous Fuel Requirements for GE Aeroderivative

Gas Turbines
Appendix A2 – MID-TD-0000-2 Liquid Fuel Requirements for GE Aero Derivative

Gas Turbines
Appendix A3 – MID-TD-0000-3 Requirements for Water and Steam Purity for Injection
in Aero Derivative Gas Turbines
Appendix A4 – MID-TD-0000-4 Compressor Cleaning Water Purity Requirements for

GE Aircraft Derivative Gas Turbines
Appendix A5 – MID-TD-0000-5 Liquid Detergent for Compressor Cleaning for GE

Aircraft Derivative Gas Turbines
Appendix A6 – MID-TD-0000-6 Lubricating Oil Guidance for GE Aero Engines
$$%ODQN
*(3URSULHWDU\,QIRUPDWLRQ6XEMHFWWRWKHUHVWULFWLRQVRQWKHFRYHURUILUVWSDJH
Appendix A1
Gaseous Fuel Requirements for GE Aeroderivative Gas

Turbines
MID-TD-0000-1 Gaseous Fue/ Requirements for GE AeroDerivative Gas Turbines
Table 2a identifies the fuel composition limits for Aeroderivative gas turbines with Dry Low Emission (OLE)
combustion systems and Table 2b identifies the fuel composition limits for Aeroderivative gas turbines with
Standard (Single Annular Combustor (SAC) combustion systems.
Table 2a. Fuel Gas Composition Limits for DLE Configuration.

Parameter Reguirement- DLE Configuration
Minimum Maximum
Modified Wobbe lndex (1)
LM1600 36 60
LM2000/LM2500 25 68
LM2500+/+G4 25 63
LM6000PD/PF 36 60
LM6000PH/PF+ 40 60
LMSlOOPB/PB+ 44 60
Methane (CH4) 50% vol 100% vol
Ethane (C2+ paraffins) (3)

LM1600 - 35% vol
LM2500 / LM2000 - 70% vol
LM2500+ - 55% vol
LM2500+G4 - 48% vol
LM6000PD/PF - 24% vol
LM6000PH / LMSlOO - 15% vol
Hydrogen (H2) - 5% Vol (2)

Diolefins (i.e. Butadiene, - See Note 4
propadiene)
Other combustibles (5) - Consult GE
Notes: l. MWI at max limits C2+.
2. Other levels may be possible with fuel treatment and/or fuel system
modifications. Consult GE far guidance.
3. C2+ constituents greater than 20% by volume could affect anticipated

NOx levels. NOx emissions with higher C2+ levels could deviate from
"Standard" Guarantees.
4. None Allowed. The presence of even trace amounts of diolefins in the

gas fuel may cause fuel system fouling.
5. Other combustibles - CO, olefin hydrocarbons. etc.
2
Appendix A2
Appendix A3
MAJOR ASSEMBLIES
Appendix A4
Appendix A5
Appendix A6
GEK 119319
VOLUME II
ON-SITE OPERATION AND MAINTENANCE MANUAL

FOR
GENERAL ELECTRIC LM6000® PF+ SERIES
GAS TURBINES
GE INDUSTRIAL
AERODERIVATIVE GAS TURBINES

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WORK PACKAGE WP 1110 00
TECHNICAL PROCEDURES
AXIAL INLET CENTERBODY ASSEMBLY
REPLACEMENT - HOT END DRIVEN
(LEVEL 1 MAINTENANCE)
())(&7,9,7</03)*$6785%,1(02'(/6
LIST OF EFFECTIVE WP PAGES

Total Number of Pages in this WP is 4
Page No. Change No.
1 - 4 .......................................................................................................................................................... 0
Alphabetical Index
Subject Page
Axial Inlet Centerbody Assembly Installation. ........................................................................................ 3

Axial Inlet Centerbody Assembly Removal. ........................................................................................... 3
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1. Introduction.
This work package contains instructions for removal and installation of the axial inlet centerbody assembly.
Refer to kit, PN 682L204.
2. Reference Material.
Title Number
Illustrated Parts Breakdown GEK 119320
3. Support Equipment.
Nomenclature Part No.

Driver, No. 10 Torque-Set Local Purchase
4. Consumable Material.
Nomenclature Specification
Marking Pen Sharpie T.E.C. (Black or Blue)
5. Expendable Material.
None required.
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6. Axial Inlet Centerbody Assembly Removal.
NOTE
Forward and aft centerbody are matched parts and are kept together as an assembly.
A. Using marking pen, matchmark aft centerbody to forward centerbody (figure 1).
B. Using No. 10 Torque-Set driver, remove 13 screws that secure forward centerbody. Remove forward
centerbody.
C. Remove 46 nuts, 92 washers, and 46 bolts that secure aft centerbody to inlet frame or variable inlet guide
vane (VIGV) forward inner casing. Remove aft centerbody.
7. Axial Inlet Centerbody Assembly Installation.
NOTE
Forward and aft centerbody are matched parts and are kept together as an assembly.
A. Using 46 bolts, 92 washers, and 46 nuts install aft centerbody onto inlet frame or VIGV forward inner
casing. Boltheads face forward. Position one washer under bolthead, and one washer under nut. Tighten
bolts to 57-67 lb in. (6.5-7.5 N·m) of torque.
B. Align matchmarks and install forward centerbody onto aft centerbody. Secure with 13 screws. Using No.
10 Torq-Set driver, tighten screws to 32-38 lb in. (3.7-4.2 N·m) of torque.
C. Inspect centerbody for proper seating.
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Figure 1. Axial Inlet Centerbody Assembly
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LOW PRESSURE COMPRESSOR INLET TEMPERATURE/
PRESSURE (T2/P2) SENSOR REPLACEMENT
())(&7,9,7</03)*$6785%,1(02'(/6

Page No. Change No.
1 - 5 .......................................................................................................................................................... 0
6 Blank ..................................................................................................................................................... 0
Alphabetical Index
Subject Page
Low Pressure Compressor Inlet Temperature/Pressure (T2/P2) Sensor Installation. .............................. 3

Low Pressure Compressor Inlet Temperature/Pressure (T2/P2) Sensor Removal................................... 3
*(. /03)
:3
1. Introduction.
This work package contains instructions for removing and installing the low pressure compressor inlet
temperature/pressure (T2/P2) sensor.
Title Number

Wrench, Strap (1/2” drive, 90° angle, 1/2” strap) BT-BS-625, Daniels Mfg Corp.
(Optional)
Pliers, Teflon-Jawed Local Purchase
Petrolatum Fed Spec VV-P-236
Safety Cable 736L680G01
Safety Wire (0.032 in.) R297P04 (ALT)
Reference GEK 119320, Illustrated Parts Breakdown (IPB).
Nomenclature Part No. Qty

Packing, Preformed J221P903 1
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6. Low Pressure Compressor Inlet Temperature/Pressure (T2/P2) Sensor Removal.
A. If installed, disconnect pressure sensing tube from T2/P2 sensor pressure port (figure 1) per packager’s
manual.
NOTE
If same T2/P2 sensor will be reinstalled, proceed to step 6.C.
B. Remove plug or fitting from T2/P2 sensor pressure port. Discard preformed packing.
WARNING
ELECTRICAL POWER SHALL BE OFF BEFORE CONNECTING OR DISCONNECTING

ELECTRICAL CONNECTORS. ELECTRICITY CAUSES SHOCK, BURNS, AND DEATH.
CAUTION
ENSURE LOCATION OF ELECTRICAL CONNECTOR IS NOTED TO AID AT
INSTALLATION. FAILURE TO COMPLY MAY CAUSE UNRELIABLE ENGINE
OPERATION.
C. Tag and disconnect electrical connector from T2/P2 sensor integral lead.
D. Remove jamnut that secures T2/P2 sensor integral lead to electrical interface panel.
E. Remove integral lead from spring clips.
F. Remove bolts that secure T2/P2 sensor to variable inlet guide vane (VIGV) assembly case. Remove T2/P2
sensor.
7. Low Pressure Compressor Inlet Temperature/Pressure (T2/P2) Sensor Installation.
A. Install T2/P2 sensor onto inlet frame or VIGV assembly case. Using two bolts, secure T2/P2 sensor to inlet
frame or VIGV assembly case. Tighten bolts to 32-38 lb in. (3.7-4.2 N·m) of torque. Safety-wire bolts.
B. Using jamnut, secure T2/P2 sensor integral lead to electrical interface panel. Tighten jamnut to 25-35 lb in.
(2.9-3.9 N·m) of torque. Safety-wire jamnut.
*(. /03)
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Figure 1. Low Pressure Compressor Inlet Temperature/Pressure (T2/P2) Sensor
/03) *(.
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C. Connect electrical connector to T2/P2 sensor integral lead as follows:
WARNING

(1) Engage connector with mating interface and turn knurled coupling ring while wiggling backshell
assembly.
(2) After fully seating connector by hand, tighten connector with Teflon-jawed pliers until slippage
occurs. Tighten connector with strap wrench (optional method).
(3) Check for full seating by wiggling accessory assembly. There shall be no movement with respect to
mating connector.
NOTE
It may be necessary to loosen lead clamps that restrict mating.
(4) Repeat step 7.C.(2) and step 7.C.(3), as required. It may be necessary to loosen lead clamps that
restrict mating.
D. Install integral lead into spring clips.
NOTE
If plug or fitting is already installed, proceed to step 7.G.
E. Lubricate preformed packing with petrolatum and install onto plug or fitting.
F. Install plug or fitting into T2/P2 sensor pressure port. Tighten plug or fitting to 87-103 lb in.
(9.9-11.6 N·m) of torque. Safety-wire plug.
G. If present, connect pressure sensing tube to fitting in T2/P2 sensor pressure port per packager’s manual.
%ODQN
/03) *(.
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VARIABLE INLET GUIDE VANE (VIGV) ACTUATOR
REPLACEMENT
())(&7,9,7</03)*$6785%,1(02'(/6

Page No. Change No.
1 - 10 ........................................................................................................................................................ 0
Alphabetical Index
Subject Page
Variable Inlet Guide Vane Actuator Installation. ..................................................................................... 7

Variable Inlet Guide Vane Actuator Length Preset Adjustment Using Check Fixture, 1C9403.............. 6
Variable Inlet Guide Vane Actuator Removal. ......................................................................................... 3
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1. Introduction.
This work package contains instructions for removing and installing the variable inlet guide vane (VIGV)
actuators.
Title Number
Operation & Maintenance Manual GEK 119319
Variable Inlet Guide Vane (VIGV) System Check WP 1113 00

Hydraulic Actuator Unit 1C3569G3
Adapter Set, Pressure Test/Rig - VIGV, VBV, VSV 1C9393G01
Fixture, Check VSV/VIGV Actuator 1C9403G01
Nitrogen Cart (with hose and pressure regulator) Local Purchase
Pliers, Teflon-Jawed (Optional) Local Purchase
Lubricating Oil MIL-PRF-23699F (C/I)
Nitrogen BB-N-411
Soap Solution Local Purchase
Thread Lubricant GE Spec A50TF201

Packing, Preformed 9365M41P117 2
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6. Variable Inlet Guide Vane Actuator Removal.
WARNING

CAUTION
ENSURE THAT LOCATION OF ELECTRICAL CONNECTOR IS NOTED TO AID AT

OPERATION.
A. Tag and disconnect electrical connector from VIGV actuator.
NOTE
Ensure that lube oil supply is shut off before disconnecting tubing.
B. Disconnect tubing as follows (figure 1):
WARNING
LUBRICATING OIL, MIL-PRF-23699F (C/I): COMBUSTIBLE. DO NOT INHALE,

INGEST, OR LET THIS MATERIAL TOUCH YOU. IRRITANT. PERSONAL
PROTECTIVE EQUIPMENT REQUIRED. USE MECHANICAL EXHAUST
VENTILATION - IF NOT AVAILABLE, USE AN APPROVED RESPIRATOR.
(1) Position a waste fluid container beneath VIGV actuator. Disconnect drain line from drain adapter.
(2) Disconnect drain adapter from VIGV actuator. Slide drain adapter away from VIGV actuator port to
expose coupling nut.
CAUTION
ENSURE CONNECTING FITTING IS RESTRAINED WHEN LOOSENING
COUPLING NUT. FAILURE TO COMPLY MAY RESULT IN PART DAMAGE.
(3) Disconnect coupling nut from VIGV actuator fitting.
(4) Remove and discard preformed packing from drain adapter.
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Figure 1. Variable Inlet Guide Vane (VIGV) Tubing
CAUTION
DO NOT CHANGE ADJUSTMENT OF ACTUATOR ROD END. ANY MOVEMENT OR

ADJUSTMENT REQUIRES THAT VARIABLE INLET GUIDE VANE ACUTATOR LENGTH
PRESET ADJUSTMENT USING CHECK FIXTURE BE PERFORMED AND THAT VIGV
ACTUATION SYSTEM RIGGING BE CHECKED.
C. If actuator-to-ring bracket must be removed, reference WP 1113 00. Remove actuator-to-ring brackets.
D. Remove nut, bolt, and bushings that secure VIGV actuator rod end (figure 2).
E. Remove nut and bolt that secure VIGV actuator to bearing block. Remove VIGV actuator.
F. Remove fittings from VIGV actuator. Remove and discard preformed packings.
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Figure 2. Variable Inlet Guide Vane (VIGV) Actuator
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*(. /03)
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7. Variable Inlet Guide Vane Actuator Length Preset Adjustment Using Check Fixture, 1C9403.
WARNING
SERIOUS INJURY CAN OCCUR WHEN APPLYING HYDRAULIC PRESSURE. EYE

PROTECTION IS REQUIRED. RELIEVE PRESSURE BEFORE DISCONNECTING LINES AND
FITTINGS.
CAUTION
MAINTAIN 250 PSI (1724 KPA) ON ACTUATOR, AT THE FULLY EXTENDED POSITION,
WHEN ADJUSTING ROD END, OR PRESET ADJUSTMENT WILL BE INCORRECT.
CAUTION
USE HYDRAULIC ACTUATOR UNIT, 1C3569, WITH ENGINES THAT USE

LUBRICATING OIL, MIL-PRF-23699F (C/I). DO NOT INTERMIX LUBRICATING OILS
MIL-PRF-7808 AND MIL-PRF-23699F (C/I) OR DAMAGE WILL OCCUR.
NOTE
This procedure is to be performed before installing a new actuator or in the event actuator rod-end
adjustment is disturbed during removal/installation.
A. Connect hydraulic actuator unit, 1C3569, to actuator. Supply 250 psi (1724 kPa) to extend actuator to fully
extended position. Maintain pressure throughout adjustment procedure.
B. Loosen jamnut that secures actuator rod end.
C. Adjust rod end so that actuator slides freely onto check fixture, 1C9403 (figure 3).
D. Tighten jamnut to secure rod end. Safety-wire jamnut.
E. Release pressure and remove hydraulic actuator unit, 1C3569.
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Figure 3. Actuator Length Preset Using Check Fixture, 1C9403
8. Variable Inlet Guide Vane Actuator Installation.
WARNING
LUBRICATING OIL, MIL-PRF-23699F (C/I): COMBUSTIBLE. DO NOT INHALE, INGEST, OR

LET THIS MATERIAL TOUCH YOU. IRRITANT. PERSONAL PROTECTIVE EQUIPMENT
REQUIRED. USE MECHANICAL EXHAUST VENTILATION - IF NOT AVAILABLE, USE AN
NOTE
If installing a new actuator, or in the event actuator rod-end adjustment is disturbed during removal/
installation, perform paragraph 7 of this work package.
A. Lubricate preformed packings, PN J221P904 and PN 9365M41P122 (figure 1), with lubricating oil and
install into groove of fitting.
B. Install fitting into VIGV actuator. Tighten fitting to 133-157 lb in. (15.1-17.7 N·m) of torque.
C. Apply thread lubricant to threads of actuator bearing block bolt and secure VIGV actuator onto actuator
bearing block with nut and bolt (figure 2, view B). Bolthead faces aft. Tighten nut to 350-410 lb in.
(39.6-46.3 N·m) of torque.
D. Install actuator-to-ring brackets per WP 1113 00.
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E. Apply thread lubricant to threads of VIGV actuator rod-end bolt (figure 2, detail A). Using bolt (bolthead
outboard) and nut, secure actuator-to-ring brackets onto VIGV actuator rod end. Tighten nut to
350-410 lb in. (39.6-46.3 N·m) of torque.
WARNING

F. Lubricate preformed packing, PN 9365M41P117 (figure 1), with lubricating oil and install into drain
adapter.
CAUTION
ENSURE CONNECTING FITTING IS RESTRAINED WHEN TIGHTENING COUPLING
NUT. FAILURE TO COMPLY MAY RESULT IN PART DAMAGE.
G. Connect tubing coupling nut onto VIGV actuator fitting. Tighten coupling nut to 262-308 lb in.
(29.7-34.7 N·m) of torque.
H. Leak-check head- and rod-end fittings as follows:
CAUTION

LUBRICATING OIL, MIL-PRF-23699F (C/I). DO NOT INTERMIX LUBRICATING
OILS MIL-PRF-7808 AND MIL-PRF-23699F (C/I) OR DAMAGE WILL OCCUR.
(1) Install reducers from pressure test/rig adapter set, 1C9393, onto hydraulic actuator unit, 1C3569.
Tighten reducers to 133-157 lb in. (15.1-17.7 N·m) of torque.
(2) Position waste fluid container under hydraulic control unit (HCU).
(3) Disconnect head tube from HCU. Install head tube on -4 to -10 reducer. Tighten coupling nut to
55-65 lb ft (75-88 N·m) of torque.
(4) Disconnect rod tube from HCU. Install rod tube on -4 to -8 reducer. Tighten coupling nut to
460-540 lb in. (52.0-61.0 N·m) of torque.
WARNING
SERIOUS INJURY CAN OCCUR WHEN APPLYING HYDRAULIC PRESSURE.

EYE PROTECTION IS REQUIRED. RELIEVE PRESSURE BEFORE
DISCONNECTING LINES AND FITTINGS.
(5) Apply 200-250 psi (1379-1724 kPa) to head tube and hold for a minimum of 2 minutes. Check head
tube/actuator connection for leakage.
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WARNING

(6) Apply 200-250 psi (1379-1724 kPa) to rod tube and hold for a minimum of 2 minutes. Check rod
(7) If required, check VIGV actuation system per WP 1113 00.
(8) Disconnect hydraulic actuator unit. Remove reducers.
(9) Connect head tube onto HCU. Tighten coupling nut to 55-65 lb ft (75-88 N·m) of torque.
(10) Connect rod tube onto HCU. Tighten coupling nut to 460-540 lb in. (52.0-61.0 N·m) of torque.
I. Slide drain adapter over coupling nut and connect onto VIGV actuator port. Hand-tighten drain adapter.
J. Leak-check drain adapters as follows:
(1) Connect source of clean, dry, regulated shop air or nitrogen onto drain line fitting on drain adapter.
WARNING
SERIOUS INJURY CAN OCCUR WHEN APPLYING PNEUMATIC PRESSURE. EYE

PROTECTION IS REQUIRED. RELIEVE PRESSURE BEFORE DISCONNECTING
LINES AND FITTINGS.
WARNING
NITROGEN, BB-N-411, CAN DISPLACE OXYGEN IN ENCLOSED AREAS. USE IN

(2) Apply 50-55 psi (345-379 kPa) to drain adapter. Shut off pressure and monitor. Pressure shall not
drop off more than 10 psi (69 kPa) in 2 minutes.
(3) If pressure drop limit is exceeded, use soap solution to detect leak. Repair, as required, and repeat
leak check.
(4) Disconnect test equipment from drain adapter.
(5) Connect drain line to drain adapter. Tighten coupling nut to 262-308 lb in. (29.7-34.7 N·m) of
torque.
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K. Connect electrical connector to VIGV actuator as follows:
WARNING
ELECTRICAL POWER SHALL BE OFF BEFORE CONNECTING OR

DISCONNECTING ELECTRICAL CONNECTORS. ELECTRICITY CAUSES
SHOCK, BURNS, AND DEATH.
(1) Engage connector with mating interface and turn knurled coupling ring while wiggling back shell
assembly.
(2) After fully seating connector by hand, tighten coupling ring to 70-75 lb in. (8.0-8.4 N·m) of torque
using strap wrench (preferred method). If strap wrench is not available, tighten connector with
Teflon-jawed pliers until slippage occurs.
mating connector.
NOTE
(4) Repeat step 8.K.(2) and step 8.K.(3), as required. It may be necessary to loosen lead clamps that
restrict mating.

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VARIABLE INLET GUIDE VANE (VIGV) SYSTEM
CHECK
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Subject Page
Variable Inlet Guide Vane System Check. ............................................................................................... 3
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1. Introduction.
This work package contains instructions for checking the variable inlet guide vane (VIGV) system. Before
performing this work package, ensure the following conditions exist:
• VIGV flaps are installed.
• Lever arms are installed in actuating rings.
• VIGV actuating ring is installed.
• VIGV actuators are installed and connected.
Title Number
Variable Inlet Guide Vane (VIGV) Actuator Replacement WP 1112 00

Rigging Set, VIGV 1C9359G02

Shim, Actuator Ring L45101P01-P08 AR
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6. Variable Inlet Guide Vane System Check.
CAUTION

LUBRICATING OIL, MIL-PRF-23699F (C/I). DO NOT INTERMIX LUBRICATING OIL,
MIL-PRF-7808 AND MIL-PRF-23699F (C/I), OR DAMAGE WILL OCCUR.
A. Connect hydraulic actuator unit, 1C3569, as follows (figure 1 and figure 2):
(1) Install reducers from adapter set, 1C9393, onto hydraulic actuator unit, 1C3569 (figure 1). Tighten
to 133-157 lb in. (15.1-17.7 N·m) of torque.
(2) Position waste fluid container under hydraulic control unit (HCU) (figure 2).
Figure 1. Hydraulic Actuator Unit, 1C3569
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Figure 2. HCU Tube Locations
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WARNING

CAUTION
ENSURE CONNECTING FITTING IS RESTRAINED WHEN TIGHTENING
(3) Disconnect head tube from HCU. Install head tube onto -4 to -10 reducer. Tighten coupling nut to
(4) Disconnect rod tube from HCU. Install rod tube onto -4 to -8 reducer. Tighten coupling nut to
460-540 lb in. (52.0-61.0 N·m) of torque.
B. Check VIGV system as follows:
WARNING
WHEN ACTUATING VIGV SYSTEM, KEEP HANDS CLEAR OF MOVING PARTS,
OR SERIOUS INJURY MAY RESULT.
WARNING

(1) Apply 200-250 psi (1379-1724 kPa) system pressure to actuate VIGV system to full open and full
closed positions several times. System shall operate smoothly throughout entire range of travel in
both directions.
(2) Check all fittings for leaks through VIGV system to full travel. Correct as required.
NOTE
VIGV position indication is read at indicator on control panel. Control panel shall be
powered up to read VIGV position indication.
(3) Apply 200-250 psi (1379-1724 kPa) system pressure to actuate VIGV system to full open position.
VIGV position indicator shall read 100 ± 1 percent (full open).
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CAUTION
VIGV ACTUATING RING MOUNT BOLTS ARE ANODIZED. DO NOT DISTURB

MOUNT BOLTS, OR COATING DAMAGE MAY OCCUR.
(4) Insert actuator locating pin, 1C9359P03, through rig fixture -10 degree hole. Locating pin shall slide
freely (figure 3). If difficulty is encountered, loosen both actuator-to-ring brackets at actuator rod
ends as follows:
(a) Release hydraulic pressure from system.
(b) Loosen nuts that secure both VIGV actuator rod ends to actuation-to-ring brackets (figure 4,
detail A).
(c) Insert actuator locating pin, 1C9359P03 (figure 3), so that pin slides freely into rig fixture
-10 degree hole.
(5) Remove bolts and nuts that secure actuator rod ends to actuator-to-ring brackets (figure 4).
(6) Apply hydraulic pressure so both actuator rod ends are fully extended.
(7) Position actuator-to-ring brackets onto actuation ring so holes align with actuator rod ends. If
required, loosen nuts that secure actuator-to-ring brackets to actuation ring.
(8) Apply thread lubricant to threads of actuator rod-end bolts. Using bolts and nuts, secure actuator
rod-ends onto actuator-to-ring brackets. Boltheads are outboard. Tighten nuts to 350-410 lb in.
(39.6-46.3 N·m) of torque.
(9) Tighten nuts that attach actuator-to-ring brackets onto actuation ring to 368-432 lb in.
(41.6-48.8 N·m) of torque.
(10) Remove actuator locating pin, 1C9359P03 (figure 3).
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Figure 3. Actuator Locating Pin, 1C9359P03, Installation
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Figure 4. VIGV Actuators and Mount Brackets Removal/Installation
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CAUTION

C. Disconnect hydraulic actuator unit, 1C3569. Remove reducers (figure 1).
D. Connect head tube onto HCU. Tighten coupling nut to 55-65 lb ft (75-88 N·m) of torque (figure 2).
E. Connect rod tube onto HCU. Tighten coupling nut to 460-540 lb in. (52.0-61.0 N·m) of torque.
F. If gas turbine still has VIGV difference alarm, perform shim adjustments as follows:
(1) Remove VIGV actuators per WP 1112 00. Check and reset rod-end per WP 1112 00. Reinstall
actuators.
(2) Locate actuation ring support blocks bolted to outer VIGV case. Measure clearance between blocks
and actuation ring inside diameter, 14 places on L45027G03, and eight places on L45027G04 and
later configurations.
(3) Plot and review clearances at support blocks 180 degrees opposite each other. Example:
12:00 o’clock position equals 0.000 inch (0.00 mm) clearance, 6:00 o’clock position equals
0.040 inch (1.02 mm) clearance. Obtain shims L45101P01 through P08. Remove two bolts
attaching support block to VIGV case at 12:00 o’clock position. Install shim to correct clearance at
6:00 o’clock position to 0.020 inch (0.51 mm). Install bolts and tighten to 32-38 lb in. (3.7-4.2 N·m)
of torque.
NOTE
Not all support block locations will have a corresponding block at 180 degrees opposite. If
no block is 180 degrees opposite and clearance is greater than 0.020 inch (0.51 mm), add
shims to reduce clearance to 0.020 inch (0.51 mm).
(4) Proceed in clockwise direction to next support block and repeat step 6.F.(3) to adjust clearances
opposite locations to be as equal as shim thicknesses will allow.
(5) After shim corrections are complete, perform rig check per this work package.
%ODQN
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FORWARD SEAL COVER PLATE REPLACEMENT
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Subject Page
Forward Seal Cover Plate Installation...................................................................................................... 3

Forward Seal Cover Plate Removal. ........................................................................................................ 3
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1. Introduction.
This work package contains instructions for removing and installing the forward seal cover plate.
None required.
None required.
None required.
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6. Forward Seal Cover Plate Removal.

Remove two bolts (figure 1) and forward seal cover plate from inlet frame at 6:00 o’clock position.
7. Forward Seal Cover Plate Installation.
A. Position variable inlet guide vane (VIGV) or inlet frame inner case so that forward seal opening is at
6:00 o’clock position.
B. Using thread lubricant, coat washer faces and threads of two bolts.
C. Position cover plate over opening in VIGV or inlet frame inner case at 6:00 o’clock position.
D. Install two bolts. Tighten bolts to 57-67 lb in. (6.5-7.5 N·m) of torque.
Figure 1. Forward Seal Cover Plate Replacement
%ODQN
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HIGH PRESSURE COMPRESSOR INLET TEMPERATURE/
PRESSURE (T25/P25) SENSOR REPLACEMENT
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High Pressure Compressor Inlet Temperature/Pressure (T25/P25) Sensor Installation. ......................... 3

High Pressure Compressor Inlet Temperature/Pressure (T25/P25) Sensor Removal. ............................. 3
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1. Introduction.
This work package contains instructions for removing and installing the high pressure compressor inlet
temperature/pressure (T25/P25) sensor.
Title Number

(Optional)

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6. High Pressure Compressor Inlet Temperature/Pressure (T25/P25) Sensor Removal.
A. If installed, disconnect pressure sensing tube from T25/P25 sensor pressure port per packager’s manual
(figure 1).
NOTE
If same T25/P25 sensor will be reinstalled, proceed to step 6.C.
B. Remove plug or fitting and preformed packing from T25/P25 sensor pressure port. Discard preformed
packing.
WARNING

CAUTION

OPERATION.
C. Tag and disconnect off engine cable from integral lead.
D. Remove jamnut that secures integral lead to electrical interface panel.
E. Remove integral lead from spring clips.
F. Remove two bolts that secure T25/P25 sensor to compressor front frame. Remove T25/P25 sensor.
7. High Pressure Compressor Inlet Temperature/Pressure (T25/P25) Sensor Installation.
A. Install T25/P25 sensor onto compressor front frame. Using two bolts, secure T25/P25 sensor to compressor
front frame. Tighten bolts to 32-38 lb in. (3.7-4.2 N·m) of torque. Safety-wire bolts.
B. Using jamnut, secure integral lead to electrical interface panel. Tighten jamnut to 25-35 lb in.
(2.9-3.9 N·m) of torque. Safety-wire jamnut.
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Figure 1. High Pressure Compressor Inlet Temperature/Pressure (T25/P25) Sensor
C. Connect off engine cable to integral lead as follows:
WARNING

assembly.
mating connector.
NOTE
restrict mating.
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D. Install integral lead in spring clips.
NOTE
If plug or fitting is already installed, proceed to step 7.G.
E. Lubricate preformed packing with petrolatum, and install onto plug or fitting.
F. Install plug or fitting into T25/P25 sensor pressure port. Tighten plug or fitting to 87-103 lb in.
(9.9-11.6 N·m) of torque. Safety-wire plug.
G. If present, connect pressure sensing tube to fitting in T25/P25 sensor pressure port per packager’s manual.
%ODQN
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VARIABLE BYPASS VALVE (VBV) ACTUATOR
REPLACEMENT
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Alphabetical Index
Subject Page
Variable Bypass Valve Actuator Installation............................................................................................ 5

Variable Bypass Valve Actuator Removal. .............................................................................................. 3
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1. Introduction.
This work package contains instructions for removing and installing the six variable bypass valve (VBV)
actuators.
Title Number
Variable Bypass Valve (VBV) System Check WP 1312 00
Front Frame Air Collector Replacement WP 2310 00

Allen Wrench, 1/8-inch Local Purchase
Nitrogen Cart with hose and regulator (Optional) Local Purchase
Molybdenum Disulfide Lubricant GE Spec A50TF79
Nitrogen (optional) BB-N-411

Gasket, Seal (Rod-End) J219P03 1
Gasket, Seal (Head-End) J219P04 1
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6. Variable Bypass Valve Actuator Removal.
A. Remove access panels from air collector, as required, to gain access per WP 2310 00.
WARNING

CAUTION

OPERATION.
NOTE
There are six actuators; two with electrical connectors, four without. The two actuators with electrical
connectors are located at the 1:00 o’clock and 7:00 o’clock positions.
B. Tag and disconnect electrical connector from VBV actuator.
C. Disconnect tubing from VBV actuator as follows (figure 1):
WARNING

(1) Position a waste fluid container beneath VBV actuator. Disconnect drain line from drain adapter.
(2) Disconnect drain adapter from VBV actuator. Slide drain adapter away from VBV actuator port to
CAUTION

(3) Disconnect coupling nut from VBV actuator fitting.
(4) Remove and discard preformed packings.
D. If required, remove air collector seal from VBV actuator per WP 2310 00.
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Figure 1. VBV Actuator Tubing
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CAUTION
DO NOT CHANGE ADJUSTMENT OF CLEVIS OR ACTUATOR ROD END. ANY

MOVEMENT OR ADJUSTMENT OF CLEVIS OR ACTUATOR ROD END LENGTH
REQUIRES THAT VBV ACTUATION SYSTEM RIGGING BE CHECKED.
E. Remove nut, washer, and bolt that secure clevis to bellcrank (figure 2).
F. Remove bolt and washer that secure VBV actuator mount leg to front frame.
G. Remove nuts and washers that secure VBV actuator mount studs to front frame. Remove VBV actuator.
H. Remove nut and bolt that secure clevis to VBV actuator rod end. Remove clevis.
I. Remove fitting from VBV actuator (figure 1). Remove and discard preformed packing.
7. Variable Bypass Valve Actuator Installation.
WARNING

A. Lubricate preformed packings, PN J221P904 and PN 9365M41P122, with lubricating oil and install into
packing groove of fitting (figure 1).
B. Install fitting into VBV actuator. Tighten fitting to 133-157 lb in. (15.1-17.7 N·m) of torque.
WARNING
SOLID FILM LUBRICANT IS TOXIC TO SKIN, EYES, AND RESPIRATORY
TRACT. SKIN, EYE, AND RESPIRATORY PROTECTION IS REQUIRED.
C. Apply molybdenum disulfide lubricant onto threads of all bolts and mount studs (figure 2).
D. Using bolt and nut, install clevis onto VBV actuator rod end. Tighten nut to 106-124 lb in. (12.0-14.0 N·m)
of torque.
E. Install VBV actuator onto front frame. Position VBV actuator so that clevis retaining bolt bolthead faces
inboard.
F. Using washers and nuts, secure VBV actuator onto front frame. Tighten nuts to 57-67 lb in. (6.5-7.5 N·m)
of torque.
G. Using bolt and washer, secure VBV actuator mount leg onto front frame. Tighten bolt to 57-67 lb in.
(6.5-7.5 N·m) of torque.
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Figure 2. VBV Actuator
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H. Using bolt, washer, and nut, secure clevis onto bellcrank. Bolthead faces inboard, washer under nut
Tighten nut to 100-130 lb in. (11.3-14.6 N·m) of torque. Restrain bolt during tightening procedure using
1/8-inch Allen wrench.
I. If required, install air collector seal as follows:
WARNING

(1) Apply molybdenum disulfide lubricant onto threads of air collector seal retaining screws.
(2) Install air collector seal and secure with screws.
(3) Tighten screws to 57-67 lb in. (6.5-7.5 N·m) of torque.
WARNING

J. Lubricate preformed packing, PN 9365M41P117, with lubricating oil and install into drain adapter
(figure 1).
CAUTION

K. Connect tubing coupling nut onto VBV actuator fittings. Tighten coupling nut to 262-308 lb in.
(29.7-34.7 N·m) of torque.
L. Leak-check head- and rod-end fittings as follows (figure 3):
(1) Remove bolts and washers that secure VBV head hose (head-end) to hydraulic control unit (HCU).
Remove seal gasket.
(2) Install seal gasket, PN J219P04, onto VBV head hose adapter from adapter set, 1C9393. Using
washers and bolts, secure adapter onto head hose. Tighten bolts to 32-38 lb in. (3.7-4.2 N·m) of
torque.
(3) Remove bolts and washers that secure VBV rod hose (rod-end) to HCU. Remove seal gasket.
(4) Install seal gasket, PN J219P03, onto VBV rod hose adapter from adapter set, 1C9393. Using
washers and bolts, secure adapter to rod hose. Tighten bolts to 32-38 lb in. (3.7-4.2 N·m) of torque.
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Figure 3. Leak Check
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CAUTION

OIL, MIL-PRF-7808 AND MIL-PRF-23699F (C/I), OR DAMAGE WILL OCCUR.
(5) Connect hydraulic actuator unit, 1C3569, to hose adapters. Tighten fittings to 133-157 lb in.
(15.1-17.7 N·m) of torque.
WARNING
hose/actuator connection for leakage.
hose/actuator connection for leakage.
(8) If required, check VBV actuation system per WP 1312 00.
(9) Release pressure on VBV hydraulic system. Disconnect hydraulic actuator unit from VBV hose
adapters.
(10) Remove VBV hose adapters. Remove seal gaskets. Inspect seal gaskets for serviceability. Discard
damaged seal gaskets.
(11) Install new or serviceable seal gasket, PN J219P03, into HCU rod-end port. Using washers and
bolts, secure rod hose to HCU. Tighten bolts to 32-38 lb in. (3.7-4.2 N·m) of torque.
(12) Install new or serviceable seal gasket, PN J219P04, into HCU head-end port. Using washers and
bolts, secure head hose to HCU. Tighten bolts to 32-38 lb in. (3.7-4.2 N·m) of torque.
CAUTION

M. Slide drain adapter over coupling nuts and connect onto adapter port (figure 1). Hand-tighten drain
adapters.
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N. Leak-check drain adapters as follows:
WARNING
WARNING
WHEN USING COMPRESSED AIR FOR CLEANING, COOLING, OR DRYING, DO

NOT EXCEED 30 PSIG (207 KPA). WEAR EYE PROTECTION AND DO NOT
DIRECT COMPRESSED AIR AT SELF OR OTHERS.
(1) Connect a source of clean, dry, regulated shop air or nitrogen to drain line fitting on drain adapter.
(3) If pressure drop limit is exceeded, use soap solution to detect leak. Repair, as required, and repeat
leak check.
(5) Connect drain line to drain adapter. Tighten coupling nuts to 262-308 lb in. (29.7-34.7 N·m) of
torque.
O. If required, connect electrical connector to VBV actuator as follows:
WARNING

assembly.
mating connector.
NOTE
(4) Repeat step 7.O.(2) and step 7.O.(3), as required. It may be necessary to loosen lead clamps that
restrict mating.
P. Using washers, bolts, and nuts, install access panels onto air collector per WP 2310 00. Tighten bolts and
nuts to 57-67 lb in. (6.5-7.5 N·m) of torque.

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VARIABLE BYPASS VALVE (VBV) SYSTEM CHECK
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Subject Page
Variable Bypass Valve (VBV) System Check.......................................................................................... 3
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1. Introduction.
This work package contains instructions for checking the variable bypass valve (VBV) system.
Title Number
Nomenclature Part No
Tool Set, Rigging, VBV Doors 1C9353G02
Molybdenum Disulfide Lubricant MIL-L-25681

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6. Variable Bypass Valve (VBV) System Check.
A. Remove air collector access panels (figure 1).
WARNING

B. Remove bolts and washers that secure VBV head hose to hydraulic control unit (HCU) (figure 2). Remove
seal gasket.
C. Install seal gasket, PN J219P04, onto VBV hose adapter from adapter set, 1C9393. Secure adapter to VBV
head hose using washers and bolts. Tighten bolts to 32-38 lb in. (3.7-4.2 N·m) of torque.
D. Remove bolts and washers that secure VBV rod hose to HCU. Remove seal gasket.
E. Install seal gasket, PN J219P03, onto VBV hose adapter from adapter set, 1C9393. Secure adapter to VBV
rod hose using washers and bolts. Tighten bolts to 32-38 lb in. (3.7-4.2 N·m) of torque.
CAUTION

CAUTION

NUT. FAILURE TO COMPLY CAN RESULT IN PART DAMAGE.
F. Connect hydraulic actuator unit, 1C3569, to hose adapters. Tighten fittings to 133-157 lb in.
(15.1-17.7 N·m) of torque.
WARNING

FITTINGS.
G. Apply 200-250 psi (1379-1723 kPa) system pressure to actuate VBV system to the full open and full
closed positions several times. System shall operate smoothly throughout entire range of travel in both
directions.
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Figure 1. Air Collector Access Panels
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Figure 2. VBV Hose Locations
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NOTE
VBV position indication is read at indicator on control panel. Control panel must be powered up to
read VBV position indication.
H. Apply 200-250 psi (1379-1723 kPa) system pressure to actuate VBV system to the full closed position.
Insert four locating pins, 1C9353P02. Locating pins shall insert freely through unison ring and thread into
the four threaded bosses at the 12:30, 2:00, 6:30, and 8:00 o’clock positions (figure 3). VBV position
indicator shall indicate 0 ± 1 percent (full closed).
I. If VBV position indicator does not indicate 0 ± 1 percent (full closed), adjust the rigging as follows
(figure 4):
(1) Release hydraulic pressure from system.
(2) Loosen nut on each of the six rod-end bearing/actuator clevis linkages.
(3) Remove six nuts and bolts attaching rod-end bearing/actuator clevis linkages to actuator rods.
Figure 3. VBV Door, Unison Ring, and Rig Pin Hole
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Figure 4. VBV Rigging
WARNING

(4) Apply hydraulic pressure so that actuator rods are fully retracted (full closed).
(5) Turn rod-end bearing(s) in or out of the actuator clevis(es), as necessary, until hole in rod-end
bearing(s) aligns with hole in the clevis on actuator rod(s). Tighten nut(s) finger-tight.
CAUTION

(6) Apply molybdenum disulfide lubricant onto threads of six bolts.
(7) Install six bolts and nuts that attach rod-end bearing/actuator clevis linkages to actuator rods.
Tighten nuts to 125 lb in. (14.1 N·m) of torque.
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(8) Ensure that a 0.055 inch (1.40 mm) diameter wire will not pass through witness hole in actuator
devises. If necessary, turn rod-end bearing and clevis on actuator rod to position rod-end bearing
centered in actuator clevis.
(9) Tighten nuts on rod-end bearing/actuator clevis linkages to 80 lb in. (9.0 N·m) of torque.
J. Remove four locating pins, 1C9353P02. Release pressure on VBV hydraulic system.
WARNING

FITTINGS.
K. Apply 200-250 psi (1379-1723 kPa) system pressure to actuate VBV system to the full open position.
VBV position indicator shall indicate 100 ± 1 percent (full open).
L. Release pressure on VBV hydraulic system.
CAUTION
ENSURE CONNECTING FITTING IS RESTRAINED WHEN LOOSENING COUPLING NUT.

FAILURE TO COMPLY CAN RESULT IN PART DAMAGE.
M. Disconnect hydraulic actuator unit from VBV hose adapters.
N. Remove VBV hose adapters. Remove seal gaskets. Inspect seal gaskets for serviceability. Discard
damaged seal gaskets.
O. Install new or serviceable seal gasket, PN J219P03, onto HCU rod-end port. Secure VBV rod hose to HCU
using washers and bolts. Tighten bolts to 32-38 lb in. (3.7-4.2 N·m) of torque.
P. Install new or serviceable seal gasket, PN J219P04, onto HCU head-end port. Secure VBV head hose to
HCU using washers and bolts. Tighten bolts to 32-38 lb in. (3.7-4.2 N·m) of torque.
Q. Using washers, bolts, and nuts, install air collector access panels (figure 1). Tighten bolts and nuts to
57-67 lb in. (6.5-7.5 N·m) of torque.
81&21752//(':+(135,17('2575$160,77('(/(&7521,&$//<
LM6000 PF+ GEK 119319
GE Industrial AeroDerivative Gas Turbines Volume II
WP 1313 00
BYPASS VALVE, BELLCRANK, AND ACTUATING RING
REPLACEMENT
EFFECTIVITY: LM6000 PF+ GAS TURBINE MODELS

Page No. Change No.
1 - 14 ........................................................................................................................................................1
Alphabetical Index
Subject Page
Bypass Valve, Bellcrank, and Actuating Ring Installation......................................................................7

Bypass Valve, Bellcrank, and Actuating Ring Removal. ........................................................................3
Change 1 1
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GEK 119319 LM6000 PF+
Volume II GE Industrial AeroDerivative Gas Turbines
WP 1313 00
1. Introduction.
This work package contains instructions for removing and installing a bypass valve, bellcrank, and actuating
ring.
Title Number

Tool Set, Rigging, VBV Doors 1C9353G02
Sling, Lift MSE-53
Bottle Jack Local Purchase
Sprayable Lubricant GE Spec A50TF192, CL-B
Loctite 271 or European Loctite 275 GE Spec A15B41A9 (MIL-S-46163A, Type I,
Grade A)

2 Change 1
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LM6000 PF+ GEK 119319
WP 1313 00
6. Bypass Valve, Bellcrank, and Actuating Ring Removal.
A. Remove access panels from front frame air collector, as required, to gain access.
B. If required, remove lower section of air collector as follows (figure 1):
(1) Position bottle jack with protective block to support accessory gearbox.
(2) Remove screws that secure engine thrust mount frame seals. Remove seals.
WARNING
ALWAYS USE APPROVED EQUIPMENT AND PROCEDURES TO LIFT PARTS.

STAY OUT FROM BELOW LOADS. IF THE PARTS ACCIDENTALLY MOVE OR
FALL, THEY CAN CAUSE AN INJURY OR DEATH.
(3) Using a 1-ton (907 kg) capacity overhead hoist, position lift sling, MSE-53, above air collector.
Secure sling arms to air collector lower section. Take up slack on hoist to support air collector lower
section.
(4) Remove nuts, washers, and bolts that secure air collector lower section.
(5) Slowly lower sling while pulling lower section clear of engine.
(6) Repeat step 6.B.(3), step 6.B.(4), and step 6.B.(5) to remove remaining lower section.
C. Remove bypass valve (figure 2) and hinge assembly as follows:
(1) Remove nut, washers, and bolt that secure clevis rod-end bearing to valve.
(2) Remove bolts (figure 2, section A-A) and washers that secure hinge to front frame. Remove valve
with attached hinge.
(3) Remove nuts, washers, screws, and bushings that secure hinge to valve. Separate hinge from valve.
(4) Repeat step 6.C.(1) through step 6.C.(3) to remove remaining 11 bypass valves.
D. Remove actuating ring and bellcranks (figure 3) as follows:
(1) Remove 12 bolts (figure 3, view B) that secure bypass valve bellcrank to actuating ring.
(2) Remove six bolts that secure variable bypass valve (VBV) actuator bellcrank to actuating ring.
NOTE
Bellcrank bearings are tack-welded to the frame.
E. Remove bolts (figure 3, section A-A), flat washers, thrust washers, sleeves, and washers that secure 18
bellcranks onto bearing. Remove bellcranks from bearing.
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GEK 119319 LM6000 PF+
WP 1313 00
Figure 1. Front Frame Air Collector
4 Change 1
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LM6000 PF+ GEK 119319
WP 1313 00
Figure 2. Bypass Valve Replacement
Change 1 5
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GEK 119319 LM6000 PF+
WP 1313 00
Figure 3. Actuating Ring and Bellcrank Removal
6 Change 1
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LM6000 PF+ GEK 119319
WP 1313 00
NOTE
Actuating ring halves are a matched set.
F. Remove four bolts from actuating ring at struts No. 2 and 5, and remove actuating ring halves from front
frame.
G. Remove nut (figure 2, detail C), bolt, and washer that secure clevis to bypass valve bellcrank.
H. Loosen nut and remove rod-end bearing from clevis.
7. Bypass Valve, Bellcrank, and Actuating Ring Installation.
A. Assemble bypass valve (figure 2) to hinge as follows:
WARNING

(1) Apply molybdenum disulfide lubricant onto threads of screws.
(2) Align hinge with bypass valve. Install bushings, flange outside, through valve and hinge.
(3) Install two screws, washers, and nuts to secure hinge to bypass valve. Install screw through bushing
from outside, washers and nuts inside.
(5) Repeat step 7.A.(1) through step 7.A.(4) for remaining 11 bypass valve/hinge assemblies.
B. Determine valve position as follows (figure 4):
(1) Measure from aft center portion of valve bottom to seal retainer lip. Record as dimension B.
(2) Subtract 0.050 inch (1.27 mm) from dimension B. Record difference as dimension C.
(3) Measure bypass port rear face from inside outward. Using marking pen, mark rear face at
dimension C.
Change 1 7
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GEK 119319 LM6000 PF+
WP 1313 00
Figure 4. Bypass Valve Positioning
8 Change 1
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LM6000 PF+ GEK 119319
WP 1313 00
C. Install bypass valve/hinge assembly (figure 2) onto front frame as follows:
WARNING

(1) Apply sprayable lubricant to seal on bypass valve and mating surface of front frame.
(2) Apply molybdenum disulfide onto bolt threads. Install bypass valve/hinge assembly in opening on
front frame.
(3) Secure bypass valve/hinge assembly onto front frame using two bolts and washers.
(4) Tighten bolts to 106-124 lb in. (12.0-14.0 N·m) of torque.
(5) Repeat step 7.C.(1) through step 7.C.(4) for remaining 11 bypass valve/hinge assemblies.
D. Assemble bypass valve bellcrank and clevis assemblies as follows:
(1) Apply thin coating of molybdenum disulfide lubricant onto threads of rod-end bearing.
(2) Thread nut onto rod-end bearing and install bearing to clevis. Thread bearing into clevis
approximately 0.375 inch (9.53 mm), until end of thread is flush with underside of clevis. Tighten
nut finger-tight.
(3) Apply thin coating of molybdenum disulfide lubricant onto threads of bellcrank-to-clevis bolt.
(4) Align clevis with bellcrank angled leg and install bolt, washer, and nut. Install washer under nut and
bolthead on frame side of bellcrank.
(5) Tighten nut to 90-110 lb in. (10.2-12.4 N·m) of torque.
(6) Repeat step 7.D.(1) through step 7.D.(5) for remaining 11 bellcrank and clevis assemblies.
E. Install actuating ring (figure 3) onto front frame as follows:
(1) Adjust six VBV actuators as follows:
(a) Remove protective caps from VBV actuators.
(b) Pull actuator rod to full extended position.
(c) Push rod into actuator to full retracted position until contact is made.
(d) Install protective caps in VBV actuator ports.
Change 1 9
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GEK 119319 LM6000 PF+
WP 1313 00
CAUTION
VARIABLE BYPASS VALVE ACTUATOR RODS MUST REMAIN IN THE FULL

RETRACTED POSITION FOR SUCCESSFUL VBV COMPONENTS
INSTALLATION. ADJUST ROD-END BEARING LENGTH TO ALIGN WITH
ACTUATOR ROD END; DO NOT EXTEND VBV ACTUATOR RODS TO ALIGN
WITH ROD-END BEARINGS.
CAUTION

(2) Apply molybdenum disulfide lubricant to threads of four bolts.
(3) Position actuating ring halves around front frame so halves connect at approximately 2:00 and
8:00 o’clock positions (over struts No. 2 and 5).
(4) Secure actuating ring halves together using bolts. Tighten bolts to 106-124 lb in. (12.0-14.0 N·m) of
torque.
F. Install 12 bypass valve bellcrank assemblies (figure 3) as follows:
(1) Apply molybdenum disulfide lubricant to threads of 12 bolts that secure bellcranks onto bearing.
(2) Install washer (figure 3, section A-A) and sleeve onto bearing. Install bellcrank assembly. Install
thrust washer on top of bellcrank.
(3) Secure bellcrank assembly onto bearing with washer and bolt. Tighten bolts to 57-67 lb in.
(4) Repeat step 7.F.(1) through step 7.F.(3) for remaining 11 bellcrank assemblies.
(5) Check that each bellcrank assembly operates freely, using finger force only.
G. Assemble 18 bellcranks to actuating ring as follows:
(1) Align actuating ring (figure 2, view B) to front frame with four locating pins, 1C9353P02. Insert
locating pins through actuating ring and thread into front frame at 4:00, 7:00, 10:00, and 12:30
o’clock positions. Tighten locating pins hand-tight; do not force the assembly. This is the bypass
valve rig position.
(2) Rotate bellcranks until straight leg engages into actuating ring.
(3) Apply Loctite 271 or European Loctite 275 to threads of 18 bolts (figure 3, view B) that secure
bellcranks to actuating ring. Align bellcranks with holes in ring. Install bolts through ring and
bellcrank. Tighten bolts to 225 lb in. (25.4 N·m) of torque.
10 Change 1
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LM6000 PF+ GEK 119319
WP 1313 00
H. Assemble rod-end bearings (figure 2) to bypass valves as follows:
CAUTION

(1) Apply molybdenum disulfide lubricant to threads of 12 bolts that secure rod-end bearings to bypass
valves.
(2) With actuator rods fully retracted and four locating pins, 1C9353P02, installed, align rod-end
bearing to bypass valve clevis.
(3) Thread rod-end bearing to bellcrank clevis to align boltholes. Adjust so bolt can be installed with
center of bypass valve aft lip protruding into air flow path aligned with mark made on bypass port
rear face in step 7.B.(3).
(4) Adjust rod-end bearings at each of 12 bellcranks to obtain required bypass valve alignment. Check
that there is full thread engagement of bearing into clevis, approximately 0.375 inch (9.53 mm). Do
not torque nuts at this time.
(5) Install bolt (figure 2, view B), washers, and nut to hold clevis to rod-end bearing. Bolthead is on
right side of valve, aft looking forward. Washer is under bolt and nut.
(6) Tighten 12 nuts at valve and clevis pivot point to 57-67 lb in. (6.5-7.5 N·m) of torque. Safety-cable
or lockwire nuts.
(7) Position 12 rod-end bearings centered in clevises. This will prevent premature failure of rod-end
bearings.
(8) Tighten 12 rod-end bearing nuts (figure 2, detail C) to 57-67 lb in. (6.5-7.5 N·m) of torque.
(9) Remove four locating pins, 1C9353P02, from actuating ring.
I. Final test VBV hydraulic system as follows:
(1) Remove bolts and washers that secure VBV head hose onto hydraulic control unit (HCU). Remove
seal gasket (figure 5).
(2) Install seal gasket, PN J219P04, onto VBV hose adapter from adapter set, 1C9393. Using washers
and bolts, secure adapter onto head hose. Tighten bolts to 32-38 lb in. (3.7-4.2 N·m) of torque.
(3) Remove bolts and washers that secure VBV rod hose onto HCU. Remove seal gasket.
(4) Install seal gasket, PN J219P03, onto VBV hose adapter from adapter set, 1C9393. Using washers
and bolts, secure adapter onto rod hose. Tighten bolts to 32-38 lb in. (3.7-4.2 N·m) of torque.
Change 1 11
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GEK 119319 LM6000 PF+
WP 1313 00
12 Change 1
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LM6000 PF+ GEK 119319
WP 1313 00
CAUTION

CAUTION

(5) Connect hydraulic actuator unit, 1C3569, onto hose adapters. Tighten fittings to 133-157 lb in.
(15.1-17.7 N·m) of torque.
WARNING

(6) Apply 200-250 psi (1379-1723 kPa) system pressure to actuate VBV system to full open and full
closed positions several times. System shall operate smoothly throughout entire range of travel in
both directions.
(7) Apply 200-250 psi (1379-1723 kPa) system pressure to actuate VBV system to full closed position.
Variable bypass valve seal retainer lip shall align with mark on inside lip of bleed port rear face.
(8) Release pressure on VBV hydraulic system.
CAUTION

(9) Disconnect hydraulic actuator unit from VBV hose adapter set.
(10) Remove VBV hose adapters (figure 5). Remove seal gaskets. Inspect seal gaskets for serviceability.
Discard damaged seal gasket.
(11) Install new or serviceable seal gasket, PN J219P03, onto HCU rod port. Using washers and bolts,
secure rod hose to HCU. Tighten bolts to 32-38 lb in. (3.7-4.2 N·m) of torque.
(12) Install new or serviceable seal gasket, PN J219P04, onto HCU head port. Using washers and bolts,
secure head hose to HCU. Tighten bolts to 32-38 lb in. (3.7-4.2 N·m) of torque.
J. If removed, install lower section of air collector as follows (figure 1):
(1) Position lower section under air collector.
Change 1 13
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GEK 119319 LM6000 PF+
WP 1313 00
WARNING

(2) Using a 1-ton (907 kg) capacity overhead hoist, position lift sling, MSE-53, above air collector.
Secure sling arms to lower section.
(3) Slowly raise lower section into position.
CAUTION

(4) Apply molybdenum disulfide lubricant onto threads of bolts.
(5) Install bolts and nuts that secure lower section onto front frame forward flange. Boltheads face aft.
(6) Install bolts that secure lower section onto front frame aft flange.
(7) Install bolts and nuts that secure flanges. Boltheads face up or outboard.
(8) Tighten flange nuts to 483-567 lb in. (54.6-64.0 N·m) of torque.
(9) Remove lift sling.
(10) Tighten nuts that secure lower section onto front frame forward flange to 57-67 lb in. (6.5-7.5 N·m)
of torque.
(11) Tighten bolts that secure lower section onto front frame aft flange to 57-67 lb in. (6.5-7.5 N·m) of
torque.
(12) Repeat step 7.J.(1) through step 7.J.(11) for remaining lower section.
(13) Install thrust mount frame seals and secure with screws.
K. Using washers, bolts, and nuts, install access panels onto air collector. Tighten bolts and nuts to 57-67 lb in.
L. Remove bottle jack and protective block.
14 Change 1
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VARIABLE STATOR VANE (VSV) ACTUATOR
COMPONENTS REPLACEMENT
())(&7,9,7</03)*$6785%,1(02'(/6

Page No. Change No.
1 - 15 ........................................................................................................................................................ 0
16 Blank ................................................................................................................................................... 0
Alphabetical Index
Subject Page
Variable Stator Vane Actuator Installation. .............................................................................................. 6

Variable Stator Vane Actuator Length Preset Adjustment Using Check Fixture, 1C9403. .................... 12
Variable Stator Vane Actuator Lever Installation.................................................................................... 13
Variable Stator Vane Actuator Lever Removal. ...................................................................................... 12
Variable Stator Vane Actuator Removal................................................................................................... 3
Variable Stator Vane Actuator Ring Installation. .................................................................................... 15
Variable Stator Vane Actuator Ring Removal......................................................................................... 14
Variable Stator Vane Connecting Link Installation. ................................................................................ 14
Variable Stator Vane Connecting Link Removal..................................................................................... 14
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1. Introduction.
This work package contains instructions for removing and installing the variable stator vane (VSV) actuation
components.
Title Number
Variable Stator Vane (VSV) Rigging WP 1411 00
High Pressure Compressor (HPC) Upper and Lower WP 2411 00
Stator Case Replacement
High Pressure Compressor (HPC) Stator Vanes WP 2412 00
Replacement

Fixture, Check VSV/VIGV Actuator 1C9403G01
Nitrogen Cart with hose and regulator (optional) Local Purchase
Isopropyl Alcohol Fed Spec TT-I-735
Nitrogen (optional) BB-N-411
Silicone Rubber Adhesive GE Spec A15F6B6 (RTV 106)

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6. Variable Stator Vane Actuator Removal.

WARNING
CAUTION
OPERATION.
NOTE
There are two actuators and two tube fittings per actuator; therefore, this procedure must be done four
times.
A. Tag and disconnect electrical connector from VSV actuator.
NOTE
B. Disconnect tubing as follows (figure 1):
WARNING
(1) Position a waste fluid container beneath VSV actuator. Disconnect drain line from drain adapter.
(2) Disconnect drain adapter from VSV actuator. Slide drain adapter away from VSV actuator ports to
CAUTION
(3) Disconnect coupling nut from VSV actuator fitting.
(4) Remove and discard preformed packing from drain adapters.
(5) Repeat previous steps for other tube fitting.
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Figure 1. VSV Actuator Tubing
C. Remove bolts that secure actuator bracket to front frame (figure 2).
CAUTION
ADJUSTMENT REQUIRES THAT VSV ACTUATOR LENGTH PRESET ADJUSTMENT
USING CHECK FIXTURE BE PERFORMED AND VSV ACTUATION SYSTEM RIGGING
BE CHECKED.
D. Remove nut and bolt that secure VSV actuator to bracket. Separate bracket from VSV actuator.
E. Rotate guide 90 degrees. Remove guide and VSV actuator from actuation lever.
F. Remove fitting from VSV actuator. Remove and discard preformed packings (figure 1).
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Figure 2. VSV Actuation Components (Sheet 1 of 2)
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Figure 2. VSV Actuation Components (Sheet 2 of 2)
7. Variable Stator Vane Actuator Installation.
WARNING

NOTE
• There are two actuators and two tube fittings per actuator; therefore, this procedure must be done
four times.
• If installing a new actuator, or in the event actuator rod end adjustment is disturbed during
removal/installation, perform paragraph 8.
A. Lubricate preformed packings, PN J221P904 and PN 9365M41P122, with lubricating oil, and install into
groove of fitting (figure 1).
B. Install fitting into VSV actuator. Tighten fitting to 133-157 lb in. (15.1-17.7 N·m) of torque.
C. Repeat previous steps for other tube fitting.
/03) *(.
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CAUTION

ADJUSTMENT REQUIRES THAT THE VARIABLE STATOR VANE ACTUATOR LENGTH
PRESET ADJUSTMENT PROCEDURE USING CHECK FIXTURE BE PERFORMED AND
VSV ACTUATION SYSTEM RIGGING BE CHECKED.
D. Position VSV actuator rod end over forward end of actuation lever (figure 2).
E. Install guide onto end of lever. AFT mark on guide faces aft. Rotate guide 90 degrees.
F. Apply thread lubricant onto threads of actuator retaining bolt and actuator bracket retaining bolts.
G. Slide VSV actuator so that guide fits into channel of bracket. Using bolt and nut, secure VSV actuator to
bracket. Bolthead faces forward. Tighten nut to 120-150 lb in. (13.6-16.9 N·m) of torque.
H. Using bolts, secure actuator bracket onto front frame. Tighten bolts per figure 3 and safety-wire.
NOTE
If the length of the VSV actuator must be adjusted, see paragraph 8.
I. Connect electrical connector to VSV actuator as follows:
WARNING

assembly.
mating connector.
NOTE
(4) Repeat step 7.I.(2) and step 7.I.(3), as required. It may be necessary to loosen lead clamps that
restrict mating.
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Figure 3. VSV Actuator Bracket Installation
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WARNING

J. Lubricate preformed packing, PN 9365M41P117, with lubricating oil and install into drain adapter
(figure 1).
CAUTION

K. Connect tubing coupling nut to VSV actuator fittings. Tighten coupling nut to 262-308 lb in.
(29.7-34.7 N·m) of torque.
L. Leak-check head- and rod-end fittings as follows (figure 4):
CAUTION
(1) Install reducers from adapter set, 1C9393, onto hydraulic actuator unit, 1C3569. Tighten reducers to
133-157 lb in. (15.1-17.7 N·m) of torque.
(2) Position waste fluid container under hydraulic control unit (HCU).
CAUTION

(3) Disconnect VSV head tube from HCU. Install head tube onto -4 to -10 reducer. Tighten coupling nut
to 55-65 lb ft (75-88 N·m) of torque.
(4) Disconnect VSV rod tube from HCU. Install rod tube onto -4 to -8 reducer. Tighten coupling nut to
460-540 lb in. (52.0-61.0 N·m) of torque.
WARNING

*(. /03)
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/03) *(.
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(7) If required, check VSV system rigging per WP 1411 00.
(8) Disconnect hydraulic actuator unit. Remove reducers.
(9) Connect head tube to HCU. Tighten coupling nut to 55-65 lb ft (75-88 N·m) of torque.
(10) Connect rod tube to HCU. Tighten coupling nut to 460-540 lb in. (52.0-61.0 N·m) of torque.
M. Slide drain adapter over coupling nut and connect to VSV actuator port (figure 1). Hand-tighten drain
adapters.
N. Leak-check drain adapters as follows:
WARNING

WARNING
WHEN USING COMPRESSED AIR FOR CLEANING, COOLING, OR DRYING,

WEAR EYE PROTECTION AND DO NOT DIRECT COMPRESSED AIR AT SELF
OR OTHERS.
(1) Connect a source of clean, dry, regulated shop air or nitrogen to drain line fitting on drain adapter.
(3) If pressure drop limit is exceeded, use soap solution to detect leak. Repair as required and repeat
leak check.
(5) Connect drain line to drain adapter. Tighten coupling nut to 262-308 lb in. (29.7-34.7 N·m) of
torque.

*(. /03)
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8. Variable Stator Vane Actuator Length Preset Adjustment Using Check Fixture, 1C9403.
WARNING

FITTINGS.
CAUTION
MAINTAIN 250 PSI (1724 KPA) ON ACTUATOR, AT THE FULLY EXTENDED POSITION,
WHEN ADJUSTING ROD END.
CAUTION

LUBRICATING OIL, MIL-PRF-23699F (C/I). DO NOT INTERMIX LUBRICATING OILS
MIL-PRF-7808 AND MIL-PRF-23699F (C/I) OR DAMAGE WILL OCCUR.
NOTE
This procedure is to be performed before installing a new actuator or in the event actuator rod end
adjustment is disturbed during removal/installation.
A. Connect hydraulic actuator unit, 1C3569, to actuator. Supply 250 psi (1724 kPa) to extend actuator to fully
extended position. Maintain pressure throughout adjustment procedure.
B. Loosen jamnut that secures actuator rod end.
C. Adjust rod end so that actuator slides freely onto check fixture, 1C9403 (figure 5).
D. Tighten jamnut to secure rod end. Safety-wire jamnut.
E. Release pressure and remove hydraulic actuator unit, 1C3569.
F. Perform VSV rigging per WP 1411 00 before operating engine.
9. Variable Stator Vane Actuator Lever Removal.
A. Remove VSV actuator per paragraph 6.
B. Remove bolts, washers, bushings (stages 3-5), and nuts that secure clevis assemblies to VSV connecting
links (figure 2).
C. Remove nut, washer, and spacer that secure actuation lever to aft mount and remove lever.
D. Mark stage number on each clevis assembly with marking pen.
E. Remove nuts and bolts that secure clevis assemblies to actuation lever.
F. Separate seal boots and slot-loaded bearings from actuation lever.

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Figure 5. Actuator Length Preset Using Check Fixture, 1C9403
10. Variable Stator Vane Actuator Lever Installation.
A. Install slot-loaded bearings into actuation lever (figure 2). Install seal boots over bearings.
B. Apply thread lubricant to threads of clevis bolts.
C. Secure clevis assemblies to actuation lever using nuts and bolts (boltheads next to engine). Tighten nuts to
62-68 lb in. (7.1-7.6 N·m) of torque.
D. Install spacer and actuation lever over aft mount stud.
E. Apply thread lubricant to stud threads and install washer and nut. Tighten nut to 190-230 lb in.
(21.5-25.9 N·m) of torque.
F. Apply thread lubricant to threads of rod-end bearing to connecting link bolts.
G. Align clevis rod-end bearings with connecting links and secure with bolts, washers, and nuts. Boltheads
face forward. One washer is under bolthead and one washer is under nut. Bushing is between aft side of rod
end bearing and connecting link on stages 3 and 4, and bushing is between forward side of bearing and
connecting link on stage 5.
H. Tighten rod-end bearing to connecting link nuts to 62-68 lb in. (7.1-7.6 N·m) of torque.

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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.
I. Using isopropyl alcohol, clean lever aft mount and spacer.
WARNING
VAPOR FROM UNCURED SEALANT IS FLAMMABLE AND TOXIC TO SKIN, EYES, AND
RESPIRATORY TRACT. AVOID CONTACT WITH SKIN AND EYES. USE IN A WELL-
VENTILATED AREA.
J. Apply silicone rubber adhesive over exposed joint between lever, spacer, and aft mount. Allow adhesive to
cure for 8 hours minimum before engine operation.
11. Variable Stator Vane Connecting Link Removal.
A. Remove VSV actuation lever per paragraph 9.
CAUTION

ADJUSTMENT REQUIRES THAT VSV ACTUATOR LENGTH PRESET ADJUSTMENT BE
PERFORMED USING CHECK FIXTURE AND VSV ACTUATION SYSTEM RIGGING BE
CHECKED.
B. Remove VSV connecting links per WP 2411 00.
12. Variable Stator Vane Connecting Link Installation.
A. Install VSV connecting links per WP 2411 00.
B. Install VSV actuation lever per paragraph 10.
13. Variable Stator Vane Actuator Ring Removal.
A. Remove VSV actuation lever per paragraph 9.
CAUTION
ADJUSTMENT REQUIRES THAT THE VARIABLE STATOR VANE ACTUATOR LENGTH
PRESET ADJUSTMENT USING CHECK FIXTURE PROCEDURE BE PERFORMED AND
VSV ACTUATOR SYSTEM RIGGING BE CHECKED.
B. Remove VSV connecting links per WP 2411 00.
C. Remove VSV actuation ring per WP 2412 00.

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14. Variable Stator Vane Actuator Ring Installation.
A. Install VSV actuation ring per WP 2412 00.
B. Install VSV connecting links per WP 2411 00.
C. Install VSV actuation lever per paragraph 10.
%ODQN
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VARIABLE STATOR VANE (VSV) RIGGING
())(&7,9,7</03)*$6785%,1(02'(/6

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18 Blank ................................................................................................................................................... 0
Alphabetical Index
Subject Page
Hydraulic Actuator Unit, 1C3569, Installation. ....................................................................................... 3

Hydraulic Actuator Unit, 1C3569, Removal........................................................................................... 17
Variable Stator Vane Actuation Ring Spacer Clearance Adjustment....................................................... 3
Variable Stator Vane Actuator Full Travel Verification. ......................................................................... 17
Variable Stator Vane System Rigging (1C9365). ..................................................................................... 8
Variable Stator Vane System Rigging (2C6925). ..................................................................................... 6
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1. Introduction.
This work package contains instructions for rigging the variable stator vane (VSV) system.
None required.

Protractor Assembly, Electronic, Portable - VSV 1C9365G03
Gage Set, VSV Clevis 2C6925G03
None required.
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6. Hydraulic Actuator Unit, 1C3569, Installation.
A. Position waste fluid container beneath hydraulic control unit (HCU) (figure 1).
WARNING

CAUTION

CAUTION

B. Install reducers, from adapter set, 1C9393, onto hydraulic actuator unit, 1C3569. Tighten reducer to
133-157 lb in. (15.1-17.7 N·m) of torque.
C. Disconnect head tube from HCU. Install head tube onto -4 to -10 reducer. Tighten tube to 55-65 lb ft
(75-88 N·m) of torque.
D. Disconnect rod tube from HCU. Install rod tube onto -4 to -8 reducer. Tighten tube to 460-540 lb in.
(52.0-61.0 N·m) of torque.
7. Variable Stator Vane Actuation Ring Spacer Clearance Adjustment.
CAUTION
PRIOR TO PERFORMING THIS WORK PACKAGE, ENSURE THE FOLLOWING

CONDITIONS EXIST:
• VSV VANE ARMS ARE INSTALLED IN ACTUATION RINGS.
• ACTUATION RINGS ARE SECURED TO BRIDGE CONNECTORS.
• ACTUATING ARM LEVERS ARE INSTALLED AND SECURED PROPERLY.
• VSV ACTUATORS ARE INSTALLED AND SECURED PROPERLY.
A. Position stator vanes to full open position (VSV actuator rods fully extended) by applying hydraulic
pressure.
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NOTE
All eight spacers per stage shall be adjusted at the same time.
B. Adjust actuation ring spacers (figure 2).
C. Tighten locknuts to 60-70 lb in. (6.8-7.9 N·m) of torque.
D. Measure clearance between spacer and high pressure compressor (HPC) case (dimension M). Clearance
shall be within limits of figure 2.
Figure 2. VSV Actuation Ring Spacer Clearance
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NOTE
An alternate method of rigging VSV system using electronic protractor, 1C9365, is provided in paragraph 9.
8. Variable Stator Vane System Rigging (2C6925).
NOTE
Stage 5 clevis assembly, PN 2038M46, is manufactured with a fixed length and does not require length
adjustment per preset rigging method.
A. Preset length of stage IGV through stage 4 clevis assemblies and confirm length of stage 5 clevis assembly
as follows (figure 3):
CAUTION
ENSURE STAGE NUMBER IS MARKED ON EACH CLEVIS ASSEMBLY.
IMPROPER LOCATION OF CLEVIS ASSEMBLIES WILL CAUSE
UNPREDICTABLE ENGINE OPERATION.
(1) Using marking pen, mark stage number on clevis assembly.
(2) Install each stage IGV through stage 4 clevis assembly into VSV clevis gage set, 2C6925, one at a
time.
(3) If necessary, loosen jamnut and adjust clevis assembly length to appropriate value as specified in
figure 3.
NOTE
Rod end adjustment must be equal within one-half thread on each matched stage (2) clevis
assembly.
(4) Tighten jamnut to 60-70 lb in. (6.8-7.9 N·m) of torque. Safety-wire jamnut.
NOTE
Stage 5 clevis assembly length is not adjustable.
(5) If required, confirm length of stage 5 clevis assembly as follows:
NOTE
Some 2C6925 tools may require modification to allow sufficient travel to measure the
length of stage 5 clevis assembly.
(a) Install stage 5 clevis assembly into VSV clevis gage set, 2C6925.
(b) Confirm stage 5 clevis length as specified in figure 3.
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Figure 3. Preset Length of Clevis Assemblies Using Gage Set, 2C6925
CAUTION
ENSURE CLEVIS ASSEMBLIES ARE INSTALLED AT THE PROPER LOCATIONS.

FAILURE TO COMPLY MAY CAUSE UNPREDICTABLE ENGINE OPERATION.
NOTE
Maintain 250 psig (1724 kPa) pressure at head-end of actuators while installing IGV through stage 5
clevises.
B. Install inlet guide vane (IGV) and stages 1 and 2 clevis assemblies as follows (figure 4):
CAUTION
JAMNUT SAFETY WIRE SHALL NOT BE BROKEN WHEN INSTALLING

CLEVIS ASSEMBLIES ON ACTUATING ARM LEVER OR BRIDGE
CONNECTOR.
(1) Apply thread lubricant to threads of clevis bolts and rod end to bridge connector bolts.
(2) Using bolt and nut, secure clevis onto actuating arm lever, bolthead facing inboard. Tighten nut to
62-68 lb in. (7.1-7.6 N·m) of torque.
(3) Using bolt, washers, and nut, secure rod end to bridge connector, bolthead facing forward. One
washer goes under bolthead, and one washer goes under nut. Tighten nut to 62-68 lb in.

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NOTE
clevises.
C. Install stage 3 and stage 4 clevis assemblies as follows (figure 4):
(2) Using bolt and nut, secure clevis to actuating arm lever, bolthead facing inboard. Tighten nut to
62-68 lb in. (7.1-7.6 N·m) of torque.
(3) Using bolt, washers, bushing, and nut, secure rod end to bridge connector, bolthead facing forward.
Bushing goes between aft face of rod end and bridge connector. One washer goes under bolthead,
and one washer goes under nut. Tighten nut to 62-68 lb in. (7.1-7.6 N·m) above run-on torque.
D. Install stage 5 clevis assembly as follows:
(1) Apply thread lubricant to threads of clevis bolt and bearing end to bridge connector bolts.
62-88 lb in. (7.1-7.6 N·m).
(3) Using bolt, washers, bushing, and nut, secure bearing end to bridge connector, bolthead facing aft.
Bushing goes between forward face of rod end and bridge connector. One washer goes under
bolthead, and one washer goes under nut. Tighten nut to 62-68 lb in. (7.1-7.6 N·m) above run-on
torque.
E. Verify full travel of VSV actuator per paragraph 10.
9. Variable Stator Vane System Rigging (1C9365).
CAUTION
ENSURE CLEVIS ASSEMBLIES ARE INSTALLED AT THE PROPER LOCATIONS.

FAILURE TO COMPLY MAY CAUSE UNPREDICTABLE ENGINE OPERATION.
NOTE
Stage 5 clevis assembly is manufactured in one piece and does not require assembly.
A. Assemble stage IGV through stage 4 clevis assemblies (figure 4). Do not tighten jamnuts at this time.
NOTE
clevises.
B. Install stage IGV through stage 2 clevis assemblies as follows:
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Figure 4. Actuator Lever Assembly (Sheet 1 of 2)
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Figure 4. Actuator Lever Assembly (Sheet 2 of 2)
(2) Using bolt and nut, secure clevis onto actuating arm lever, bolthead facing inboard. Tighten nut to
62-68 lb in. (7.1-7.6 N·m) of torque.
(3) Adjust clevis length to correct any mismatch of rod-ends and connectors.
(4) Using bolt, washers, and nut, secure rod end onto bridge connector, bolthead facing forward. One
washer under bolthead, and one washer under nut. Tighten nut to 62-68 lb in. (7.1-7.6 N·m) of
torque.
NOTE
clevises.
C. Install stage 3 and stage 4 clevis assemblies as follows:
62-68 lb in. (7.1-7.6 N·m) of torque.
(3) If necessary, adjust clevis length to correct any mismatch of rod-ends and connectors.

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(4) Using bolt, washers, bushings, and nut, secure rod end onto bridge connector, bolthead facing
forward. Bushing goes between aft face of rod end and bridge connector. One washer goes under
torque.
NOTE
clevises.
D. Install stage 5 clevis assembly as follows:
(1) Apply thread lubricant to threads of clevis bolt and bearing end to bridge connector bolts.
62-68 lb in. (7.1-7.6 N·m) of torque.
(3) Using bolt, washers, bushing, and nut, secure bearing end to bridge connector, bolthead facing aft.
Bushing goes between forward face of rod end and bridge connector. One washer goes under
torque.
E. Calibrate portable electronic protractor, 1C9365, to set master as follows (figure 5):
(1) Set 110v/60Hz, 230v/50Hz switch on back panel to proper setting for power supply being used.
NOTE
P38 encoders should remain connected to readout unit to ensure pre-rig check accuracy.
(2) Install encoder on set master ensuring tangs are engaged. Position locator arm at zero degree. Install
alignment pin through locator arm into zero degree hole of set master.
(3) Connect encoder to digital position readout unit.
(4) Power up readout unit and allow to warm up for 15 minutes. When unit is powered up, display will
show P-UP. Press any R key to clear display.
NOTE
Ensure locator arm is in zero degree position before pressing reset button.
(5) Move locator arm to zero position. Press reset button to set readout counter to zero.

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Figure 5. VSV Portable Electronic Protractor Assembly, 1C9365

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CAUTION
• DO NOT MAKE ANY MECHANICAL ADJUSTMENTS TO ENCODER OR

LOCATOR ARM. MOVE ARM SLOWLY; RAPID MOVEMENT WILL
CAUSE INACCURATE READINGS. OPERATE ONE COMPLETE CYCLE
BETWEEN READOUTS.
• ALWAYS PASS THROUGH ZERO DEGREE ON SET MASTER WHEN

CHECKING ANGLES. INACCURATE READINGS WILL RESULT IF NOT
ACTUATED THROUGH ZERO FROM EITHER + OR - READINGS.
(6) Move locator arm to each degree hole in set master and check readout of counter. Readings shall be
within 0.2 degree of degree mark on set master. If readings cannot be met within 0.2 degree, check
for proper setup and security of plugs in receptacle. Replace encoder or digital position readout unit
as required.
(7) Return to zero hole in set master. Zero hole shall give zero reading after other settings have been
checked.
(8) Repeat step 9.E.(1) through step 9.E.(7) for remaining encoders.
F. Install P38 encoders on stage IGV through stage 2 vane stems as follows:
NOTE
• Refer to figure 6 for tool part numbers.
• Vane angles shall be measured from the vane positions listed in figure 7, table 1. When
adequate thread engagement cannot be obtained (less than two threads), an alternate
vane location, one vane position either side of the locations listed in figure 7, table 1,
may be used. Vane positions are numbered from the 9 o’clock position, aft looking
forward.
(1) Install post locators onto four vane stems as listed in figure 7, table 1. Tighten post locator to
5-10 lb in. (0.6-1.1 N·m) of torque (figure 6).
(2) Install tang adapters over four post locators and engage adapter tangs in vane arms. Scribe lines on
tang adapters must face aft.
(3) Install arm locator onto second vane in either direction from the four vane positions listed in
figure 7, table 1.
(4) Install encoder over post locator. Engage slots in encoder with tangs of tang adapter.
Simultaneously, engage encoder arm with pin on arm locator.
(5) Measure stator vane angles per step 9.H.

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Figure 6. Installation of P38 Encoders on Stage IGV Through Stage 5

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Figure 7. Portable VSV Electronic Protractor Tool Set, 1C9365
G. Install encoders on stages 3 through 5 vanes as follows (figure 6 and figure 7):
CAUTION
USE SAFETY WIRE TO ENSURE STATOR VANE DOES NOT DROP INTO
STATOR CASE WHEN RETAINING NUT IS REMOVED.
(1) Remove stator vane arm retaining nuts at locations where encoders will be installed.
(2) Secure stator vane arm with nut. Tighten nut finger-tight.
(3) Install tang adapter over vane arm. Tighten setscrew to 57-67 lb in. (6.5-7.5 N·m) of torque.
(4) Install post locator and arm locator.
(5) Install encoder over post locator. Engage slot in encoder with tang of tang adapter. Simultaneously,
engage arm of encoder with arm locator pin.
(6) Measure stator vane angles per step 9.H.

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H. Measure stator vane angles as follows:
WARNING

(1) Apply 200-250 psi (1379-1724 kPa) system pressure to actuate VSV system to full open and full
closed positions several times. System shall operate smoothly through entire range of travel in both
directions.
(2) Apply 200-250 psi (1379-1724 kPa) system pressure to actuate VSV system to full closed position.
Pushrods for stage IGV through stage 4 shall be positioned for maximum clearance to actuation
rings and actuator lever arms. Record average of encoder readouts. The average reading shall be
between upper and lower limits listed in figure 7, table 2.
(3) Apply 200-250 psi (1379-1724 kPa) system pressure to actuate VSV system to full open position.
Pushrods for stage IGV through stage 4 shall be positioned for maximum clearance to actuation
rings and actuator lever arms. Record average of encoder readouts. The average reading shall be
between upper and lower limits listed in figure 7, table 2.
NOTE
• Rod end adjustment must be equal within one-half thread on both sides of the engine.
• Stage 5 clevis assembly, PN 2038M46, is manufactured with a fixed length and does
not require length adjustment.
(4) Adjust rod ends for stage IGV through stage 4 to obtain required angles at both open and closed
positions per preset rigging method.
(5) Check stage IGV through stage 4 clevis assemblies for proper engagement of rod end bearing
threads by attempting to insert No. 56 drill (0.55 inch [14.0 mm] diameter) through witness hole at
each end of clevis assembly. Drill shall not pass through.
(6) Tighten jamnuts to 60-70 lb in. (6.8-7.9 N·m) of torque. Safety-wire jamnuts.
CAUTION
ENSURE STATOR VANE DOES NOT DROP INTO STATOR CASE WHEN
RETAINING NUT IS REMOVED.
(7) Remove encoders, post locators, tang adapter, arm locator, and retaining nut. Install stator vane arm
retaining nuts. Replace any nut when run-on torque falls below 5 lb in. (0.6 N·m) or exceeds
40 lb in. (4.5 N·m) of torque. Tighten nuts to 85-95 lb in. (9.7-10.7 N·m) of torque.
I. Verify full travel of VSV actuator per paragraph 10.

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10. Variable Stator Vane Actuator Full Travel Verification.
WARNING

FITTINGS.
A. Apply 200-250 psi (1379-1724 kPa) system pressure to actuate VSV system to full open and full closed
positions several times. System shall operate smoothly through entire range of travel in both directions.
NOTE
VSV position indication is read at indicator on control panel. Control panel must be powered up to
read VSV position indication.
B. Apply 200-250 psi (1379-1724 kPa) system pressure to actuate VSV system to full closed position. VSV
position indicator shall indicate 0 ± 1 percent.
C. Apply 200-250 psi (1379-1724 kPa) system pressure to actuate VSV system to full open position. VSV
position indicator shall indicate 100 ± 1 percent.
11. Hydraulic Actuator Unit, 1C3569, Removal.
CAUTION
A. Disconnect hydraulic actuator unit, 1C3569 (figure 1). Remove reducers.
B. Connect head tube to HCU. Tighten coupling nut to 55-65 lb ft (75-88 N·m) of torque.
C. Connect rod tube to HCU. Tighten coupling nut to 460-540 lb in. (52.0-61.0 N·m) of torque.
%ODQN
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VARIABLE STATOR VANE (VSV)
STAGES 3 TO 5 BUSHING REPLACEMENT
(HIGH-BOSS HPC STATOR CASE)
())(&7,9,7</03)+,*+%266&$6(+3&67$725

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Alphabetical Index
Subject Page
HPC Stages 3 to 5 Bushing Replacement. ............................................................................................... 4
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1. Introduction.
This work package provides instruction for replacement of high-boss case stages 3 to 5 high pressure
compressor (HPC) variable stator vane (VSV) bushings on engine while engine is installed in the package.
Title Number
Variable Stator Vane (VSV) Actuator Component WP 1410 00
Replacement
Core Module External Tubing, Electrical Leads, and SWP 1913 02
Clamping
Engine Assembly External Tubing, Harnesses, and SWP 1913 04
Clamping
Gas Turbine External Inspection (Visual) WP 4012 00
Variable Stator Vane Off-Schedule Inspection WP 4028 00

Fixture Set, VSV Torque Measuring 1C9408G02
Fixture, Retention, HPC Variable Stator Vane 1C9412P01
Wrench, VSV Locknut Torque Break 1C9428G01
Wrench, VSV Spacer Spanner 2C6647G01
Handle, Stator Vane Tang Extension Local Manufacture
Pull Scale, Calibrated 0-50 lb Local Purchase
Pliers, Soft Jaw Local Purchase
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NOTE
Quantities below are for complete change for all three stages. Smaller quantities are required if individual
bushing changes are accomplished.

Bushing, Vane Actuation (Stg 3 and 4) 1704M66P05 92
Bushing, Vane Actuation (Stg 3 and 4 - above splitline, left 1704M68P09 02
side)
Bushing, Vane Actuation (Stg 3 and 4 - 2nd above splitline, left 1704M68P05 02
side)
Bushing, Vane Actuation (Stg 5) 1704M66P06 56
Bushing, Vane Actuation (Stg 5 - above splitline, left side) 1704M68P10 01
Bushing, Vane Actuation (Stg 5 - 2nd above splitline, left side) 1704M68P06 01
Sleeve, Actuation Ring (Stg 3, 4, and 5) 9146M80P03 AR
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6. HPC Stages 3 to 5 Bushing Replacement.
A. Before disassembly, inspect VSV actuation system for problems per applicable section of WP 4012 00 and
IGV to stage 5 stator vanes for off-schedule condition per WP 4028 00. Obtain vane retention fixture,
1C9412, or locally manufacture vane tang extension handle (figure 1).
B. Perform the following:
(1) Remove any interfering tubing or electrical cables per appropriate work packages (SWP 1913 02
and SWP 1913 04).
(2) Remove VSV actuation lever arms per WP 1410 00.
(3) Remove VSV connecting links as follows:
(a) Using marking pen, mark stage number on connecting links to be removed.
(b) Remove bolts, washers, and lineup pin from stages 3 and 4 connecting links and remove links
from actuation rings. Retain sleeves, if not damaged, for reinstallation.
(c) Remove bolts from stage 5 connecting links and remove links from actuation rings. Retain
sleeves, if not damaged, for reinstallation.
Figure 1. Locally Manufactured Vane Tang Extension Handle
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C. Remove any safety cable or safety wire from all bushings to be replaced. Ensure that all safety cable/safety
wire pieces are removed from VSV area to prevent binding in rotating elements and to prevent any cable or
wire from entering the HPC flowpath (FOD risk).
D. Starting at left horizontal splitline, aft looking forward, and working clockwise, number all bushings or
housing using marking pen.
NOTE
In the event that bushings are replaced randomly, i.e., not a complete stage is replaced, new bushings
should be marked, using the shallow vibropeen method, on the aft facing edge with the number of
engine hours at time of replacement. This will aid in identifying replaced bushings and determining
length of bushing service.
E. Starting at bushing or housing marked number 1, remove bushings or housing as follows (figure 2).
NOTE
It is recommended that the vane assemblies be disassembled and reassembled one at a time to ensure
that reusable parts are not mixed. If more than one vane assembly is to be disassembled at a time, care
must be taken to ensure that reusable parts are placed on the same vane assembly from which they
were removed.
(1) Note direction of V scribed in end of vane tang. Ensure apex of each V is pointing forward.
CAUTION
• EXTREME CAUTION MUST BE USED WHEN DISASSEMBLING VANE
BUSHINGS. ONCE THE BUSHING IS REMOVED, THE VANE MAY BE
EASILY DROPPED OR ROTATED IN THE CASE. THIS MAY CAUSE
DAMAGE TO THE VANE WHICH WOULD NECESSITATE
REPLACEMENT. CARE MUST BE TAKEN TO MAINTAIN CONTROL OF
THE VANE AT ALL TIMES WHILE THE BUSHING AND ATTACHING
HARDWARE ARE REMOVED, TO AVOID VANE DAMAGE AND NEED TO
REMOVE HPCS TOP CASE.
• MOVEMENT OF THE HPC ROTOR EVEN IN SMALL INCREMENTS
DURING BUSHING REMOVAL MAY CAUSE IRREPARABLE DAMAGE TO
THE VANE AND SCORING OF THE ROTOR SURFACE. EXTREME
CAUTION SHALL BE TAKEN TO ENSURE THAT THE ROTOR DOES NOT
TURN DURING THIS PROCEDURE.
(2) Remove locknut (1) and lever arm (2) as follows:
(a) Using torque break wrench, 1C9428, and channel-lock pliers (figure 3), loosen locknut
(1, figure 2) while providing countertorque on lever arm (2) body using soft jaw pliers.
(b) If torque break wrench, 1C9428, is not available, use standard socket or wrench to loosen
locknut (1), while providing countertorque on lever arm (2) body, using soft jaw pliers.
(c) Remove locknut (1) and lever arm (2).
(3) Inspect lever arm (2) for serviceability per WP 4012 00, table 8.

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(4) Remove actuation ring sleeve (10) from actuation ring (11).
CAUTION
WHEN USING A SCREWDRIVER TO HOLD VANE IN POSITION, DO NOT

APPLY EXCESSIVE FORCE ON VANE OR DAMAGE TO VANE WILL OCCUR.
A NONMETALLIC CONTACT SURFACE IS RECOMMENDED.
NOTE
When removing bushings from upper case or lower case near splitline, use step 6.E.(5).
When removing bushings from the lower case, use step 6.E.(6).
(5) Remove jamnut (3), alignment sleeve (4), and spacer (5) from upper case as follows:
(a) Hold vane (9) with spacer spanner wrench, 2C6647. Break torque on jamnut (3). Remove
wrench.
(b) Ensuring vane (9) does not turn, install vane retention fixture, 1C9412, or locally manufactured
tool onto end of vane stem.
(c) Insert small blade-tipped screwdriver under spacer (5). Gently lift spacer and alignment sleeve
(4) while slowly sliding screwdriver in until it contacts vane stem. Apply gentle force against
the vane stem to hold vane (9) in case. Remove vane retention fixture or locally manufactured
tool.
(d) While still maintaining force on vane stem with screwdriver, remove jamnut (3), alignment
sleeve (4), and spacer (5).
(e) Reinstall vane retention fixture on vane stem and remove screwdriver.
(6) Remove jamnut (3), alignment sleeve (4), and spacer (5) from lower case as follows:
(a) Hold vane (9) with spacer spanner wrench, 2C6647. Break torque on jamnut. Remove wrench.
(b) Remove jamnut (3), alignment sleeve (4), and spacer (5).
(c) Ensuring vane (9) does not turn, install vane retention fixture, 1C9412, or locally manufactured
fixture onto end of vane stem.
(7) Remove washer (8), housing (6), and bushing (13) as follows (figure 2):
(a) Examine housing (6) and securing bolts (7) to ensure that bolts are clamping housing in place.
If housings are loose, threaded holes in case must be examined to determine if repair is needed.
(b) Remove bolts (7) securing housing (6) to case.
(c) Remove washer (8), housing (6), and bushing (13) from case.
F. Clean HPC case in area of bushings, taking care to ensure that no material enters the HPC case. Remove all
preformed packing residue and inspect HPC case for damage per WP 4012 00.
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Figure 2. High-Boss Stages 3-5
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Figure 3. Locknut Removal Tool (High-Boss)
G. Inspect threaded holes in high-boss case (12). Ensure internal threads are not damaged.
H. Inspect vane tang and threaded stem for damage.
I. Install bushings (13) or housing (6) in case as follows (figure 2):
(1) Pre-assemble multiple-piece bushing assemblies as follows:
CAUTION
• PART NUMBERS ARE NOT MARKED ON NEW BUSHINGS AND ARE

DIFFICULT TO DIFFERENTIATE BY SIZE AND SHAPE. STAGE 5
BUSHINGS HAVE A PAINT MARKING ON BUSHING BARREL AND
STAGE 3 AND 4 BUSHINGS HAVE NO PAINT MARKINGS. FAILURE TO
ASSEMBLE CORRECTLY MAY CAUSE VSV OFF-SCHEDULE
OPERATION.
• PART NUMBERS ARE NOT MARKED ON NEW WASHERS AND ARE

DIFFICULT TO DIFFERENTIATE BY SIZE AND SHAPE. STAGE 5
WASHERS HAVE A PAINT MARKING ON WASHER FACE AND STAGES 3
AND 4 WASHERS HAVE NO PAINT MARKINGS. FAILURE TO ASSEMBLE
CORRECTLY MAY CAUSE VSV OFF-SCHEDULE OPERATION.
(a) Pre-assemble multiple-piece bushing assemblies for stages 3 and 4 as follows:
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1 Insert barrel end of unpainted stages 3 and 4 flanged bushing (13) inside barrel end of
stages 3 and 4 compressor stator vane actuation housing (6).
2 Insert unpainted stages 3 and 4 flat washer (8) in recessed area on housings assembled in
previous step.
(b) Pre-assemble multiple-piece bushing assemblies for stage 5 as follows:
1 Insert barrel end of painted stage 5 flanged bushing (13) inside barrel end of stage 5
compressor stator vane actuation housing (6).
2 Insert painted stage 5 flat washer (8) in recessed area on housings assembled in previous
step.
(2) Install multiple-piece bushing assemblies into HPCS cases as follows:
CAUTION
MULTIPLE-PIECE BUSHING ASSEMBLIES WITH CUTOUTS ARE INSTALLED
AT BORESCOPE LOCATIONS. IMPROPER INSTALLATION WILL PREVENT
BORESCOPE USE.
(a) Install multiple-piece bushing assemblies, pre-assembled in step 6.I.(1)(a), into HPCS stages 3
and 4 high-boss case outer bores.
(b) Install multiple-piece bushing assemblies with cutouts, pre-assembled in step 6.I.(1)(a), into
HPCS stages 3 and 4 high-boss case outer bores adjacent to borescope ports.
(c) Verify that borescope ports in stages 3 and 4 are not blocked. If blocked, repeat step 6.I.(1). If
not blocked, perform remaining installation steps.
(d) Install multiple-piece bushing assemblies, pre-assembled in step 6.I.(1)(b), into HPCS stage 5
high-boss case outer bores.
CAUTION
THE BOLTS, J644P04F, ARE NON-SELF-LOCKING BOLTS AND MUST
BE SAFETY-WIRED OR BOLTS MAY VIBRATE LOOSE.
(3) Visually check for evidence of locking feature on bolts (7), PN 1855M35P08. Lightly coat threads
and seating surfaces of bolts with thread lubricant.
(4) Secure previously installed housing (6) onto high-boss case (12) as follows:
(a) Secure each housing (6) that is not located adjacent to a borescope plug onto high-boss case
(12) as follows:
1 Install two self-locking bolts (7), PN 1855M35P08, through housing (6) boltholes and into
high-boss case (12) by hand.
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2 If self-locking bolt (7), PN 1855M35P08, can be run into case without stopping,
self-locking feature is not adequate. Replace bolt with new self-locking bolt (7), PN
1855M35P08.
3 If self-locking bolt (7), PN 1855M35P08, can still be run into case without stopping,
bolthole condition does not allow self-locking feature to engage. Use two non-self locking
bolts (7), PN J644P04F, to secure housing (6) so they may be safety-wired. Tighten bolts
hand-tight.
4 If two self-locking bolts (7), PN 1855M35P08, are used to secure housing (6), make sure
installation (run-on) torque of each bolt does not exceed 40 lb in. (4.5 N·m). If maximum
run-on torque is exceeded, replace bolt with new bolt (7), PN 1855M35P08, and re-check.
5 Final-tighten bolts (7), J644P04F, to 109-127 lb in. (12.4-14.3 N·m) of torque and
self-locking bolts (7), 1855M35P08, to 85-105 lb in. (9.7-11.8 N·m) of torque.
6 Safety-wire non-self-locking bolts (7), PN J644P04F.
(b) Secure each housing (6) that is located adjacent to a borescope plug onto high-boss case (12) as
follows:
1 Install one non-self-locking bolt (7), PN J644P04F, through housing (6) bolthole adjacent
to borescope plug and into case (12). Tighten bolt hand-tight.
2 Install one self-locking bolt (7), PN 1855M35P08, through remaining housing (6) bolthole
and into high-boss case (12) by hand.
3 If self-locking bolt (7), PN 1855M35P08, can be run into case without stopping,
self-locking feature is not adequate. Replace bolt with new self-locking bolt (7),
PN 1855M35P08.
4 If self-locking bolt (7), PN 1855M35P08, can still be run into case without stopping,
bolthole condition does not allow self-locking feature to engage. Replace bolt with
non-self-locking bolt (7), PN J644P04F, so bolt may be safety-wired.
5 If self-locking bolt (7), PN 1855M35P08, is used to secure housing (6), make sure
installation (run-on) torque of bolt does not exceed 40 lb in. (4.5 N·m). If maximum run-on
torque is exceeded, replace bolt with new self-locking bolt (7), PN 1855M35P08, and
re-check.
6 Final-tighten bolts (7), PN J644P04F, to 109-127 lb in. (12.4-14.3 N·m) of torque and
self-locking bolts (7), PN 1855M35P08, to 85-105 lb in. (9.7-11.8 N·m) of torque.
7 If one self-locking bolt (7), PN 1855M35P08, and one non-self-locking bolt (7),
PN J644P04F, are used to secure housing (6), safety-wire non-self-locking bolt (7),
PN J644P04F, to adjacent borescope plug.
8 If two non-self-locking bolts (7), PN J644P04F, are used to secure housing (6), safety-wire
two non-self-locking bolts (7), PN J644P04F, and adjacent borescope plug.

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CAUTION
WHEN USING A SCREWDRIVER TO HOLD VANE IN POSITION, DO NOT

APPLY EXCESSIVE FORCE ON VANE OR DAMAGE TO VANE WILL OCCUR.
A NONMETALLIC CONTACT SURFACE IS RECOMMENDED.
NOTE
When installing spacer (5), alignment sleeve (4), and jamnut (3) in upper case or lower
case near splitline, use step 6.I.(5). When installation is in lower case, use step 6.I.(6).
(5) Install spacer (5), alignment sleeve (4), and jamnut (3) into upper case as follows:
(a) Using small blade tipped screwdriver, apply gentle force against vane stem to hold vane (9) in
position.
(b) Ensuring vane (9) does not turn, remove vane retention fixture.
(c) Install spacer (5) and alignment sleeve (4) onto vane (9). Flat on alignment sleeve faces
forward.
(d) Install jamnut (3) onto vane (9).
(e) Remove screwdriver.
(f) Install spacer spanner wrench, 2C6647, or soft jaw pliers over spacer (5) to hold vane (9).
(g) Tighten jamnut (3) to 50-70 lb in. (5.7-7.9 N·m) of torque. Replace jamnut if run-on torque
exceeds 20 lb in. (2.3 N·m).
(h) Remove spanner wrench, 2C6647, or soft jaw pliers.
(6) Install spacer (5), alignment sleeve (4), and jamnut (3) into lower case as follows:
(a) Ensuring vane does not turn, remove vane retention fixture.
(b) Install spacer (5) and alignment sleeve (4) onto vane (9). Flat on alignment sleeve faces
forward.
(c) Install jamnut (3) onto vane (9).
(d) Install spacer spanner wrench, 2C6647, over spacer to hold vane.
(e) Tighten jamnut (3) to 50-70 lb in. (5.7-7.9 N·m) of torque. Replace jamnut if run-on torque
exceeds 20 lb in. (2.3 N·m).
(f) Remove spanner wrench, 2C6647, or soft jaw pliers.

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CAUTION
ENSURE THAT ALL STAGES 3-5 STATOR VANES HAVE THE LETTER
V MARKED AT TOP OF VANE STEM. APEX OF V SHALL POINT
FORWARD. FAILURE TO COMPLY MAY RESULT IN SERIOUS
ENGINE OR PART DAMAGE.
NOTE
A 0.0 lb in. (0.0 N·m) torque limit implies that vane can rotate with a minimum
force applied. However, it is important to ensure that the vane assembly is not
loose after assembly as a result of a spacer that is too thin. Vane assembly
should be tight and should not rattle or demonstrate any looseness.
(7) Check and adjust vane rotational torque as follows:
(a) Manually rotate vane (9) several times to ensure vane is seated.
(b) Ensure vane rotational torque is within range of 0-10 lb in. (0.0-1.1 N·m).
(c) Replace spacer (5) as required to obtain proper rotational torque. A thinner spacer will reduce
rotational torque. A thicker spacer will increase rotational torque.
(d) Small changes to vane rotational torque may be accomplished by lapping spacer (5) face, using
a figure eight motion to remove material. Final surface finish shall match original.
(e) Record rotational torque.
(8) Install new actuation ring sleeve (10) into actuation ring (11).
(9) Install lever arm (2) onto vane (9). Flat on lever arm faces forward. Insert pin end of lever arm into
actuation ring sleeve.
(10) Install locknut (1) onto vane (9) by hand. If nuts can be run onto vane without stopping, self-locking
feature is not adequate. Replace nut with new nut. Tighten locknut to 50-70 lb in. (5.7-7.9 N·m) of
torque. Take care when torquing nut to prevent lever arm damage.
J. Once all bushings in a stage have been replaced, perform actuation ring pull check as follows:
NOTE
There are two methods for performing the actuation ring pull check. The first uses the torque
measuring fixture set, 1C9408, and the other uses a pull scale. Perform only the paragraphs that
correspond with the method used.
(1) Using torque measuring fixture set, 1C9408, perform pull check on stages 3-5 as follows:
(a) Remove parts from vane near center of actuation ring (figure 4).
(b) Remove sleeve from actuation ring.
(c) Install dummy lever arm, locator plug, and drive adapter from fixture set, 1C9408.
(d) Tighten locator plug to 50-70 lb in. (5.7-7.9 N·m) of torque.

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(e) Measure torque required to move actuation ring +5 degrees from axial position (figure 5). On
stages 3 and 4, torque required shall not exceed 140 lb in. (15.8 N·m). On stage 5, torque
required shall not exceed 204 lb in. (23.0 N·m).
(2) Using a pull scale, perform pull check as follows:
(a) Install slave bolt into actuation ring connecting link bolthole.
(b) Attach pull scale to slave bolt.
(c) Measure force required to move actuation ring +5 degrees from axial position. Multiply reading
by the following scale factors to obtain torque:
Stage Scale Factor

3 2.18 inch (55.4 mm)
4 1.92 inch (48.8 mm)
5 1.46 inch (37.1 mm)
(d) On stages 3 and 4, torque required shall not exceed 140 lb in. (15.8 N·m). On stage 5, torque
(3) Actuate each stage by hand, through complete open and closed mechanical travel. Each stage shall
move freely with no catching or binding.
(4) If pull check requirements are not met, perform the following:
(a) Check actuation ring spacer clearance (figure 6). Adjust as required.
(b) Check for vane binding at casing bore. Correct as required.
(c) Check recorded rotational torques for individual vanes per step 6.I.(7). Replace or rework
spacers on vanes with high torques per step 6.I.(5) and step 6.I.(6).
(d) Repeat step 6.J.(4)(a) through step 6.J.(4)(c) as necessary to bring torque values into range
required.
K. Reassemble VSV actuating ring connecting links as follows:
(1) Install sleeves into connecting link ID. Ensure connecting link is correct for stage being installed.
(2) Position connecting link onto actuation rings, ensuring FWD marking faces forward. Install stage
3 and 4 lineup pins, ensuring lever arm pins engage sleeves.
(3) Install bolts. Tighten bolts to 57-67 lb in. (6.5-7.5 N·m) of torque and safety-wire or safety-cable.
(4) Ensure that all lever arm pins are engaged in sleeves and not engaged with connecting link
lightening holes.
L. Reinstall actuation levers per WP 1410 00.
M. Reconnect all piping and electrical connections per appropriate work packages.

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Figure 4. VSV Actuation Ring Pull Check

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Figure 5. VSV Actuation Ring Travel
Figure 6. Actuation Ring Spacer Clearance
%ODQN
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GAS FUEL SYSTEM REPLACEMENT
())(&7,9,7</03)*$6785%,1(02'(/6

Page No. Change No.
1 - 61 ....................................................................................................................................................... 0
62 Blank .................................................................................................................................................. 0
Alphabetical Index
Subject Page
Acoustic Baffles and Fuel Nozzle Plugs Installation............................................................................. 12

Acoustic Baffles and Fuel Nozzle Plugs Removal ................................................................................ 12
Fuel Hose Assembly Installation ............................................................................................................ 7
Fuel Hose Assembly Removal................................................................................................................ 3
Fuel Nozzle Installation ......................................................................................................................... 13
Fuel Nozzle Removal............................................................................................................................. 13
Staging Valves and Jumper Tube Installation ........................................................................................ 15
Staging Valves and Jumper Tube Removal............................................................................................ 15
Tubular Fuel Manifold Installation ........................................................................................................ 42
Tubular Fuel Manifold Removal............................................................................................................ 24
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1. Introduction.
This work package provides instructions for the removal and installation of the tubular fuel manifold
used on LM6000 engines. Instructions for the removal and installation of associated fuel system
components is covered as well. Reference kit 738L677.
Title Number
Dual Fuel Manifold Support Fixture Replacement WP 3015 00

Tool, Remove/Install - Fuel Nozzle 1C9427G01
Fixture, Support-Dual Fuel Manifold 1C9621G01 (Gas Systems Only) or 1C9621G03
(Gas and Liquid Systems)
(Optional)
Lubricating Oil MIL-PRF-23699 (C/I)
Marking Pen Sharpie T.E.C.
(Black or Blue)
Tape Local Purchase

Gasket L54659P01 5
Gasket, Seal - Flange J1215P17 18
Seal, Case Hose L42604P01 30
Seal, Fuel Nozzle L47618P01 30
Seal, Manifold Valve L42602P01 13
Seal Ring, Metal C L52068P01 60
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6. Fuel Hose Assembly Removal.
A. Remove fuel hose assembly at even number fuel nozzle locations as follows:
CAUTION
COVER OPEN FUEL MANIFOLD AND FUEL NOZZLE PORTS IMMEDIATELY

AFTER REMOVAL OF EACH FUEL HOSE ASSEMBLY TO PREVENT ENGINE
CONTAMINATION.
(1) Disconnect fuel hose assembly from fuel manifolds (figure 1) as follows:
NOTE
• Aft-most fuel hoses at even numbered fuel nozzles are connected to C-manifold.
• Middle fuel hoses at all fuel nozzles are connected to A-manifold.
• Forward-most fuel hoses at even numbered fuel nozzles are connected to

B3-manifold.
NOTE
There is a loop clamp installed on fuel hose routed to the C-manifold and a loop
clamp installed on the fuel hose routed to the A-manifold. The loop clamps are
attached together to maintain space between the hoses.
(a) If required, remove self-locking nut and bolt that secures two loop clamps together and
remove loop clamp from fuel hose routed to A- or C-manifold.
(b) Loosen B-nut that secures fuel hose to check valve at C-manifold. Disconnect fuel hose
from fuel check valve.
(c) If required, loosen B-nut and remove check valve from C-manifold.
(d) Loosen B-nut that secures fuel hose to A-manifold. Disconnect fuel hose from fuel
manifold.
(e) Loosen B-nut that secures fuel hose to B3-manifold. Disconnect fuel hose from fuel
manifold.
(2) Remove bolts (7, figure 2) that secure fuel hose assembly (8) to fuel nozzle (6). Remove fuel
hose assembly.
(3) Remove and discard hose seal (9).
(4) Cover open fuel nozzle port with tape.
(5) Repeat step 6.A.(1) through step 6.A.(4) to remove as many fuel hose assemblies as required to
perform maintenance.
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Figure 1. Fuel Hose Replacement
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Figure 2. Acoustic Baffles, Fuel Nozzle Plugs, and fuel Nozzles (Sheet 1 of 2)
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Figure 2. Acoustic Baffles, Fuel Nozzle Plugs, and fuel Nozzles (Sheet 2 of 2)
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B. Remove fuel hose assembly at odd number fuel nozzle locations as follows:
CAUTION

CONTAMINATION.
NOTE
• Aft-most fuel hoses at odd numbered fuel nozzles are connected to enhanced lean
blow out (ELBO) manifold.
• Forward-most fuel hoses at odd numbered fuel nozzles are connected to

B2-manifold.
(a) Loosen B-nut that secures fuel hose to ELBO manifold. Disconnect fuel hose from fuel
manifold.
(b) Loosen B-nut that secures fuel hose to A-manifold. Disconnect fuel hose from fuel
manifold.
(c) Loosen B-nut that secures fuel hose to B2-manifold. Disconnect fuel hose from manifold.
(2) Remove bolts (7, figure 2) that secure fuel hose assembly (8) to fuel nozzle (6). Remove fuel
hose assembly.
(3) Remove and discard hose seal (9).
(5) Repeat step 6.B.(1) through step 6.B.(4) to remove as many fuel hose assemblies as required to
7. Fuel Hose Assembly Installation.
A. Install fuel hose assemblies (figure 2) at odd number fuel nozzle locations as follows:
1) Remove tape from fuel nozzle port.
(2) Install new hose seal (9) between fuel hose assembly (8) plate and fuel nozzle (6).
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(3) Lightly coat threads and contact faces of four bolts (7) with thread lubricant.
CAUTION
• EXCESSIVE TORQUE ON ONE BOLT WILL RESULT IN FUEL HOSE PAD

IMPROPERLY SEATING ONTO FUEL NOZZLE.
• IMPROPER SEATING OF FUEL HOSE WILL RESULT IN FUEL LEAKAGE

DURING ENGINE OPERATION.
• DO NOT EXCEED 15 LB IN. (1.7 N·M) OF TORQUE DURING SEATING OF

HOSE ASSEMBLY PLATE ONTO FUEL NOZZLE OR DISTORTION OF FUEL
NOZZLE MAY OCCUR.
• ENSURE THAT GRAPHITE GREASE (THREAD LUBRICANT) DOES NOT

CONTAMINATE FUEL WETTED SURFACES.
(4) Install four bolts (7) hand-tight to seat fuel hose assembly (8) onto fuel nozzle (6).
(5) Connect aft-most fuel hoses onto ELBO manifold (figure 1) as follows:
WARNING
LUBRICATING OIL, MIL-PRF-23699 (C/I): COMBUSTIBLE. DO NOT

INHALE, INGEST, OR LET THIS MATERIAL TOUCH YOU. IRRITANT.
PERSONAL PROTECTIVE EQUIPMENT REQUIRED. USE
MECHANICAL EXHAUST VENTILATION - IF NOT AVAILABLE, USE
AN APPROVED RESPIRATOR.
(a) Lightly coat B-nut fitting on ELBO manifold with lubricating oil.
(b) Slide B-nut back on aft-most fuel hose. Lubricate ferrule with lubricating oil.
(c) Install B-nut hand-tight onto ELBO manifold.
6) Connect middle fuel hoses onto A-manifold as follows:
(a) Lightly coat B-nut fitting on A-manifold with lubricating oil.
(b) Slide B-nut back on middle fuel hose. Lubricate ferrule with lubricating oil.
(c) Install B-nut hand-tight onto A-manifold.
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(7) Connect forward-most fuel hoses onto B2-manifold as follows:
WARNING

(a) Lightly coat B-nut fitting on B2-manifold with lubricating oil.
(b) Slide B-nut back on forward-most fuel hose. Lubricate ferrule with lubricating oil.
(c) Install B-nut hand-tight onto B2-manifold.
B. Install fuel hose assemblies at even number fuel nozzle locations as follows:
(1) Install hose assembly (8, figure 2) onto fuel nozzle (6) per step 7.A.(1) through step 7.A.(4).
(2) Connect aft-most fuel hoses onto C-manifold (figure 1) as follows:
(a) Lightly coat B-nut fitting on C-manifold with lubricating oil.
(b) If check valve is removed, lightly coat ferrule on check valve with lubricating oil.
(c) Install check valve onto C-manifold hand-tight.
(d) Slide B-nut back on aft-most fuel hose. Lubricate ferrule with lubricating oil.
(e) Install fuel hose B-nut onto check valve hand-tight.
(3) Connect middle fuel hoses onto A-manifold as follows:
NOTE
There is a loop clamp installed on the fuel hose routed to the C-manifold and a loop clamp
installed on the fuel hose routed to the A-manifold. The loop clamps are attached together
to maintain space between the hoses.
(4) Install loop clamp onto fuel hose routed to C-manifold and install loop clamp onto fuel hose
routed to A-manifold as follows:
(a) Install one loop clamp onto fuel hose midway between C-manifold and fuel nozzle with
loop facing aft.
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(b) Install one loop clamp onto fuel hose midway between A-manifold and fuel nozzle with
loop facing forward.
(c) Lightly coat self-locking nut and bolt that secure two loop clamps together with thread
lubricant.
(d) Using self-locking nut and bolt, secure two loop clamps together. Tighten nut hand-tight.
(e) Adjust clamps to maintain space and avoid contact between hoses.
(f) Tighten self-locking nut to 60-70 lb in. (6.8-7.9 N·m) of torque.
(5) Connect forward-most fuel hoses onto B3-manifold as follows:
WARNING

(b) Slide B-nut back on forward-most fuel hose. Lubricate ferrule with lubricating oil.
C. After all fuel hose assemblies that were removed have been reinstalled, perform following steps:
(1) Refer to figure 2, view B for bolt numbers, and sequentially final-tighten bolts that secure fuel
hose assembly plates onto fuel nozzle pads as follows:
(a) Tighten bolts in a sequence of bolt No. 3, bolt No. 1, bolt No. 4, and bolt No. 2 to
46-54 lb in. (5.2-6.1 N·m) of torque. Repeat three times to ensure bolts are equally
tightened.
(b) Tighten bolts in a sequence of bolt No. 3, bolt No. 1, bolt No. 4, and bolt No. 2 to
tightened.
(c) Tighten bolts in a sequence of bolt No. 1, bolt No. 3, bolt No. 2, and bolt No. 4 to
tightened.
(d) Tighten bolts in a sequence of bolt No. 3, bolt No. 1, bolt No. 4, and bolt No. 2 to
tightened.
(e) Safety-wire four bolts at fuel nozzle.

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CAUTION
ENSURE ALIGNMENT STRIPE ON FLEX FUEL HOSE IS NOT TWISTED, OR

PREMATURE HOSE FAILURE MAY OCCUR.
(2) Final tighten B-nuts that secure fuel hoses onto manifolds as follows:
(a) Final tighten B-nuts that secure fuel hoses onto A-, B2-, B3-, and ELBO manifolds
(manifolds with no check valves) as follows:
1 Tighten B-nuts to 460-540 lb in. (52.0-61.0 N·m) of torque at each joint sequentially
around in a CW direction, ALF.
2 Loosen until B-nut is free running and retighten to 460-540 lb in. (52.0-61.0 N·m) of
torque at each joint sequentially around in a CW direction, ALF.
3 Check joint by reapplying 460-540 lb in. (52.0-61.0 N·m) of torque to the B-nut in the
tightening direction at each joint sequentially around in a CW direction, ALF.
(b) Final tighten B-nuts that secure check valves onto C-manifold at 15 locations as follows:
1 Restrain check valve with wrench and tighten B-nuts to 460-540 lb in. (52.0-61.0 N·m)
of torque at each joint sequentially around in a CW direction, ALF.
2 Restrain check valve with wrench and loosen until B-nut is free running and retighten to
460-540 lb in. (52.0-61.0 N·m) of torque at each joint sequentially around in a CW
direction, ALF.
3 Restrain check valve with wrench and check joint by reapplying 460-540 lb in.
(52.0-61.0 N·m) of torque to the B-nut in the tightening direction at each joint
sequentially around in a CW direction, ALF.
(c) Final tighten B-nuts that secure fuel hoses onto check valves at 15 locations as follows:
1 Restrain check valve with wrench and tighten fuel hose B-nuts to 460-540 lb in.
(52.0-61.0 N·m) of torque at each joint sequentially around in a CW direction, ALF.
2 Restrain check valve with wrench and loosen until fuel hose B-nut is free running and
retighten to 460-540 lb in. (52.0-61.0 N·m) of torque at each joint sequentially around
in a CW direction, ALF.
3 Restrain check valve with wrench and check joint by reapplying 460-540 lb in.
(52.0-61.0 N·m) of torque to the fuel hose B-nut in the tightening direction at each joint
sequentially around in a CW direction, ALF.

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8. Acoustic Baffles and Fuel Nozzle Plugs Removal.
NOTE
There are 30 fuel nozzle ports located in compressor rear frame (CRF). There are 18 acoustic
baffles (two different lengths) and 12 fuel nozzle plugs.
A. Remove acoustic baffle and/or fuel nozzle plug as follows:
(1) Starting at 12:00 o'clock position, indexing counterclockwise (forward looking aft), number
acoustic baffles and fuel nozzle plugs (figure 2).
CAUTION
COVER OPEN FUEL NOZZLE PORT IMMEDIATELY AFTER REMOVAL OF EACH

ACOUSTIC BAFFLE OR FUEL NOZZLE PLUG TO PREVENT ENGINE
CONTAMINATION.
NOTE
Various brackets shall require removal with fuel nozzle plugs. Ensure brackets are tagged
for location and orientation prior to removal.
(2) Remove bolts (1 and 2) that secure acoustic baffle (3 or 4) or fuel nozzle plug (5) to fuel nozzle
(6). Remove acoustic baffle or fuel nozzle plug.
(4) Remove and inspect metal seal rings (10) and replace if required.
(5) Repeat step 8.A.(1) through step 8.A.(4) to remove as many acoustic baffles and/or fuel nozzle
plugs as required to perform maintenance.
9. Acoustic Baffles and Fuel Nozzle Plugs Installation.
A. Lightly coat threads and contact faces of bolts (1 and 2, figure 2), with thread lubricant.
B. Remove tape from fuel nozzle port. Install metal seal rings (10) onto fuel nozzle.
C. Install correct acoustic baffle (3 or 4) or fuel nozzle plug (5) onto correct fuel nozzle.
D. Using two short bolts (1), secure fuel nozzle plug (5) or acoustic baffle (3 or 4) onto fuel nozzle (6).
Tighten bolts hand-tight.
E. Using two long bolts (2), secure fuel nozzle plug (5) or acoustic baffle (3 or 4) onto fuel nozzle (6).
F. Using crisscross pattern, incrementally tighten bolts (1 and 2) to 202-238 lb in. (22.9-26.8 N·m) of
torque and safety-wire.

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10. Fuel Nozzle Removal.
A. Remove fuel nozzle as follows:
(1) Start at 12:00 o'clock position. Moving counterclockwise (forward looking aft), use marking pen
to number fuel nozzles on CRF (13) from 1 to 30 (figure 2).
(2) Remove fuel hose assembly per paragraph 6.
(3) Remove acoustic baffle and/or fuel nozzle plug per paragraph 8.
(4) Using four capscrews, install fuel nozzle removal/installation tool, 1C9427, onto fuel nozzle
(figure 3).
CAUTION
COVER OPEN CRF PORT IMMEDIATELY AFTER REMOVAL OF EACH
FUEL NOZZLE TO PREVENT ENGINE CONTAMINATION.
(5) Remove remaining four bolts (11, figure 2) and spacers (12) that secure fuel nozzle (6) to CRF
(13).
(6) Remove fuel nozzle from CRF (13).
(7) Remove and discard fuel nozzle seal (14).
(8) Using tape, cover CRF (13) port.
(9) Remove fuel nozzle removal/installation tool, 1C9427, from fuel nozzle.
(10) Repeat step 10.A. (1) through step 10.A.(9), as required, to perform required maintenance.
11. Fuel Nozzle Installation.
A. Install fuel nozzle as follows:
(figure 3).
(2) Apply thread lubricant onto threads and contact faces of bolts (11, figure 2, detail A) that secure
fuel nozzle (6) onto CRF (13).
(3) Remove tape from CRF (13) port.
(4) Install fuel nozzle seal (14) onto fuel nozzle (6).

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Figure 3. Fuel Nozzle Removal/Installation Tool, 1C9427
CAUTION
• USE CARE WHEN INSTALLING FUEL NOZZLES. DO NOT FORCE FUEL

NOZZLES INTO POSITION, OR DAMAGE COULD RESULT.
• INSTALL 3-CUP FUEL NOZZLES INTO EVEN NUMBER CRF PORTS AND
2-CUP FUEL NOZZLES INTO ODD NUMBER CRF PORTS, OR DAMAGE
COULD RESULT.
(5) Install correct fuel nozzle (6) into CRF (13) port.
(6) Using four bolts (11, figure 2, detail A) and spacers (12), attach fuel nozzle (6) onto CRF (13).
Tighten bolts finger-tight.
(7) Remove fuel nozzle removal/installation tool (figure 3), 1C9427, from fuel nozzle.
(8) Install correct acoustic baffle (3 or 4, figure 2), or fuel nozzle plug (5) onto correct fuel nozzle.
(9) Apply thread lubricant to threads and faces of short bolts (1) and long bolts (2) that secure acoustic
baffles and/or fuel nozzle plugs onto fuel nozzle.
(10) Using two short bolts (1), secure fuel nozzle plug (5), or acoustic baffle (3 or 4) onto fuel nozzle
(6). Tighten bolts finger-tight.

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(11) Using two long bolts (2), secure fuel nozzle plug (5), or acoustic baffle (3 or 4) onto fuel nozzle
(6). Tighten bolts finger-tight.
(12) Using crisscross pattern, incrementally tighten two bolts (2) and four bolts (11) (center two bolts
first) to 202-238 lb in. (22.9-26.8 N·m) of torque and safety-wire.
(13) Tighten two short bolts (1) to 202-238 lb in. (22.9-26.8 N·m) of torque and safety-wire.
12. Staging Valves and Jumper Tube Removal.
A. Remove staging valve from valve rack bracket, support bracket, or valve bracket (figure 4) as
follows:
WARNING

(1) Loosen and disconnect electrical harness connector from staging valve connector.
(2) Remove four bolts (2) that secure staging valve (3) to adapter plate (25).
(3) Remove staging valve from adapter plates at valve rack brackets (1 and 9), valve bracket (35),
and support bracket (36).
(4) Remove and discard gasket (4).
(5) Cover adapter plate port with tape.
B. Remove jumper tube from valve bracket as follows:
(1) Remove four bolts (2) that secure jumper tube (52) to adapter plate (25).
(2) Remove jumper tube from adapter plate at valve bracket (51).
13. Staging Valves and Jumper Tube Installation.
A. Install jumper tube onto valve bracket (figure 4) as follows:
(1) Remove tape from adapter plate (25).
(2) Lightly coat bolt (2) threads and contact faces with thread lubricant.
(3) Install new gasket (4) onto jumper tube (52).

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Figure 4. Manifold Assembly - Aft View (Sheet 1 of 7)

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(4) Place jumper tube onto adapter plate (25).
(5) Using four bolts (2), secure jumper tube (52) onto adapter plate (25) at valve bracket (51).
(6) Using running torque, tighten four bolts (2) in a sequence of bolt No. 2, bolt No. 4, bolt No. 3,
and bolt No. 1. Refer to figure 4, view C for bolt numbers.
(7) Loosen bolt No. 2 and retighten to its running torque.
(8) Tighten bolts in a sequence of bolt No. 4, bolt No. 2, bolt No. 1, and bolt No. 3 to 50-58 lb in.
(5.7-6.5 N·m) of torque. Repeat three times to ensure bolts are equally tightened.
B. Install staging valve onto valve rack bracket, support bracket, or valve bracket (figure 4) as follows:
(3) Install new gasket (4) onto staging valve (3).
NOTE
• All staging valves installed on valve rack brackets and support bracket have electrical
connectors pointing forward.
• Staging valve installed on valve bracket attached to B2-manifold has electrical

connector pointing aft.
(4) Place staging valve (3) onto adapter plate (25).
(5) Using four bolts (2), secure staging valve (3) onto adapter plate (25) at valve rack brackets (1 and
9), valve bracket (35), and support bracket (36). Tighten bolts hand-tight.
(6) Final tighten bolts per step 13.A.(6) through step 13.A.(11).

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WARNING

C. Connect staging valve onto electrical harness as follows:
(1) Engage electrical harness connector onto staging valve connector.
(2) Turn knurled coupling ring while wiggling backshell of electrical connector.
(3) Fully seat electrical harness connector by hand.
(5) Check tightness by wiggling connector backshell. No movement shall occur.
14. Tubular Fuel Manifold Removal.
A. Disconnect all fuel and electrical connections from fuel system and secure per packager's manual.
NOTE
Dual fuel manifold support fixture, 1C9621G01, can only be used on gas turbines with a gas
fuel system. The dual fuel manifold support fixture, 1C9621G03, can be used for either gas
turbines with a gas fuel system or a gas and liquid fuel system.
B. Install dual fuel manifold support fixture, 1C9621, per WP 3015 00.
C. Remove enclosure fuel manifold supports per packager's manual.
D. Remove electrical harnesses (41, 42, and 43, figure 4) and harness support brackets (5 and 8) as
follows:
(1) Disconnect electrical harnesses (41, 42, and 43) connectors from staging valves.
(2) Remove self-locking nut (45, view P), bolt (46), and loop clamp (47) that secure electrical
harness (42) to valve rack bracket (9) at 9:30 o'clock position, ALF, then remove loop clamp (50)
that secures electrical harness (41) to valve rack bracket (9).
(3) Remove self-locking nut (45), bolt (46), and loop clamp (48) that secure electrical harness (41) to
valve rack bracket (9) at 8:30 o'clock position, ALF, then remove loop clamp (50) that secures
electrical harness (42) to valve rack bracket (9).
(4) Remove self-locking nut (45, view P), bolt (46), and loop clamp (49) that secure electrical
harness (41) to valve rack bracket (9) at 7:30 o'clock position, ALF.

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(5) Remove bolt (53, figure 4, view S) and loop clamp (54) that secure electrical harness (42) to fuel
tube (28) integral bracket.
(6) Remove screws (6, view A) and self-locking nuts (7) that secure electrical harness (41)
connector to harness support bracket (8).
(7) Remove screws (33) and self-locking nuts (34) that secure electrical harness (42) connector to
harness support bracket (8).
(8) Remove electrical harnesses (41 and 42).
(9) Remove self-locking nut (45, view R), bolt (46), and loop clamp (47) that secure electrical
harness (43) to valve rack bracket (1) at 2:30 o'clock position, ALF.
valve rack bracket (1) at 3:30 o'clock position, ALF.
(12) Remove self-locking nut (45, view B), bolt (46), and loop clamp (47) that secure electrical
harness (43) to harness support bracket (5).
(13) Remove screws (6, view B) and self-locking nuts (7) that secure electrical harness (43) connector
to harness support bracket (5).
(14) Remove electrical harness (43).
(15) If required, remove bolts (40, view B) that secure harness support bracket (5) to valve rack
bracket (1).
(16) If required, remove bolts (40, view A) that secure harness support bracket (8) to valve rack
bracket (9).
E. Remove staging valves and jumper tube per paragraph 12.
F. Remove fuel hoses as follows:
(1) Remove fuel hoses from B2-manifold, B3-manifold, ELBO assembly, C-manifold, and
A-manifold per paragraph 6.
(2) If required, remove fuel hose assembly from fuel nozzle per paragraph 6.

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G. Remove adapter plates as follows:
(1) Remove four bolts (26, figure 4) that secure two fuel tubes to adapter plates (25) at 10 locations
on valve rack brackets (1 and 9), one location on valve brackets (35 and 51), and support bracket
(36).
(2) Remove four bolts (44) that secure adapter plate (25) to valve rack brackets (1 or 9), support
bracket (36), and valve brackets (35 and 51). Remove adapter plate.
H. Remove A-manifold fuel tubes as follows:
(1) Remove four bolts (2, figure 5) and self-locking nuts (3) that secure fuel tube (5) to A-manifold.
Remove fuel tube (5) and discard gasket (4).
(2) Remove four bolts (2) and self-locking nuts (3) that secure fuel tube (7) to A-manifold. Remove
fuel tube (7) and discard gasket (4).
fuel tube and discard gasket (4).
(6) Remove eight bolts (10) and self-locking nuts (11) that secure fuel tube (13) to fuel tube (6).
(7) Remove U-bolts (9, figure 6, section B-B) and self-locking nuts (7) that secure fuel tube (8) to
bracket (3).
(8) Remove U-bolts (13, figure 6, section A-A) and self-locking nuts (7) that secure fuel tube (12) to
bracket (5).
(9) Remove U-bolt (23, figure 4, section H-H) and self-locking nuts (24) that secure fuel tube (22) to
bracket (19).
(10) Remove fuel tubes (6 and 13, figure 5) and discard gasket (12).

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Figure 5. A-Manifold

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Figure 6. Fuel Manifold-Forward Side (Sheet 1 of 2)

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Figure 6. Fuel Manifold-Forward Side (Sheet 2 of 2)
J. Remove C-manifold fuel tubes as follows:
(1) Remove four bolts (2, figure 7) and self-locking nuts (3) that secure fuel tube (5) to C-manifold.
(2) Remove four bolts (2) and self-locking nuts (3) that secure fuel tube (9) to C-manifold. Remove
(7) Remove U-bolt (11, figure 6, section B-B) and self-locking nuts (7) that secure fuel tube (10) to
bracket (2).

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Figure 7. C-Manifold

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(8) Remove U-bolt (15, figure 6, section A-A) and self-locking nuts (7) that secure fuel tube (14) to
bracket (4).
bracket (19).
K. Remove bolts (1, figure 6) that secure brackets (2, 3, 4, and 5) to valve rack brackets (6 and 16).
Remove brackets.
L. Remove A-manifold as follows:
(1) Remove bolts (8, figure 5) and self-locking nuts (9) that secure A-manifold fuel tube (1) at
12:30 o'clock position.
(2) Remove bolts (8) and self-locking nuts (9) that secure A-manifold fuel tube (1) at 2:30 o'clock
position.
position.
position.
position.
(6) Remove bolts (12, figure 4) and loop clamps (11) that secure A-manifold (13) at two locations
(section G-G).
(7) Remove bolts (12) and loop clamps (11) that secure A-manifold (13) to brackets (10) at two
locations (section E-E).
(8) Remove bolt (12, view J) and loop clamp (11) that secure A-manifold (13) to valve bracket (35).
(9) Remove bolt (12, section H-H) and loop clamp (11) that secure A-manifold (13) to bracket (19).
(10) Remove bolt (12, section F-F) and loop clamp (11) that secure A-manifold (13) to bracket (30).
(11) Remove bolt (12, view M) and loop clamp (11) that secure A-manifold (13) to valve bracket
(35).
(12) Remove A-manifold fuel tubes (1, figure 5) from brackets.

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M. Remove C-manifold as follows:
(1) Remove bolts (6, figure 7) and self-locking nut (7) that secure C-manifold fuel tube (1) at 2:00
o'clock position.
(2) Remove bolts (6) and self-locking nuts (7) that secure C-manifold fuel tube (1) at 4:00 o'clock
position.
position.
position.
position.
(6) Remove bolts (12, figure 4) and loop clamps (11) that secure C-manifold (14) at two locations
(section G-G).
(7) Remove bolts (12) and loop clamps (11) that secure C-manifold (14) to brackets (10) at two
(8) Remove bolt (12, view J) and loop clamp (11) that secure C-manifold (14) to valve bracket (35).
(9) Remove bolt (12, section H-H) and loop clamp (11) that secure C-manifold (14) to bracket (19).
(10) Remove bolt (12, section F-F) and loop clamp (11) that secure C-manifold (14) to bracket (30).
(11) Remove bolt (12, view M) and loop clamp (11) that secure C-manifold (14) to valve bracket
(35).
(12) Remove C-manifold fuel tubes (1, figure 7) from brackets.
N. Remove ELBO assembly as follows:
(1) Remove bolt (7, figure 8) and loop clamp (6) that secure fuel tube (1) to support bracket (8).
(2) Disconnect fuel tube (1) from ELBO assembly fuel tube (3). Remove fuel tube.
(3) Remove bolt (9), self-locking nut (10), and loop clamp (11) that secure fuel tube (2) to valve rack
bracket (14). Remove fuel tube.
(4) Disconnect ELBO assembly fuel tube (3) from ELBO assembly fuel tube (4).

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Figure 8. ELBO Assembly

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NOTE
The ELBO assembly is made with integral loop clamps.
(7) Remove bolts (12, figure 4) that secure ELBO assembly (15) at two locations (section G-G).
NOTE
The same bolt is used to secure both the ELBO assembly and the B3-manifold in the
following steps.
(8) If not previously accomplished, remove bolt (12, section H-H) that secures ELBO assembly (15)
to bracket (19).
(9) If not previously accomplished, remove bolts (12) that secure ELBO assembly (15) to brackets
(10) at two locations (section E-E).
(10) If not previously accomplished, remove bolt (12, section F-F) that secures ELBO assembly (15)
to bracket (30).
NOTE
The same bolt and nut are used to secure both ELBO assembly and the B3-manifold in the
following step.
(11) If not previously accomplished, remove bolt (12, section L- L) and self-locking nut (37) that
secure ELBO assembly (15) to B3 manifold (29).
(12) Remove ELBO assembly.
P. Remove B3-supply manifold and fuel tubes as follows:
(1) Remove bolts (38) and loop clamps (39) that secure B3-supply manifold (31) to valve rack
bracket (9) at two locations.
(2) Remove bolts (38) and loop clamps (39) that secure B3-supply manifold (31) to valve rack
bracket (1) at two locations.
(3) Remove bolt (12, section H-H) and loop clamp (32) that secure B3-supply manifold (31) to
bracket (19).
(4) Remove bolt (12, section F-F) and loop clamp (32) that secure B3-supply manifold (31) to
bracket (30).
(5) Remove four bolts (10, figure 9) and self-locking nuts (11) that secure supply manifold (1) to
supply manifold (2).
(6) Remove four bolts (9) and self-locking nuts (11) that secure supply manifold (1) to fuel manifold
(5).
(7) Remove supply manifold (1) and orifice plate (14). Discard gaskets (12 and 13).

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Figure 9. B3-Manifold (Sheet 1 of 2)

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(7).
(9) Remove supply manifold (2) and orifice plate (16). Discard gaskets (12).
(10) Remove four bolts (10) and self-locking nuts (11) that secure fuel tube (3) to fuel manifold (6).
(11) Remove fuel tube (3) and orifice plate (25). Discard gaskets (12).
(12) Remove bolt (20, figure 9, view A) and loop clamp (21) that secure fuel tube (4) to bracket (19).
(13) Remove bolts (22, section B-B) and retaining strap (23) that secure fuel tube (4) to bracket (24).
(15) Remove fuel tube (4) and spacer plate (15). Discard gaskets (12).
Q. Remove B3-manifold as follows:
(1) Remove bolts (17, figure 9) and self-locking nuts (18) that secure fuel manifold (7) to fuel
manifold (8) at 2:00 o'clock position.
(2) Remove bolts (17) and self-locking nuts (18) that secure fuel manifold (6) to fuel manifold (7) at
(5) Remove bolts (12, figure 4) and loop clamps (11) that secure B3-manifold (29) at two locations
(section G-G).
(6) Remove bolt (12, view J) and loop clamp (11) that secure B3-manifold (29) to valve bracket
(35).
NOTE
The same bolt is used to secure both the B3-manifold and the ELBO assembly in the
following steps.
(7) If not previously accomplished, remove bolt (12, section H-H) and loop clamp (11) that secure
B3-manifold (29) to bracket (19).
(8) If not previously accomplished, remove bolts (12) and loop clamps (11) that secure B3-manifold
(29) to brackets (10) at two locations (section E-E).
(9) If not previously accomplished, remove bolt (12, section F-F) and loop clamp (11) that secure

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NOTE
The same bolt and nut are used to secure both the B3-manifold and the ELBO assembly in
the following step.
(10) If not previously accomplished, remove bolt (12, figure 4, section L- L), self-locking nut (37),
and loop clamp (11) that secure B3-manifold (29) to ELBO assembly (15).
(11) Remove B3-manifold from brackets.
R. Remove U-bolts (10, figure 10) and self-locking nuts (11) that secure valve brackets (12 and 16) to
fuel tube (6). Remove valve brackets.
S. Remove U-bolts (18, figure 4) and self-locking nuts (16) that secure two brackets (10, section E-E),
bracket (19, section H-H), and bracket (30, section F-F) to B2-manifold (17). Remove brackets.
T. Remove B2-manifold as follows:
(1) Remove eight bolts (3, figure 10) and self-locking nuts (5) that secure fuel tube (6) to fuel tube
(9).
(3) Remove fuel tube (6) and discard gaskets (4).
(5) Remove self-locking nuts (13, section A-A) and U-bolt (14) that secure fuel tube (9) to bracket
(15).
(6) Remove six bolts (2) that secure fuel tube (9) to valve rack bracket (1). Remove fuel tube and
discard gasket (4).
(7) Remove six bolts (2) that secure fuel tube (8) to valve rack bracket (1). Remove fuel tube.
U. Remove four bolts (7, figure 11) and self-locking nuts (8) that secure support bracket (6) to valve rack
bracket (1). Remove support bracket.
V. Remove two bolts (12, figure 8) that secure support bracket (8) to valve rack bracket (14). Remove
support bracket.
W. Remove valve rack brackets from dual fuel manifold support fixture, 1C9621, as follows:
(1) Remove eight capscrews (3, figure 11), flat washers (4), and self-locking nuts (5) that secure two
valve rack brackets (1) to rails (2). Remove valve racket brackets.

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Figure 10. B2-Manifold

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Figure 11. Valve Rack Bracket (Sheet 1 of 2)

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15. Tubular Fuel Manifold Installation.
NOTE
Dual fuel manifold support fixture, 1C9621G01, can only be used on gas turbines with a gas
fuel system. The dual fuel manifold support fixture, 1C9621G03, can be used for either gas
turbines with a gas fuel system or a gas and liquid fuel system.
A. If not previously accomplished, install dual fuel manifold support fixture, 1C9621, per WP 3015 00.
B. Install two valve rack brackets (1, figure 11) onto dual fuel manifold support fixture, 1C9621, as
follows:
(1) Align valve rack brackets (1) with rails (2).
(2) Install four capscrews (3), heads down with flat washers (4) under heads, through each valve
rack bracket (1) and rail (2).
(3) Using eight self-locking nuts (5) secure valve rack bracket (1) onto rails (2). Tighten self-locking
C. Install support bracket as follows:
(1) Lightly coat bolt (7, figure 11) threads and contact faces with thread lubricant.
(2) Using four bolts (7) and self-locking nuts (8), secure support bracket (6) onto valve rack bracket
(1). Tighten nuts to 202-238 lb in. (22.9-26.8 N·m) of torque.
D. Install B2-manifold as follows:
NOTE
Ensure bracket tabs on fuel tubes point forward.
(1) Align fuel tube (6, figure 10) with aft rail of valve rack bracket (1).
(2) Install new gaskets (4) onto fuel tube (6) flanges at 4:00 and 8:00 o'clock positions.
(4) Using six bolts (2), secure fuel tube (8) onto valve rack bracket (1). Tighten bolts hand-tight.
(6) Using eight bolts (3), boltheads up, and self-locking nuts (5), secure fuel tube (8) onto fuel tube
(6). Tighten nuts hand-tight.
(7) Install new gasket (4) onto fuel tube (8) flange at 12:00 o'clock position.
(8) Using eight bolts (3), boltheads up, and self-locking nuts (5), secure fuel tube (9) onto fuel tube
(6). Tighten nuts hand-tight.

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(9) Using eight bolts (3), boltheads right (aft looking forward), and self-locking nuts (5), secure fuel
tube (9) onto fuel tube (8). Tighten nuts hand-tight.
(11) Lightly coat U-bolt (14, figure 10, section A-A) threads with thread lubricant.
(12) Using self-locking nuts (13) and U-bolt (14), secure fuel tube (9) onto bracket (15). Tighten nuts
hand-tight.
CAUTION
ENSURE GASKET IS PROPERLY CENTERED BETWEEN FUEL TUBE FLANGES

PRIOR TO APPLYING FINAL TORQUE, OR FUEL LEAKAGE MAY OCCUR.
(13) Tighten nuts (5) at each fuel tube flange as follows:
(a) Using crisscross pattern, tighten nuts (5) to 115-135 lb in. (13.0-15.2 N·m) of torque.
(b) Using crisscross pattern, tighten nuts (5) to 230-270 lb in. (26.0-30.5 N·m) of torque.
(c) Using crisscross pattern, tighten nuts (5) to 345-405 lb in. (39.0-45.7 N·m) of torque.
(d) Using clockwise sequence, verify final torque of 345-405 lb in. (39.0-45.7 N·m) has been
applied to all nuts.
(14) Tighten bolts (2) to 60-70 lb in. (6.8-7.9 N·m) of torque.
(15) Tighten self-locking nuts (13, section A-A) to 202-238 lb in. (22.9-26.8 N·m) of torque.
(16) If required, install cap (7) onto fuel tube (6) at 5:00 o'clock position as follows:
(a) Lightly coat fuel tube nipple threads with thread lubricant and install cap onto fuel tube.
(b) Triple torque cap as follows:
1 Tighten cap to 133-157 lb in. (15.1-17.7 N·m) of torque.
2 Loosen cap until free running and retighten to 133-157 lb in. (15.1-17.7 N·m) of torque.
3 Check cap by reapplying 133-157 lb in. (15.1-17.7 N·m) of torque in the tightening
direction.
E. Install valve brackets as follows:
(1) Lightly coat U-bolt (10, figure 10) threads with thread lubricant.
(2) Using U-bolts (10) and self-locking nuts (11) secure valve bracket (12) onto fuel tube (6) at
4:00 o'clock position and valve bracket (16) onto fuel tube (6) at 7:00 o’clock position.
Tighten nuts to 202-238 lb in. (22.9-26.8 N·m) of torque.

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F. Install bracket (30, figure 4, section F-F) as follows:
(1) Lightly coat U-bolt (18) threads with thread lubricant.
(2) Using U-bolt (18) and self-locking nuts (16), secure bracket (30) onto B2-manifold (17) at
5:30 o'clock position. Tighten self-locking nuts hand-tight.
G. Install B3-manifold (29, figure 4) as follows:
(1) Position fuel manifolds (5 and 8, figure 9) from the 10:00 to 2:00 o'clock position.
(3) Using loop clamps (11), loops forward, and bolts (12), secure B3-manifold (29) onto
B2-manifold (17) support brackets at 11:00 and 1:00 o'clock positions (section G-G). Tighten
bolts hand-tight.
(5) Using bolts (17) and self-locking nuts (18), secure fuel manifold (5) onto fuel manifold (8) at
11:30 o'clock position. Tighten nuts hand-tight.
(9) Using bolt (12, figure 4, view J) and loop clamp (11), secure B3-manifold (29) onto valve
bracket (35). Tighten bolt hand-tight.
(10) Install loop clamp (11), loop forward, onto B3-manifold (29) at 5:30 o'clock position
(section F-F).
NOTE
• The ELBO assembly is made with integral loop clamps.
• The same bolt is used to secure both the B3-manifold and ELBO assembly in the
following step.
(11) If ELBO assembly (15) is positioned onto bracket (30) at 5:30 o'clock position (section F-F) per
step 15.K.(11), perform the following step:
(a) Using bolt (12), secure both ELBO assembly (15) and loop clamp (11), previously installed
onto B3-manifold (29), onto bracket (30). Ensure ELBO assembly is positioned against
bracket and loop clamp is positioned against bolthead. Tighten bolt hand-tight.

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(12) Install loop clamp (12, figure 4, section L-L), loop aft, onto B3-manifold (29).
NOTE
The same bolt and nut are used to secure both the B3-manifold and ELBO assembly in the
following step.
(13) If ELBO assembly is positioned adjacent to B3-manifold per step 15.K.(12), perform the
following step:
(a) Using bolt (12, figure 4, section L-L), bolthead aft, and self-locking nut (37), secure ELBO
assembly (15) onto loop clamp (11), previously installed onto B3-manifold. Ensure ELBO
assembly is positioned against nut and loop clamp is positioned against bolthead. Tighten
nut to 60-70 lb in. (6.8-7.9 N·m) of torque.
(15) Tighten self-locking nuts (18, figure 9) to 60-70 lb in. (6.8-7.9 N·m) of torque.
(16) Tighten self-locking nuts (16, figure 4, section F-F) to 202-238 lb in. (22.9-26.8 N·m) of torque.
H. Install B3-supply manifold and fuel tubes as follows:
(2) Using bolts (44), secure adapter plate (25) onto valve bracket (35) at 7:30 o'clock position.
Tighten bolts to 60-70 lb in. (6.8-7.9 N·m) of torque.
(3) Install preformed packings (27) onto supply manifolds (1 and 2, figure 9) and fuel tubes (3 and
4).
(5) Using loop clamps (39), loops inboard, and bolts (38), secure supply manifold (1, figure 9) onto
valve rack bracket (9, figure 4) at two locations. Tighten bolts hand-tight.
(6) Position supply manifold (1, figure 9) onto fuel manifold (5) and into adapter plate (25, figure 4)
at 7:30 o'clock position. Secure tube onto adapter plate using two bolts (26). Tighten bolts to
60-70 lb in. (6.8-7.9 N·m) of torque.
NOTE
The orifice plate is marked with the words INBOARD and OUTBOARD. The side marked
INBOARD is installed toward the manifold ring. Proper installation is required to meet
engine emissions.
(7) Install two new gaskets (12, figure 9) and orifice plate (14), orifice plate between gaskets,
between supply manifold (1) and fuel manifold (5).

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(9) Using four bolts (9), boltheads radially outward, and self-locking nuts (11), secure supply
manifold (1) onto fuel manifold (5). Tighten nuts to 60-70 lb in. (6.8-7.9 N·m) of torque.
(10) Position fuel tube (3) onto fuel manifold (6) and into adapter plate (25, figure 4) at 7:30 o'clock
position. Secure tube onto adapter plate using two bolts (26). Tighten bolts to 60-70 lb in.
NOTE
engine emissions.
(11) Install two new gaskets (12, figure 9) and orifice plate (25), orifice plate between gaskets,
between fuel tube (3) and fuel manifold (6).
(13) Using four bolts (10), boltheads oriented outward, and self-locking nuts (11), secure fuel tube (3)
onto fuel manifold (6). Tighten nuts to 60-70 lb in. (6.8-7.9 N·m) of torque.
(14) Tighten bolts (38, figure 4) that secure loop clamps (39) onto valve rack bracket (9), at two
locations, to 60-70 lb in. (6.8-7.9 N·m) of torque.
(15) Using bolts (44), secure adapter plate (25) onto valve bracket (35) at 4:00 o'clock position.
(16) Using loop clamps (39), loops inboard, and bolts (38), secure fuel tube (4, figure 9) onto valve
rack bracket (1, figure 4) at two locations. Tighten bolts hand-tight.
(17) Position fuel tube (4, figure 9) onto fuel manifold (8) and into adapter plate (25, figure 4) at
4:00 o'clock position. Secure tube onto adapter plate using two bolts (26). Tighten bolts to
60-70 lb in. (6.8-7.9 N·m) of torque.
NOTE
The spacer plate is marked with the words INBOARD and OUTBOARD. The side marked
INBOARD is installed toward the manifold ring.
(18) Install two new gaskets (12, figure 9) and spacer plate (15), orifice plate between gaskets,
between fuel tube (4) and fuel manifold (8).
(19) Using four bolts (9), boltheads oriented outward, and self-locking nuts (11), secure fuel tube (4)
(20) Lightly coat bolts (22, section B-B) with thread lubricant.
(21) Using bolts (22) and retaining strap (23), secure fuel tube (4) onto bracket (24). Tighten bolts to
60-70 lb in. (6.8-7.9 N·m) of torque.

/03) *(.
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(22) Lightly coat bolt (20, figure 9, view A) with thread lubricant.
(23) Using bolt (20) and loop clamp (21), secure fuel tube (4) onto bracket (19). Tighten bolt to
60-70 lb in. (6.8-7.9 N·m) of torque.
(24) Using loop clamp (32, figure 4) and bolt (12), secure B3-supply manifold (31) onto bracket (30)
at 5:30 o'clock position (section F-F). Tighten bolt hand-tight.
(25) Position supply manifold (2, figure 9) onto supply manifold (1) and fuel manifold (7), and into
adapter plate (25, figure 4) at 4:00 o'clock position. Secure tube onto adapter plate using two
bolts (26). Tighten bolts to 60-70 lb in. (6.8-7.9 N·m) of torque.
(26) Install new gasket (13, figure 9) between supply manifolds (1 and 2).
(27) Using four bolts (10), boltheads oriented outward, and self-locking nuts (11), secure supply
manifold (2) onto supply manifold (1). Tighten nuts to 60-70 lb in. (6.8-7.9 N·m) of torque.
NOTE
engine emissions.
(28) Install two new gaskets (12) and orifice plate (16), orifice plate between gaskets, between supply
manifold (2) and fuel manifold (7).
(29) Using four bolts (9), boltheads oriented outward, and self-locking nuts (11), secure supply
manifold (2) onto fuel manifold (7). Tighten nuts to 60-70 lb in. (6.8-7.9 N·m) of torque.
(31) Tighten bolt (12, section F-F) that secures loop clamp (32) onto bracket (30) to 60-70 lb in.
J. Install support bracket onto valve rack bracket as follows:
(1) Lightly coat bolt (12, figure 8) threads with thread lubricant.
(2) Using two bolts (12), secure support bracket (8) onto valve rack bracket (14). Tighten bolts to
60-70 lb in. (6.8-7.9 N·m) of torque.

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K. Install ELBO assembly as follows:
WARNING

PERSONAL PROTECTIVE EQUIPMENT REQUIRED. USE MECHANICAL
EXHAUST VENTILATION - IF NOT AVAILABLE, USE AN APPROVED
RESPIRATOR.
(1) Slide B-nuts back and lubricate ferrules of ELBO assembly fuel tubes (3 and 5, figure 8) with
lubricating oil.
(2) Lightly coat ELBO assembly fuel tubes (3 and 5) nipple threads with thread lubricant.
(3) Position ELBO assembly fuel tube (3) onto ELBO assembly fuel tube (5).
(4) Secure ELBO assembly fuel tube (3) onto ELBO assembly fuel tube (5). Tighten B-nut hand-
tight.
(6) Using two bolts (12), secure ELBO assembly (15) onto B2-manifold (17) support brackets at
11:00 and 1:00 o'clock positions (section G-G). Tighten bolts to 60-70 lb in. (6.8-7.9 N·m) of
torque.
(7) Slide B-nut back and lubricate ferrule of ELBO assembly fuel tube (4, figure 8) with lubricating
oil.
(8) Lightly coat ELBO assembly fuel tube (4) nipple threads with thread lubricant.
(9) Position ELBO assembly fuel tube (4) onto ELBO assembly fuel tubes (3 and 5).
(10) Secure ELBO assembly fuel tube (4) onto ELBO assembly fuel tubes (3 and 5). Tighten B-nuts
hand-tight.
NOTE
The same bolt is used to secure both the ELBO assembly and B3-manifold to bracket in the
following step.
11) Ensure loop clamp (11, figure 4) is installed, loop forward, onto B3-manifold (29) per
step 15.G.(10), and is positioned onto bracket (30) at 5:30 o'clock position (section F-F). Position
ELBO assembly (15) onto bracket (30). Using bolt (12), secure both the ELBO assembly (15)
and loop clamp (11) onto bracket (30). Ensure ELBO assembly is positioned against bracket and
loop clamp is positioned against bolthead. Tighten bolt to 60-70 lb in. (6.8-7.9 N·m) of torque.

/03) *(.
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NOTE
The same bolt and nut are used to secure both the ELBO assembly and B3-manifold in the
following step.
(12) Ensure loop clamp (11, figure 4, section L-L) is installed, loop aft, onto B3-manifold (29) per
step 15.G.(12), and is positioned adjacent to ELBO assembly (15). Using bolt (12), bolthead aft,
and self-locking nut (37), secure ELBO assembly (15) onto loop clamp (11), previously installed
onto B3-manifold. Ensure ELBO assembly is positioned against nut and loop clamp is positioned
against bolthead. Tighten nut to 60-70 lb in. (6.8-7.9 N·m) of torque.
(13) Triple torque B-nuts on ELBO assembly fuel tubes (3, 4, and 5, figure 8) as follows:
(a) Tighten B-nuts to 60-70 lb ft (82-94 N·m) of torque at each joint sequentially around in a
clockwise direction, ALF.
(b) Loosen until B-nut is free running and retighten to 60-70 lb ft (82-94 N·m) of torque at each
joint sequentially around in a clockwise direction, ALF.
(c) Check joint by reapplying 60-70 lb ft (82-94 N·m) of torque to the B-nut in the tightening
direction at each joint sequentially around in a clockwise direction, ALF.
(15) Using bolts (44), secure adapter plate (25) onto support bracket (36). Tighten bolts to 60-70 lb in.
(16) Install preformed packings (27) onto fuel tubes (1 and 2, figure 8).
WARNING

PERSONAL PROTECTIVE EQUIPMENT REQUIRED. USE MECHANICAL
EXHAUST VENTILATION - IF NOT AVAILABLE, USE AN APPROVED
RESPIRATOR.
(17) Slide B-nut back and lubricate ferrule of fuel tube (1) with lubricating oil.
(18) Lightly coat ELBO assembly fuel tube (3) nipple threads (10:00 o'clock position) with thread
lubricant.
(20) Using bolt (7) and loop clamp (6), secure fuel tube (1) onto support bracket (8). Tighten bolt
hand-tight.

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(22) Position fuel tube (1, figure 8) onto ELBO assembly fuel tube (3) at 10:00 o'clock position and
into adapter plate (25, figure 4). Secure tube to adapter plate using two bolts (26). Tighten bolts
(23) Tighten bolt (7, figure 8) to 60-70 lb in. (6.8-7.9 N·m) of torque.
(24) Triple torque B-nut on fuel tube (1) as follows:
(a) Tighten B-nut to 78-92 lb ft (106-124 N·m) of torque.
(b) Loosen until B-nut is free running.
(c) Retighten B-nut to 78-92 lb ft (106-124 N·m) of torque.
(d) Check the joint by reapplying 78-92 lb ft (106-124 N·m) of torque to the B-nut in the
tightening direction.
(26) Using loop clamp (11), bolt (9), and self-locking nut (10), secure fuel tube (2) onto valve rack
bracket (14). Tighten nut hand-tight.
(27) Position fuel tube (2) into adapter plate (25, figure 4). Secure tube onto adapter plate using two
(28) Tighten self-locking nut (10, figure 8) to 60-70 lb in. (6.8-7.9 N·m) of torque.
(29) If required, install tube cap (13) onto ELBO assembly fuel tube (4) at 5:30 o'clock position as
follows:
(a) Lightly coat ELBO assembly fuel tube nipple threads with thread lubricant and install tube
cap onto fuel tube.
(b) Triple torque tube cap as follows:
1 Tighten tube cap to 60-70 lb in. (6.8-7.9 N·m) of torque.
2 Loosen tube cap until free running and retighten to 60-70 lb in. (6.8-7.9 N·m) of torque.
3 Check tube cap by reapplying 60-70 lb in. (6.8-7.9 N·m) of torque in the tightening
direction.
L. Assemble C-manifold as follows:
(2) Using bolts (6) and self-locking nuts (7), join two C-manifold fuel tubes (1). Tighten nuts hand-
tight.
(3) Position C-manifold fuel tubes (1) from 9:30 to 2:00 o'clock position.

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(5) Using loop clamp (11), loop aft, and bolt (12), secure C-manifold (14) onto B2-manifold (17)
support bracket at 11:00 o'clock position (section G-G). Tighten bolt hand-tight.
(7) Using bolts (6, figure 7) and self-locking nuts (7), secure C-manifold fuel tube (1) section onto
C-manifold at 2:00 o'clock position. Tighten nuts hand-tight.
(8) Using bolts (6) and self-locking nuts (7), secure C-manifold fuel tube (1) section onto
(9) Using bolts (6) and self-locking nuts (7), secure C-manifold fuel tube (1) section onto
C-manifold at 4:00 and 7:00 o'clock positions. Tighten nuts hand-tight.
(10) Using loop clamp (11, figure 4), loop aft, and bolt (12), secure C-manifold (14) onto bracket (30)
(11) Using loop clamp (11, view J), loop aft, and bolt (12), secure C-manifold (14) onto valve bracket
(35). Tighten bolt hand-tight.
(12) Using loop clamp (11, view M), loop aft, and bolt (12), secure C-manifold (14) onto valve
M. Assemble A-manifold as follows:
(2) Using bolts (8) and self-locking nuts (9), join two A-manifold fuel tubes (1). Tighten nuts hand-
tight.
(3) Position A-manifold section from 10:00 to 2:30 o'clock position.
(5) Using loop clamp (11), loop aft, and bolt (12), secure A-manifold (13) onto B2-manifold (17)
support bracket at 11:00 o'clock position (section G-G). Tighten bolts hand-tight.
(7) Using bolts (8, figure 5) and self-locking nuts (9), secure A-manifold fuel tube (1) section onto
A-manifold at 2:30 o'clock position. Tighten nuts hand-tight.

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(8) Using bolts (8) and self-locking nuts (9), secure A-manifold fuel tube (1) section onto
(9) Using bolts (8) and self-locking nuts (9), secure A-manifold fuel tube (1) section onto
A-manifold at 5:00 and 10:00 o'clock positions. Tighten nuts hand-tight.
(10) Using loop clamp (11, figure 4), loop aft, and bolt (12), secure A-manifold (13) onto bracket (30)
(11) Using loop clamp (11, view J), loop aft, and bolt (12), secure A-manifold (13) onto valve bracket
(12) Using loop clamp (11, view M), loop aft, and bolt (12), secure A-manifold (13) onto valve
N. Install two brackets (10, figure 4, section E-E) onto fuel manifolds as follows:
(2) Using U-bolt (18) and two self-locking nuts (16), secure brackets (10) onto B-manifold (17) at
3:00 and 9:30 o'clock positions (section E-E). Tighten nuts hand-tight.
(3) Install loop clamps (11), loops forward, onto B3-manifold (29) at 3:00 and 9:30 o'clock positions
(section E-E).
NOTE
The same bolt is used to secure both the B3-manifold and ELBO assembly in the following
step.
(5) Using bolts (12), secure both ELBO assembly (15) and loop clamps (11), previously installed
onto B3-manifold (29), onto bracket (10) at 3:00 and 9:30 o'clock positions (section E-E). Ensure
ELBO assembly is positioned against brackets and loop clamps are positioned against boltheads.
(6) Using loop clamp (11), loop aft, and bolt (12), secure C-manifold (14) onto bracket (10) at 3:00
and 9:30 o'clock positions (section E-E). Tighten bolts hand-tight.
(7) Using loop clamp (11), loop aft, and bolt (12) secure A-manifold (13) onto bracket (10) at 3:00
and 9:30 o'clock positions (section E-E). Tighten bolts hand-tight.
(9) Tighten self-locking nuts (16) to 202-238 lb in. (22.9-26.8 N·m) of torque.

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P. If removed, install 10 adapter plates (25, figure 4) onto valve rack brackets (1 or 9) as follows:
(2) Position adapter plate (25) onto valve rack brackets (1 or 9).
(3) Using four bolts (44), secure adapter plate (25) onto valve rack brackets (1 or 9). Tighten bolts to
60-70 lb in. (6.8-7.9 N·m) of torque.
Q. Install C-manifold supply tubes and brackets as follows:
(1) Install three preformed packings (27, figure 4) onto fuel tube (8, figure 7).
(3) Using six bolts (26), secure fuel tube (8, figure 7) onto three adapter plates (25, figure 4) at 2:00,
3:00, and 4:00 o'clock positions. Tighten bolts hand-tight.
(5) Using two bolts (1), secure brackets (4 and 5) onto valve rack bracket (16). Tighten bolts to
60-70 lb in. (6.8-7.9 N·m) of torque.
(7) Using U-bolt (15) and self-locking nuts (7), secure fuel tube (14) onto bracket (4). Tighten self-
locking nuts hand-tight.
(8) Install two preformed packings (27, figure 4) onto fuel tube (15, figure 7).
(10) Using four bolts (26) secure fuel tube (15, figure 7) onto two adapter plates (25, figure 4) at the
8:30 and 9:30 o'clock positions. Tighten bolts hand-tight.
(11) Secure fuel tube (8, figure 7) to fuel tube (15) as follows:
(a) Install new gasket (13) between fuel tube (15) and fuel tube (8).
(b) Lightly coat bolt (11) threads and contact faces with thread lubricant.
(c) Using eight bolts (11) and self-locking nuts (12), secure fuel tube (8) onto fuel tube (15).
Tighten nuts hand-tight.
60-70 lb in. (6.8-7.9 N·m) of torque.

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(16) Tighten eight nuts (12, figure 7) as follows:
CAUTION
ENSURE GASKET IS PROPERLY CENTERED BETWEEN FUEL TUBE
FLANGES PRIOR TO APPLYING FINAL TORQUE, OR FUEL
LEAKAGE MAY OCCUR.
(a) Using crisscross pattern, tighten eight nuts (12) to 115-135 lb in. (13.0-15.2 N·m) of torque.
(b) Using crisscross pattern, tighten eight nuts (12) to 230-270 lb in. (26.0-30.5 N·m) of torque.
(c) Using crisscross pattern, tighten eight nuts (12) to 345-405 lb in. (39.0-45.7 N·m) of torque.
(17) If required, install tube cap (14) onto fuel tube (15) at 6:00 o'clock position as follows:
(a) Lightly coat fuel tube nipple threads with thread lubricant and install tube cap onto fuel
tube.
direction.
(18) Install preformed packings (27, figure 4) onto fuel tubes (5, 9, 10, 16, and 17, figure 7).
(20) Position fuel tube (5, figure 7) into adapter plate (25, figure 4). Route fuel tube towards
2:00 o'clock position. Secure using two bolts (26). Tighten bolts hand-tight.

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(24) Position fuel tube (17, figure 7) into adapter plate (25, figure 4). Route fuel tube towards 9:30
o'clock position. Secure using two bolts (26). Tighten bolts hand-tight.
(25) Install new gaskets (4, figure 7) between C-manifold fuel tube (1) flanges and fuel tubes (5, 9,
10, 16, and 17) flanges.
(27) Using four bolts (2), boltheads radially outward, and self-locking nuts (3), secure C-manifold
fuel tube (1) onto fuel tube (5). Tighten nuts hand-tight.
(32) Tighten bolts (26, figure 4) to 60-70 lb in. (6.8-7.9 N·m) of torque.
R. Install A-manifold supply tubes and brackets as follows:
(8) Using six bolts (26) secure fuel tube (13, figure 5) onto three adapter plates (25, figure 4) at the
8:00, 9:00, and 10:00 o'clock positions. Tighten bolts hand-tight.

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(9) Secure fuel tube (13, figure 5) onto fuel tube (6) as follows:
CAUTION

FLANGES PRIOR TO APPLYING FINAL TORQUE, OR FUEL
LEAKAGE MAY OCCUR.
(a) Lightly coat fuel tube nipple threads with thread lubricant and install tube cap onto fuel
tube.
(b) Triple torque tube cap per step 15.Q.(17)(b).

/03) *(.
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(21) Install new gaskets (4, figure 5) between A-manifold fuel tube (1) flanges and fuel tubes (5, 7,
14, 15, and 16) flanges.
(23) Using four bolts (2), boltheads radially outward, and self-locking nuts (3), secure A-manifold
fuel tube (1) sections onto fuel tube (5). Tighten nuts hand-tight.
S. Install bracket (19, figure 4, section H-H) as follows:
(2) Using U-bolt (18) and self-locking nuts (16), secure bracket (19) onto B2-manifold (17). Tighten
self-locking nuts hand-tight.

*(. /03)
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NOTE
The same bolt is used to secure both the ELBO assembly and B3-manifold in the following
step.
(4) Ensure loop clamp (11) is installed, loop forward, onto B3-manifold (29) and is positioned onto
bracket (19) at 6:30 o'clock position. Position ELBO assembly (15) onto bracket (19). Using bolt
(12), secure both the ELBO assembly (15) and loop clamp (11) to bracket (19). Ensure ELBO
assembly is positioned against bracket and loop clamp is positioned against bolthead. Tighten
bolt hand-tight.
(5) Using loop clamp (32), loop forward, and bolt (12), secure B3-supply manifold (31) onto bracket
(7) Using loop clamp (11), loop aft, and bolt (12), secure C-manifold (14) onto bracket (19). Tighten
bolt hand-tight.
(8) Using loop clamp (11), loop aft, and bolt (12), secure A-manifold (13) onto bracket (19). Tighten
bolt hand-tight.
(10) Using U-bolt (21) and self-locking nuts (24), secure bracket (19) onto fuel tube (20). Tighten
(12) Using U-bolt (23) and self-locking nuts (24), secure bracket (19) onto fuel tube (22). Tighten
T. If required, install fuel hoses onto fuel nozzles per paragraph 7.
U. Install fuel hoses onto manifolds per paragraph 7.
V. Install staging valves per paragraph 13.
W. Install left (aft looking forward) harness support bracket and electrical harnesses as follows:
(1) If removed, attach harness support bracket (8, figure 4) onto valve rack bracket (9) as follows:
(a) Lightly coat bolt (40, view A) threads and contact faces with thread lubricant.

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(b) Using bolts (40), attach harness support bracket (8) onto valve rack bracket (9).
(c) Tighten bolts to 60-70 lb in. (6.8-7.9 N·m) of torque.
(2) Install electrical harness (41) connector onto harness support bracket (8).
(3) Position connector keyway at 12:00 o'clock position.
(4) Lightly coat screw (6) threads and contact faces with thread lubricant.
(5) Using four screws (6) and self-locking nuts (7), secure electrical harness connector (41) onto
harness support bracket (8). Tighten nuts to 9-11 lb in. (1.1-1.2 N·m) of torque.
(9) Using four screws (33) and self-locking nuts (34), secure electrical harness (42) connector onto
(10) Route electrical harnesses (41 and 42) to staging valves (3) on valve rack bracket (9).
(11) Lightly coat bolt (53, figure 4, view S) threads and contact faces with thread lubricant.
(12) Using bolt (53, view S) and loop clamp (54), secure electrical harness (42) onto fuel tube (28)
integral bracket. Tighten bolt to 60-70 lb in. (6.8-7.9 N·m) of torque.
(13) Lightly coat bolts (46) threads and contact faces with thread lubricant.
(14) Using self-locking nut (45, figure 4, view P), bolt (46), and loop clamp (49), secure electrical
harness (41) onto valve rack bracket (9) at 7:30 o'clock position, ALF. Tighten nut hand-tight.
(15) Install loop clamp (48) onto electrical harness (41) and install loop clamp (50) onto electrical
harness (42) at 8:30 o'clock position, ALF.
NOTE
The same self-locking nut (45) and bolt (46) secure both loop clamps (48 and 50) onto
valve rack bracket (9).
(16) Using self-locking nut (45) and bolt (46), secure loop clamp (48) and loop clamp (50) onto valve
rack bracket (9) at 8:30 o'clock position, ALF. Tighten nut hand-tight.

*(. /03)
:3
NOTE
(20) Secure electrical harness onto staging valves per paragraph 13.
X. Install right (aft looking forward) harness support bracket and electrical harnesses as follows:
(1) If removed, secure harness support bracket (5, figure 4) onto valve rack bracket (1) as follows:
(a) Lightly coat bolt (40, figure 4, view B) threads and contact faces with thread lubricant.
(b) Using bolts (40), secure harness support bracket (5) onto valve rack bracket (1).
(6) Using self-locking nut (45, figure 4, view B), bolt (46), and loop clamp (47), secure electrical
harness (43) onto harness support bracket (5). Tighten nut hand-tight.
(7) Route electrical harness (43) to staging valves (3) on valve rack bracket (1).
(8) Lightly coat bolts (46, view R) threads and contact faces with thread lubricant.
(9) Using self-locking nut (45), bolt (46), and loop clamp (49), secure electrical harness (43) onto
valve rack bracket (1) at 4:30 o'clock position, ALF. Tighten nut hand-tight.
(13) Secure electrical harness onto staging valves per paragraph 13.

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Y. Install enclosure fuel manifold supports per packager's manual.
Z. Remove dual fuel manifold support fixture, 1C9621, per WP 3015 00.
AA.Make all fuel and electrical connections onto fuel system per packager's manual.
%ODQN
/03) *(.
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1091174WP 1511 00
WP 1511 00
WORK PACKAGE
DUAL FUEL SYSTEM REPLACEMENT
())(&7,9,7</03)*$6785%,1(02'(/6

Page No. Change No.
1 - 171 ...................................................................................................................................................... 0
172 Blank ................................................................................................................................................. 0
Alphabetical Index
Subject Page
Acoustic Baffles, Fuel Nozzle Plugs, and Fuel Hose Assembly Installation ............................18
Acoustic Baffles, Fuel Nozzle Plugs, and Fuel Hose Assembly Removal................................ 18
Fuel Hose Assembly Installation .............................................................................................. 122
Fuel Hose Assembly Removal.................................................................................................. 119
Fuel Nozzle Installation.............................................................................................................24
Fuel Nozzle Removal ................................................................................................................21
Gas Staging Valves and Jumper Tube Installation.................................................................... 133
Gas Staging Valves and Jumper Tube Removal ....................................................................... 125
Liquid Fuel Brackets and Electrical Harness Brackets Installation...........................................93
Liquid Fuel Brackets and Electrical Harness Brackets Removal. .............................................89
Liquid Fuel Electrical Harness and Temperature Sensor Installation. ......................................85
Liquid Fuel Electrical Harness and Temperature Sensor Removal ...........................................82
Liquid Fuel Manifold Fuel Tube Installation ............................................................................ 12
Liquid Fuel Manifold Fuel Tube Removal .................................................................................4
81&21752//(':+(135,17('2575$160,77('(/(&7521,&$//<
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Alphabetical Index - Continued
Subject Page
Liquid Fuel Staging Valve Installation.......................................................................................80

Liquid Fuel Staging Valve Removal. .........................................................................................76
Liquid Fuel Staging Valve Supply and Purge Tubes Installation...............................................56
Liquid Fuel Staging Valve Supply and Purge Tubes Removal ..................................................25
Tubular Gas Fuel Manifold Installation ....................................................................................152
Tubular Gas Fuel Manifold Removal........................................................................................134
Tubular Liquid Fuel Manifold Installation. ..............................................................................104
Tubular Liquid Fuel Manifold Removal. ...................................................................................96
1. Introduction.
This work package provides instructions for the removal and installation of the dual fuel manifolds used on
LM6000 engines. Instructions for the removal and installation of associated fuel system components are cov-
ered as well. Reference kit 738L681.
Title Number
Gas and Dual Fuel Manifold Support Fixture Replacement WP 3015 00

Tool, Removal/Installation, Fuel Nozzle 1C9427G01
Fixture, Support-Dual Fuel Manifold 1C9621G03
Wrench, Strap (1/2” drive, 90° angle, 1/2” strap) (Optional) BT-BS-625, Daniels Mfg Corp.
81&21752//(':+(135,17('2575$160,77('(/(&7521,&$//<
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Tape Local Purchase

Gasket L54659P01 5
Gasket, Seal, Square 9608M08G44 1
Seal, Fuel Nozzle L47618P01 30
Seal, Manifold Valve L42602P01 13
Seal Ring, Metal 4058T39P04 9
Seal Ring, Metal C L52068P01 60
81&21752//(':+(135,17('2575$160,77('(/(&7521,&$//<
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6. Liquid Fuel Manifold Fuel Tube Removal.
WARNING
• FUEL IN LIQUID, VAPOR, OR MIST FORM IS FLAMMABLE, IRRITATING TO THE SKIN

AND RESPIRATORY TRACT, AND POISONOUS IN THE DIGESTIVE TRACT. REMOVE
SATURATED CLOTHING, WASH SKIN WELL, DON'T SWALLOW LIQUID, AND DON'T
BREATHE MIST OR VAPOR.
• FUEL SYSTEM IS PRESSURIZED. USE CARE TO PREVENT INJURY WHEN

DISCONNECTING LINES.
A. Disconnect fuel tubes from liquid fuel manifolds and fuel nozzles (figure 1) as follows:
CAUTION
COVER OPEN FUEL MANIFOLD AND FUEL NOZZLE NIPPLES

IMMEDIATELY AFTER REMOVAL OF EACH FUEL TUBE TO PREVENT
ENGINE CONTAMINATION.
NOTE
A single ring is named B1A B1B-manifold. Internal plugs create a B1A section and a B1B
section of the manifold. Each section has a separate fuel supply.
(1) Disconnect fuel tubes (1) located at upper B1A B1B-manifold (2) or lower B1A B1B-manifold (3)
as follows:
(a) Loosen B-nut that secures fuel tube (1, section B-B) to upper B1A B1B-manifold (2) or lower
B1A B1B-manifold (3).
(b) Loosen B-nut that secures fuel tube (1) to fuel nozzle (19) nipple.
(c) Remove fuel tube (1).
NOTE
A single ring is named A2A A2B-manifold. Internal plugs create an A2A section and an
A2B section of the manifold. Each section has a separate fuel supply.
1
(2) Disconnect fuel tubes (4) located at upper A2A A2B-manifold (5) or lower A2A A2B-manifold (6)
as follows:
(a) Loosen B-nut that secures fuel tube (4, section C-C) to upper A2A A2B-manifold (5) or lower
A2A A2B-manifold (6).
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Figure 1. Liquid Fuel Manifold Fuel Tube Replacement (Sheet 1 of 6)
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NOTE
A single ring is named B2 B3-manifold. Internal plugs create a B2 section and a B3
(3) Disconnect fuel tubes (7) located at upper B2 B3-manifold (8) or lower B2 B3-manifold (9) as
follows:
(a) Loosen B-nut that secures fuel tube (7, section D-D) to upper B2 B3-manifold (8) or lower B2
and B3-manifold (9).

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(4) Disconnect fuel tubes (10) located at upper A1-manifold (11) and lower A1-manifold (12) as
follows:
(a) Loosen B-nut that secures fuel tube (10, section E-E) to upper A1-manifold (11) or lower
A1-manifold (12).
CAUTION
COVER OPEN FUEL MANIFOLD AND FUEL NOZZLE NIPPLES

IMMEDIATELY AFTER REMOVAL OF EACH FUEL TUBE TO
PREVENT ENGINE CONTAMINATION.
(5) Disconnect fuel tubes (13) located at upper C1-manifold (14) or lower C1-manifold (15) as follows:
(a) Loosen B-nut that secures fuel tube (13, section F-F) to upper C1-manifold (14) or lower
C1-manifold (15).
(6) Disconnect fuel tubes (16) located at upper C2-manifold (17) or lower C2-manifold (18) as follows:
(a) Loosen B-nut that secures fuel tube (16, section G-G) to upper C2-manifold (17) or lower
C2-manifold (18).
B. Cover open fuel nozzle and fuel manifold nipples with tape.
C. Repeat step 6.A. and step 6.B. to remove as many fuel tubes as required to perform maintenance.

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7. Liquid Fuel Manifold Fuel Tube Installation.
A. Remove covers from fuel nozzle and fuel manifold nipples.
B. Using tape, start at 12:00 o'clock position, indexing CCW, forward FLA, number each fuel nozzle (19,
figure 1) 1 through 30. The No. 1 fuel nozzle is just CCW of 12:00 o'clock position, FLA.
WARNING

C. Lightly coat fuel nozzle nipples with lubricating oil.
D. Install upper C2-manifold (17) fuel tubes as follows:
(1) Lubricate B-nut threads and ferrules of fuel tubes (16) with lubricating oil.
(2) Install straight end of each fuel tube (16, section G-G) onto most CW nipple port, FLA, of even
number fuel nozzles No. 26 and No. 28. Tighten B-nuts finger-tight.
(3) Lightly coat upper C2-manifold (17) nipple threads with lubricating oil.
(4) Connect remaining end of each fuel tube (16) onto upper C2-manifold (17). Tighten B-nuts finger-
tight.
(5) Triple torque B-nuts at fuel nozzle joints as follows:
(a) Tighten B-nuts to 263-307 lb in. (29.8-34.6 N·m) of torque at each fuel nozzle joint
sequentially around in a CW direction ALF.
(b) Loosen until B-nut is free running and retighten to 263-307 lb in. (29.8-34.6 N·m) of torque at
each joint sequentially around in a CW direction ALF.
(c) Check joint by reapplying 263-307 lb in. (29.8-34.6 N·m) of torque to the B-nut in the
tightening direction at each joint sequentially around in a CW direction ALF.
(6) Triple torque B-nuts at manifold joints as follows:
(a) Tighten B-nuts to 134-156 lb in. (15.2-17.6 N·m) of torque at each manifold joint sequentially
around in a CW direction ALF.

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E. Install lower C2-manifold (18) fuel tubes as follows:
WARNING

(1) Lubricate B-nut threads and ferrules of fuel tubes (16) with lubricating oil
(2) Install straight end of each fuel tube (16) onto most CW nipple port, FLA, of even number fuel
nozzles Nos. 12, 14, 16, and 24. Tighten B-nuts finger-tight.
(3) Lightly coat lower C2-manifold (18) nipple threads with lubricating oil.
(4) Connect remaining end of each fuel tube (16) onto lower C2-manifold (18). Tighten B-nuts finger-
tight.
(5) Triple torque B-nuts at fuel nozzle joints per step 7.D.(5).
(6) Triple torque B-nuts at manifold joints per step 7.D.(6).
F. Install upper C1-manifold (14) fuel tubes as follows:
(2) Install straight end of each fuel tube (13, section F-F) onto most CW nipple port, FLA, of even
number fuel nozzles Nos. 2, 4, 6, 8, and 30. Tighten B-nuts finger-tight.
(3) Lightly coat upper C1-manifold (14) nipple threads with lubricating oil.
(4) Connect remaining end of each fuel tube (13) onto upper C1-manifold (14). Tighten B-nuts finger-
tight.
G. Install lower C1-manifold (15) fuel tubes as follows:
(2) Install straight end of each fuel tube (13) onto most CW nipple port, FLA, of even number fuel

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(3) Lightly coat lower C1-manifold (15) nipple threads with lubricating oil.
(4) Connect remaining end of each fuel tube (13) onto lower C1-manifold (15). Tighten B-nuts finger-
tight.
H. Install upper A1-manifold (11) fuel tubes as follows:
(2) Install straight end of each fuel tube (10, section E-E) onto center nipple port (FLA), of fuel nozzles
Nos. 1, 8, 9, and No. 26 through No. 30. Tighten B-nuts finger-tight.
(3) Lightly coat upper A1-manifold (11) nipple threads with lubricating oil.
(4) Connect remaining end of each fuel tube (10) onto upper A1-manifold (11). Tighten B-nuts finger-
tight.
I. Install lower A1-manifold (12) fuel tubes as follows:
(2) Install straight end of each fuel tube (10) onto center nipple port, FLA, of fuel nozzles No. 10
through No. 13.
(3) Lightly coat lower A1-manifold (12) nipple threads with lubricating oil.
(4) Connect remaining end of each fuel tube (10) onto lower A1-manifold (12). Tighten B-nuts finger-
tight.
J. Install upper B2 B3-manifold (8) fuel tubes as follows:
WARNING

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(2) Install straight end of each fuel tube (7, section D-D) onto least CW nipple port, FLA, of even
number fuel nozzles Nos. 2, 4, 24, and 30. Tighten B-nuts finger-tight.
(3) Lightly coat upper B2 B3-manifold (8) nipple threads with lubricating oil.
(4) Connect remaining end of each fuel tube (7) onto upper B2 B3-manifold (8). Tighten B-nuts finger-
tight.
K. Install lower B2 B3-manifold (9) fuel tubes as follows:
(2) Install straight end of each fuel tube (7) onto least CW center nipple port, FLA, of even number fuel
nozzles Nos. 14, 16, 18, 20, and 22. Tighten B-nuts finger-tight.
(3) Lightly coat lower B2 B3-manifold (9) nipple threads with lubricating oil.
(4) Connect remaining end of each fuel tube (7) onto lower B2 B3-manifold (9). Tighten B-nuts finger-
tight.
NOTE
A single ring is named A2A A2B-manifold. Internal plugs create an A2A section and an A2B section
of the manifold. Each section has a separate fuel supply.
L. Install upper A2A A2B-manifold (5) fuel tubes as follows:
WARNING

(2) Install straight end of each fuel tube (4, section C-C) onto center nipple port, FLA, of fuel nozzles
No. 2 through No. 7, No. 24 and No. 25. Tighten B-nuts finger-tight.
(3) Lightly coat upper A2A A2B-manifold (5) nipple threads with lubricating oil.
(4) Connect remaining end of each fuel tube (4) onto upper A2A A2B-manifold (5). Tighten B-nuts
finger-tight.

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M. Install lower A2A A2B-manifold (6) fuel tubes as follows:
(2) Install straight end of each fuel tube (4) onto center nipple port, FLA, of fuel nozzles No. 14 through
No. 23. Tighten B-nuts finger-tight.
(3) Lightly coat lower A2A A2B-manifold (6) nipple threads with lubricating oil.
(4) Connect remaining end of each fuel tube (4) onto lower A2A A2B-manifold (6). Tighten B-nuts
finger-tight.
NOTE
A single ring is named B1A B1B-manifold. Internal plugs create a B1A section and a B1B section of
the manifold. Each section has a separate fuel supply.
N. Install upper B1A B1B-manifold (2) fuel tubes as follows:
WARNING

(2) Install straight end of each fuel tube (1, section B-B) onto least CW nipple port, FLA, of fuel nozzles
No.1 and No. 3, No. 5 through No. 8, and No. 25 through No. 29. Tighten B-nuts finger-tight.
(3) Lightly coat upper B1A B1B-manifold (2) nipple threads with lubricating oil.
(4) Connect remaining end of each fuel tube (1) onto upper B1A B1B-manifold (2). Tighten B-nuts
finger-tight.

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O. Install lower B1A B1B-manifold (3) fuel tubes as follows:
(2) Install straight end of each fuel tube (1) onto least CW nipple port, FLA, of fuel nozzles No. 9
through No. 13 and Nos. 15, 17, 19, 21, and 23. Tighten B-nuts finger-tight.
(3) Lightly coat lower B1A B1B-manifold (3) nipple threads with lubricating oil.
(4) Connect remaining end of each fuel tube (1) onto lower B1A B1B-manifold (3). Tighten B-nuts
finger-tight.

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8. Acoustic Baffles, Fuel Nozzle Plugs, and Fuel Hose Assembly Removal.
NOTE
There are 30 fuel nozzle ports located in compressor rear frame (CRF). There are 18 acoustic baffles
(two different lengths) and 12 fuel nozzle plugs.
A. Starting at 12:00 o'clock position, use approved yellow tape and number each acoustic baffle, fuel nozzle
plug, fuel hose assembly, and fuel nozzle port (1 through 30, figure 2) indexing CCW (FLA). The No. 1
position is just CCW of 12:00 0’clock (FLA).
NOTE
Various brackets shall require removal with fuel nozzle plugs. Ensure brackets are tagged for location
and orientation prior to removal.
B. If required, remove bolts that secure bracket to fuel nozzle plug (5). Matchmark and attach tag that notes
location and orientation onto bracket. Remove brackets.
CAUTION
COVER OPEN FUEL NOZZLE PORT IMMEDIATELY AFTER REMOVAL OF EACH

ACOUSTIC BAFFLE, FUEL NOZZLE PLUG, OR FUEL HOSE ASSEMBLY TO PREVENT
ENGINE CONTAMINATION.
C. Remove four bolts (7, detail A), fuel hose assembly (8), and hose seal (9). Discard hose seal.
D. Remove bolts (1 and 2) that secure acoustic baffle (3 or 4) or fuel nozzle plug (5) to fuel nozzle (6).
Remove acoustic baffle or fuel nozzle plug. Remove and inspect metal seal rings (10) and replace if
required. Cover fuel nozzle port with tape.
E. Repeat step 8.A. through step 8.D. to remove remaining acoustic baffles and/or fuel nozzle plugs and fuel
hose assemblies as required.
9. Acoustic Baffles, Fuel Nozzle Plugs, and Fuel Hose Assembly Installation.
A. Lightly coat bolts (1, 2, and 7, figure 2), threads, and contact faces with thread lubricant.
B. Remove tape from fuel nozzle port. Install metal seal rings (10) onto fuel nozzle.
C. Install correct acoustic baffle (3 or 4) or fuel nozzle plug (5) onto correct fuel nozzle.
D. Using two short bolts (1), secure fuel nozzle plug (5) or acoustic baffle (3 or 4) onto fuel nozzle (6).
E. Using two long bolts (2), secure fuel nozzle plug (5) or acoustic baffle (3 or 4) onto fuel nozzle (6). Tighten
bolts hand-tight.
F. Using crisscross pattern, incrementally tighten bolts (1 and 2) to 202-238 lb in. (22.9-26.8 N·m) of torque
and safety-wire.

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Figure 2. Acoustic Baffles and Fuel Nozzle Plug Locations (Sheet 1 of 2)

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Figure 2. Acoustic Baffles and Fuel Nozzle Plug Locations (Sheet 2 of 2)

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G. Install fuel hose assembly (8) as follows:
(1) Install new hose seal (9) between fuel hose assembly (8) plate and fuel nozzle (6).
CAUTION
• EXCESSIVE TORQUE ON ONE BOLT WILL RESULT IN FUEL HOSE

ASSEMBLY IMPROPERLY SEATING ONTO FUEL NOZZLE.
• IMPROPER SEATING OF FUEL HOSE WILL RESULT IN FUEL LEAKAGE

DURING ENGINE OPERATION.
• DO NOT EXCEED 15 LB IN. (1.7 N·M) OF TORQUE DURING SEATING OF

FUEL HOSE ASSEMBLY ONTO FUEL NOZZLE OR DISTORTION OF FUEL
NOZZLE MAY OCCUR.
(2) Install four bolts (7) hand-tight to seat fuel hose assembly (8) onto fuel nozzle (6).
(3) Tighten bolts (figure 2, view B) in a sequence of bolt No. 3, bolt No. 1, bolt No. 4, and bolt No. 2, to
46-54 lb in. (5.2-6.1 N·m) of torque. Repeat three times to ensure bolts are equally tightened.
(4) Tighten bolts in a sequence of bolt No. 3, bolt No. 1, bolt No. 4, and bolt No. 2, to 92-108 lb in.
(7) Safety-wire four bolts (7).
H. Reinstall any brackets that were removed. Safety-wire bolts and remove tags.
I. Repeat step 9.A. through step 9.H. to reinstall all acoustic baffles and/or fuel nozzle plugs and fuel hose
assemblies that were removed to perform maintenance.
10. Fuel Nozzle Removal.
A. Starting at 12:00 o'clock position, number fuel nozzles (1 and 2, figure 3) on CRF from 1 to 30 with
marker, indexing CCW (FLA). The No. 1 fuel nozzle is just CCW of 12:00 0’clock position, FLA.
B. Remove liquid fuel manifold fuel tubes per paragraph 6.
C. Remove fuel hose assembly, hose seal, acoustic baffle, and/or fuel nozzle plug per paragraph 8.
D. Install fuel nozzle removal/installation tool, 1C9427, onto fuel nozzle and secure with four capscrews
(figure 4).

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Figure 3. Fuel Nozzle Removal/Installation

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Figure 4. Fuel Nozzle Removal/Installation Tool, 1C9427
CAUTION
COVER OPEN CRF PORT IMMEDIATELY AFTER REMOVAL OF EACH FUEL NOZZLE
TO PREVENT ENGINE CONTAMINATION.
E. Remove remaining four bolts (11, figure 2, detail A) and spacers (12) that secure fuel nozzle (6) to CRF
(13).
F. Remove fuel nozzle (6) from CRF (13).
G. Remove and inspect fuel nozzle seal (14). Replace seal if required.
H. Using tape, cover CRF port.
I. Remove fuel nozzle removal/installation tool, 1C9427, from fuel nozzle.
J. Repeat step 10.A. through step 10.I., as required, to perform required maintenance.

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11. Fuel Nozzle Installation.
A. Install fuel nozzle as follows:
(figure 4).
(2) Apply thread lubricant onto threads and contact faces of bolts (11, figure 2, detail A) that secure fuel
nozzle (6) onto CRF (13).
(3) Remove tape from CRF (13) port.
(4) Install fuel nozzle seal (14) onto fuel nozzle (6).
CAUTION
• USE CARE WHEN INSTALLING FUEL NOZZLES. DO NOT FORCE FUEL

NOZZLES INTO POSITION, OR DAMAGE COULD RESULT.
• INSTALL 3-CUP FUEL NOZZLES INTO EVEN NUMBER CRF PORTS AND
2-CUP FUEL NOZZLES INTO ODD NUMBER CRF PORTS, OR DAMAGE
COULD RESULT.
(5) Install fuel nozzle (6) into CRF (13) port. Refer to figure 3 to install correct fuel nozzle into correct
CRF port.
(6) Using four bolts (11, figure 2, detail A) and spacers (12), attach fuel nozzle (6) onto CRF (13).
(7) Remove fuel nozzle removal/installation tool (figure 4), 1C9427, from fuel nozzle.
(8) Install correct acoustic baffle (3 or 4, figure 2), or fuel nozzle plug (5) onto correct fuel nozzle.
(9) Apply thread lubricant to threads and faces of short bolts (1) and long bolts (2) that secure acoustic
baffles and/or fuel nozzle plugs onto fuel nozzle.
(10) Using two short bolts (1), secure fuel nozzle plug (5), or acoustic baffle (3 or 4) onto fuel nozzle (6).
(11) Using two long bolts (2), secure fuel nozzle plug (5), or acoustic baffle (3 or 4) onto fuel nozzle (6).
(12) Using crisscross pattern, incrementally tighten two bolts (2) and four bolts (11) (center two bolts
first) to 202-238 lb in. (22.9-26.8 N·m) of torque and safety-wire.
(13) Tighten two short bolts (1) to 202-238 lb in. (22.9-26.8 N·m) of torque and safety-wire.
(14) Install remaining removed fuel nozzles per step 11.A.(1) through step 11.A.(13).

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(15) Install fuel hose assemblies (8) per step 9.G.
(16) Install removed liquid fuel manifold tubes per paragraph 7.
12. Liquid Fuel Staging Valve Supply and Purge Tubes Removal.
WARNING


A. Remove fuel supply tube (19, figure 5, sheet 1) and fuel manifold (20) as follows:
(1) Loosen B-nut that secures fuel manifold (20) to fuel supply tube (19).
(2) Loosen B-nut that secures fuel supply tube (19) to aft port of B3-STG liquid fuel staging valve (1).
CAUTION
COVER OPEN STAGING VALVE FITTINGS IMMEDIATELY AFTER REMOVAL
OF EACH FUEL TUBE TO PREVENT ENGINE CONTAMINATION.
(3) Remove fuel supply tube (19).
WARNING

(4) Disconnect electrical connector (50) from sensor (49) on fuel manifold (20).
(5) Remove bolt (52, sheet 8, detail A) and clamp (53) that secure fuel manifold (20) to bracket (51).
See sheet 1 for location of detail A.
(6) Loosen B-nut that secures fuel manifold (20, sheet 1) to forward port of B3-PRG liquid fuel staging
valve (2).
(7) Loosen B-nut that secures fuel manifold (20, sheet 1) to B3 inlet on upper B2 B3-manifold (8,
figure 1, sheet 4, section D-D).
CAUTION

(8) Remove fuel manifold (20, figure 5).

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Figure 5. Liquid Fuel Staging Valve Fuel Supply and Purge Tubes Replacement (Sheet 1 of 16)

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WARNING


B. Remove fuel tube (21), fuel manifold (22), fuel manifold (23), fuel manifold (24), and fuel tube (25) as
follows:
(1) Loosen B-nut that secures fuel tube (21, sheet 4) and orifice cone to forward port of B3-STG liquid
fuel staging valve (1). Ensure orifice cone remains inside B-nut on fuel tube (21).
(2) Loosen B-nut that secures fuel manifold (22) to fuel tube (21).
CAUTION

(3) Remove fuel tube (21).
(4) Remove bolt (52, sheet 8, detail B) and clamp (53) that secure fuel manifold (22) to bracket (54).
See sheet 5 for location of detail B.
NOTE
The same bolt is used to secure both fuel manifold (22) and fuel manifold (36) in the
following step.
(5) Remove bolt (55, sheet 8, detail C) and clamp (53) that secure fuel manifold (22) to bracket (56).
See sheet 4 for location of detail C.
(6) Remove bolt (52, sheet 8, detail D) and clamp (53) that secure fuel manifold (22) to bracket (57).
See sheet 4 for location of detail D.
(7) Loosen B-nut that secures fuel manifold (22) to fuel manifold (23).
(8) Loosen B-nut that secures fuel tube (22, sheet 4) and orifice cone to forward port of B1A-STG
liquid fuel staging valve (3). Ensure orifice cone remains inside B-nut on fuel manifold (22).
CAUTION

(9) Remove fuel manifold (22).

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(10) Remove bolt (52, sheet 9, detail E) and clamp (53) that secure fuel manifold (23) to bracket (58).
See sheet 4 for location of detail E.
(11) Remove bolt (52, sheet 9, detail F) and clamp (53) that secure fuel manifold (23) to bracket (59). See
sheet 4 for location of detail F.
(12) Loosen B-nut that secures fuel manifold (23) to fuel manifold (24).
(14) Remove bolt (52, sheet 9, detail G) and clamp (53) that secure fuel manifold (24) to bracket (60).
See sheet 4 for location of detail G.
(15) Remove bolt (62, sheet 9, detail H) and clamp (53) that secure fuel manifold (24) to bracket (61).
See sheet 2 for location of detail H.
(16) Loosen B-nut that secures fuel tube (24, sheet 2) and orifice cone to forward port of C1-STG liquid
(17) Loosen B-nut that secures fuel tube (25, sheet 3) to fuel manifold (24, sheet 2).
CAUTION
(19) Remove bolt (52, sheet 10, detail J) and clamp (53) that secure fuel tube (25) to bracket (63). See
sheet 3 for location of detail J.
(20) Loosen B-nut that secures fuel tube (25, sheet 3) and orifice cone to forward port of B2-STG liquid
CAUTION


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WARNING


C. Remove fuel manifold (26), fuel tube (27), and fuel tube (28) as follows:
(1) Remove bolt (52, sheet 10, detail J) and clamp (53) that secure fuel manifold (26) to bracket (63).
See sheet 3 for location of detail J.
(2) Loosen B-nut that secures fuel manifold (26, sheet 3) to aft port of B2-STG liquid fuel staging valve
(18).
(3) Loosen B-nut that secures fuel manifold (26) to forward port of B2-PRG liquid fuel staging valve
(17).
(4) Loosen B-nut that secures fuel manifold (26) to fuel tube (27, sheet 2).
CAUTION
(6) Remove bolt (52, sheet 10, detail K) and clamp (53) that secure fuel tube (27) to bracket (64). See
sheet 2 for location of detail K.
(7) Remove bolt (52, sheet 9, detail G) and clamp (53) that secure fuel tube (27) to bracket (60). See
sheet 4 for location of detail G.
(8) Remove bolt (52, sheet 9, detail F) and clamp (53) that secure fuel tube (27) to bracket (59). See
sheet 4 for location of detail F.
(9) Loosen B-nut that secures fuel tube (28, sheet 2) to fuel tube (27).
WARNING

(11) Disconnect electrical connector (50) from sensor (49) on fuel tube (28, sheet 2).

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(12) Remove bolt (55, sheet 10, detail L) and clamp (53) that secure fuel tube (28) to bracket (65). See
sheet 2 for location of detail L.
(13) Remove bolt (52, sheet 10, detail M), nut (77), and clamp (53) that secure fuel tube (28) to clamp
(67) at two locations. See sheet 6 for location of detail M.
(14) Remove bolt (52, sheet 10, detail M) and clamp (53) that secure fuel tube (28) to bracket (66). See
sheet 6 for location of detail M.
(15) Loosen B-nut that secures fuel tube (28) to B2 inlet on lower B2 B3-manifold (9, figure 1, sheet 4,
section D-D).
(16) Remove fuel tube (28, figure 5).
WARNING

D. Remove fuel manifold (29), fuel tube (30), fuel manifold (31), fuel tube (32), and fuel manifold (33) as
follows:
(1) Loosen B-nut that secures fuel manifold (29, sheet 7) to aft port of B2-PRG liquid fuel staging valve
(17).
(2) Loosen B-nut that secures fuel manifold (29) to aft port of B1B-STG liquid fuel staging valve (15).
CAUTION
(5) Remove bolt (62, sheet 9, detail H) and clamp (53) that secure fuel tube (30) to bracket (61). See
sheet 2 for location of detail H.
(6) Remove bolt (52, sheet 11, detail N) and clamp (53) that secure fuel tube (30) to bracket (68). See
sheet 6 for location of detail N.
(7) Remove bolt (52, sheet 11, detail P) and clamp (53) that secure fuel tube (30) to bracket (69). See
sheet 7 for location of detail P.
(8) Loosen B-nut that secures fuel tube (30) to fuel manifold (31).

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(10) Remove bolt (52, sheet 11, detail R) and clamp (53) that secure fuel manifold (31) to bracket (70).
See sheet 7 for location of detail R.
(11) Remove bolt (52, sheet 11, detail T) and clamp (53) that secure fuel manifold (31) to bracket (71).
See sheet 4 for location of detail T.
(14) Remove bolt (62, sheet 12, detail U) and clamp (53) that secure fuel tube (32) to bracket (72). See
sheet 6 for location of detail U.
(15) Remove bolt (52, sheet 12, detail V) and clamp (53) that secure fuel tube (32) to bracket (73). See
sheet 6 for location of detail V.
(16) Loosen B-nut that secures fuel tube (32, sheet 5) to fuel manifold (33).
(18) Loosen B-nut that secures fuel manifold (33, sheet 5) to aft port of B1A-PRG liquid fuel staging
valve (4).
(19) Loosen B-nut that secures fuel manifold (33) to aft port of B3-PRG liquid fuel staging valve (2).
CAUTION
E. Remove fuel tube (34) and fuel tube (35) as follows:
(1) Remove bolt (52, sheet 12, detail W) and clamp (53) that secure fuel tube (34) to bracket (74). See
sheet 5 for location of detail W.
(2) Loosen B-nut that secures fuel manifold (34, sheet 5) to aft port of B1A-STG liquid fuel staging
valve (3).
(3) Loosen B-nut that secures fuel manifold (34) to forward port of B1A-PRG liquid fuel staging valve
(4).
(4) Loosen B-nut that secures fuel tube (35) to fuel manifold (34).

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CAUTION

(6) Remove bolt (52, sheet 12, detail V) and clamp (53) that secure fuel tube (35) to bracket (73). See
sheet 6 for location of detail V.
(7) Remove bolt (55, sheet 12, detail U) and clamp (53) that secure fuel tube (35) to bracket (72). See
sheet 6 for location of detail U.
WARNING
(8) Disconnect electrical connector (50) from sensor (49) on fuel tube (35).
(9) Remove bolt (52, sheet 12, detail X) and clamp (53) that secure fuel tube (35) to bracket (75). See
sheet 1 for location of detail X.
(10) Loosen B-nut that secures fuel tube (35) to B1A inlet on lower B1A B1B-manifold (3, figure 1,
sheet 3, section C-C).
WARNING


F. Remove fuel manifold (36) as follows:
NOTE
following step.
(2) Remove bolt (52, sheet 8, detail D) and clamp (53) that secure fuel manifold (36) to bracket (57).
See sheet 4 for location of detail D.

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(3) Remove bolt (52, sheet 13, detail Y) and clamp (76) that secure fuel manifold (36) to bracket (79).
See sheet 5 for location of detail Y.
(4) Loosen B-nut that secures fuel manifold (36, sheet 4) and orifice cone to forward port of A1-STG
(5) Loosen B-nut that secures fuel manifold (36, sheet 5) and orifice cone to forward port of A2A-STG
(6) Loosen B-nut that secures fuel manifold (36) and orifice cone to forward port of A2B-STG liquid
fuel staging valve (10). Ensure orifice cone remains inside B-nut on fuel manifold (36).
CAUTION
WARNING


G. Remove fuel manifold (37) as follows:
WARNING

(4) Remove bolt (52, sheet 13, detail Z), nut (77), and clamp (53) that secure fuel tube (37) to clamp
(67). See sheet 3 for location of detail Z.
(5) Remove bolt (52, sheet 13, detail AA), nut (77), and clamp (53) that secure fuel tube (37) to clamp
(78). See sheet 3 for location of detail AA.

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(6) Remove bolt (52, sheet 13, detail AB) and clamp (53) that secure fuel manifold (37) to bracket (80).
See sheet 2 for location of detail AB.
(7) Loosen B-nut that secures fuel manifold (37, sheet 4) to aft port of A1-STG liquid fuel staging valve
(5).
(8) Loosen B-nut that secures fuel manifold (37) to forward port of A1-PRG liquid fuel staging valve
(6).
(9) Loosen B-nut that secures fuel manifold (37) to A1 inlet on lower A1-manifold (figure 1, sheet 4,
section E-E).
CAUTION
WARNING


H. Remove fuel manifold (38) as follows:
(1) Remove bolt (52, sheet 14, detail AC) and clamp (53) that secure fuel manifold (38) to bracket (81).
See sheet 7 for location of detail AC.
(2) Remove bolt (52, sheet 11, detail R) and clamp (53) that secure fuel manifold (38) to bracket (70).
See sheet 7 for location of detail R.
(3) Loosen B-nut that secures fuel manifold (38, sheet 7) to aft port of A1-PRG liquid fuel staging valve
(6).
(4) Loosen B-nut that secures fuel manifold (38) to aft port of A2A-PRG liquid fuel staging valve (7).
(5) Loosen B-nut that secures fuel manifold (38) to aft port of A2A-STG liquid fuel staging valve (8).

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CAUTION

WARNING


I. Remove fuel manifold (39) as follows:
(1) Remove bolt (52, sheet 13, detail AB) and clamp (53) that secure fuel manifold (39) to bracket (80).
See sheet 2 for location of detail AB.
(2) Remove bolt (55, sheet 10, detail L) and clamp (53) that secure fuel manifold (39) to bracket (65).
See sheet 2 for location of detail L.
WARNING

(4) Loosen B-nut that secures fuel manifold (39, sheet 2) to forward port of A2A-PRG liquid fuel
staging valve (7).
(5) Loosen B-nut that secures fuel manifold (39) to aft port of A2A-STG liquid fuel staging valve (8).
(6) Loosen B-nut that secures fuel manifold (39) to A2A inlet on lower A2A A2B-manifold (6, figure 1,
CAUTION

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WARNING


J. Remove fuel manifold (40) as follows:
(1) Remove bolt (55, sheet 14, detail AD) and clamp (53) that secure fuel manifold (40) to bracket (65).
See sheet 2 for location of detail AD.
(2) Loosen B-nut that secures fuel manifold (40, sheet 2) to forward port of A2B-PRG liquid fuel
staging valve (9).
(3) Loosen B-nut that secures fuel manifold (40) to aft port of A2B-STG liquid fuel staging valve (10).
WARNING

(5) Loosen B-nut that secures fuel manifold (40) to A2B inlet on lower A2A A2B-manifold (6, figure 1,
CAUTION
WARNING


K. Remove fuel manifold (41) as follows:

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(2) Remove bolt (52, sheet 14, detail AE) and clamp (82) that secure fuel manifold (41) to bracket (83).
See sheet 3 for location of detail AE.
NOTE
following step.
(3) Remove bolt (55, sheet 14, detail AF) and clamp (82) that secure fuel manifold (41) to bracket (85).
See sheet 3 for location of detail AF.
(4) Loosen B-nut that secures fuel manifold (41, sheet 2) to aft port of C2-STG liquid fuel staging valve
(11).
(5) Loosen B-nut that secures fuel manifold (41) to forward port of C2-PRG liquid fuel staging valve
(12).
WARNING

(7) Loosen B-nut that secures fuel manifold (41) to C2 inlet on lower C2-manifold (18, figure 1, sheet 5,
section G-G).
CAUTION

WARNING


L. Remove fuel tube (42) and fuel tube (43) as follows:
(1) Loosen B-nut that secures fuel tube (42, sheet 5) and orifice cone to forward port of C2-STG liquid
(2) Loosen B-nut that secures fuel tube (43) to fuel tube (42).

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CAUTION

(4) Remove bolt (55, sheet 15, detail AG) and clamp (82) that secure fuel tube (43) to bracket (65). See
sheet 5 for location of detail AG.
(5) Loosen B-nut that secures fuel manifold (43) and orifice cone to forward port of B1B-PRG liquid
fuel staging valve (14). Ensure orifice cone remains inside B-nut on fuel manifold (43).
CAUTION
WARNING


M. Remove fuel manifold (44) as follows:
(2) Loosen B-nut that secures fuel manifold (44, sheet 5) to aft port of C2-PRG liquid fuel staging valve
(12).
(3) Loosen B-nut that secures fuel manifold (44) to aft port of C1-STG liquid fuel staging valve (13).
CAUTION

N. Remove fuel manifold (45) and fuel tube (46) as follows:
(1) Remove bolt (62, sheet 9, detail H) and clamp (53) that secure fuel manifold (45) to bracket (61).
See sheet 2 for location of detail H.

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(2) Remove bolt (52, sheet 11, detail N) and clamp (53) that secure fuel manifold (45) to bracket (68).
See sheet 6 for location of detail N.
(3) Loosen B-nut that secures fuel manifold (45) to fuel tube (46, sheet 2).
(4) Loosen B-nut that secures fuel manifold (45) to aft port of C1-STG liquid fuel staging valve (16).
(5) Loosen B-nut that secures fuel manifold (45) to forward port of B1B-STG liquid fuel staging valve
(15).
CAUTION

(7) Remove bolt (55, sheet 15, detail AH) and clamp (53) that secure fuel tube (46) to bracket (65). See
sheet 6 for location of detail AH.
(8) Remove bolt (52, sheet 15, detail AJ) and clamp (53) that secure fuel tube (46) to bracket (86). See
sheet 1 for location of detail AJ.
(9) Remove bolt (52, sheet 15, detail AJ) and clamp (53) that secure fuel tube (46) to bracket (87).
WARNING

(11) Loosen B-nut that secures fuel tube (46) to B1B inlet on lower B1A B1B-manifold (3, figure 1,
sheet 3, section B-B).
WARNING


O. Remove fuel tube (47) and fuel manifold (48) as follows:
(1) Remove bolt (62, sheet 15, detail AG) and clamp (82) that secure fuel tube (47) to bracket (65). See
sheet 5 for location of detail AG.

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(2) Loosen B-nut that secures fuel tube (47, sheet 5) to fuel manifold (48).
(3) Loosen B-nut that secures fuel tube (47) to aft port of B1B-PRG liquid fuel staging valve (14).
CAUTION

WARNING

(7) Remove bolt (52, sheet 14, detail AE) and clamp (82) that secure fuel manifold (48) to bracket (83).
See sheet 3 for location of detail AE.
(8) Remove bolt (52, sheet 15, detail AK), nut (77), and clamp (82) that secure fuel manifold (48) to
clamp (84). See sheet 3 for location of detail AK.
NOTE
following step.
(9) Remove bolt (55, sheet 14, detail AF) and clamp (82) that secure fuel manifold (48) to bracket (85).
See sheet 3 for location of detail AF.
(10) Remove bolt (52, sheet 15, detail AF), nut (77), and clamp (82) that secure fuel manifold (48) to
clamp (84).
(11) Loosen B-nut that secures fuel manifold (48, sheet 5) to forward port of C1-PRG liquid fuel staging
valve (13).
(12) Loosen B-nut that secures fuel manifold (48) to C1 inlet on lower C1-manifold (15, figure 1, sheet 5,
section F-F).
CAUTION

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13. Liquid Fuel Staging Valve Supply and Purge Tubes Installation.
A. Install fuel manifold (48, figure 5) and fuel tube (47) as follows:
WARNING

(1) Lubricate B-nut threads and ferrules of fuel manifold (48) with lubricating oil.
(2) Position short leg of fuel manifold (48, sheet 3) adjacent to forward port of C1-PRG liquid fuel
staging valve (13). Route end of long leg up over staging valves pointing aft.
(3) Connect B-nut to secure fuel manifold (48) onto C1 inlet on lower C1-manifold (15, figure 1,
sheet 5, section F-F). Tighten B-nut hand-tight.
(4) Connect B-nut to secure fuel manifold (48) onto forward port of C1-PRG liquid fuel staging valve
(13). Tighten B-nut hand-tight.
(5) Lightly coat threads and contact faces of three bolts (52), bolt (54), and bolt (55) with thread
lubricant.
(6) Using bolt (52, sheet 15, detail AF), nut (77), and clamp (82), secure fuel manifold (48) onto clamp
(84). Tighten nut to 60-70 lb in. (6.8-7.9 N·m) of torque. See sheet 3 for location of detail AF.
(7) Using bolt (55, sheet 14, detail AF) and clamp (82), secure fuel manifold (48) onto bracket (85).
Tighten bolt to 60-70 lb in. (6.8-7.9 N·m) of torque.
(8) Using bolt (52, sheet 15, detail AK), nut (77), and clamp (82), secure fuel manifold (48) onto clamp
(84). Tighten nut to 60-70 lb in. (6.8-7.9 N·m) of torque. See sheet 3 for location of detail AK.
(9) Using bolt (52, sheet 14, detail AE) and clamp (82), secure fuel manifold (48) onto bracket (83).
Tighten bolt to 60-70 lb in. (6.8-7.9 N·m) of torque. See sheet 3 for location of detail AE.
WARNING

(10) Connect electrical connector (50) onto sensor (49) on fuel manifold (48) as follows:
(a) Engage electrical connector with mating threads of sensor and turn knurled coupling rings
while wiggling backshells of electrical connector.
(b) Fully seat electrical connector by hand.

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(c) After fully seating connector by hand, tighten connector with Teflon-jawed pliers until slippage
(d) Check tightness by wiggling connector backshell. No movement shall occur.
(11) Using bolt (54, sheet 9, detail G) and clamp (82), secure fuel manifold (48) onto bracket (65).
Tighten bolt to 60-70 lb in. (6.8-7.9 N·m) of torque. See sheet 4 for location of detail G.
(12) Triple torque B-nut at staging valve joint as follows:
(d) Check the joint by reapplying 55-65 lb ft (75-88 N·m) of torque to the B-nut in the tightening
direction.
(13) Triple torque B-nut at manifold ring joint as follows:
(a) Tighten B-nut to 460-540 lb in. (52.0-61.0 N·m) of torque.
(c) Retighten B-nut to 460-540 lb in. (52.0-61.0 N·m) of torque.
(d) Check the joint by reapplying 460-540 lb in. (52.0-61.0 N·m) of torque to the B-nut in the
WARNING

(14) Lubricate B-nut threads and ferrules of fuel tube (47) with lubricating oil.
(15) Position ends of fuel tube (47, sheet 3) adjacent to aft port of B1B-PRG liquid fuel staging valve
(14) and open end of fuel manifold (48).
(16) Connect B-nut to secure fuel tube (47) onto forward port of B1B-PRG liquid fuel staging valve (14).
Tighten B-nut hand-tight.
(17) Connect B-nut to secure fuel tube (47) onto open end of fuel manifold (48). Tighten B-nut hand-
tight.
(18) Lightly coat threads and contact faces of bolt (62) with thread lubricant.

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(19) Using bolt (62, sheet 15, detail AG) and clamp (82), secure fuel tube (47) onto bracket (65). Tighten
bolt to 60-70 lb in. (6.8-7.9 N·m) of torque. See sheet 5 for location of detail AG.
(20) Triple torque B-nut at staging valve joint per step 13.A.(12).
(21) Triple torque B-nut at tube joint as follows:
(a) Tighten B-nut to 460-540 lb in. (52.0-61.0 N·m) of torque.
(c) Retighten B-nut to 460-540 lb in. (52.0-61.0 N·m) of torque.
(d) Check the joint by reapplying 460-540 lb in. (52.0-61.0 N·m) of torque to the B-nut in the
B. Install fuel tube (46) and fuel manifold (45) as follows:
(1) Lubricate B-nut threads and ferrules of fuel tube (46, sheet 1) with lubricating oil.
(2) Position fuel tube (46) adjacent to brackets (86 and 87, sheet 15, detail AJ). See sheet 1 for detail AJ.
(3) Connect B-nut to secure fuel tube (46) onto B1B inlet on lower B1A B1B-manifold (3, figure 1,
sheet 3, section B-B). Tighten B-nut hand-tight.
WARNING

(4) Connect electrical connector (50) onto sensor (49) on fuel tube (46) per step 13.A.(10)(a) through
step 13.A.(1)(d).
(5) Lightly coat threads and contact faces of two bolts (52, sheet 5) and bolt (55) with thread lubricant.
(6) Using bolt (52, sheet 15, detail AJ) and clamp (53), secure fuel tube (46) onto bracket (87). Tighten
bolt to 60-70 lb in. (6.8-7.9 N·m) of torque. See sheet 1 for location of detail AJ.
(7) Using bolt (52, sheet 15, detail AJ) and clamp (53) that secure fuel tube (46) to bracket (86). Tighten
bolt to 60-70 lb in. (6.8-7.9 N·m) of torque.
(8) Using bolt (55, sheet 15, detail AH) and clamp (53), secure fuel tube (46) onto bracket (65). Tighten
bolt to 60-70 lb in. (6.8-7.9 N·m) of torque. See sheet 6 for location of detail AH.

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direction.
WARNING
(10) Lubricate B-nut threads and ferrules of fuel manifold (45, sheet 2) with lubricating oil.
(11) Position fuel tube (45) with two ends adjacent to forward port of B1B-STG liquid fuel staging valve
(15) and aft port of C1-STG liquid fuel staging valve (16) with remaining end adjacent to open end
of fuel tube (46).
(12) Connect B-nut to secure fuel manifold (45) onto forward port of B1B-STG liquid fuel staging valve
(13) Connect B-nut to secure fuel manifold (45) onto aft port of C1-STG liquid fuel staging valve (16).
(14) Connect B-nut to secure fuel manifold (45) onto open end of fuel tube (46, sheet 2). Tighten B-nut
hand-tight.
(15) Lightly coat threads and contact faces of bolt (52) and bolt (62) with thread lubricant.
(16) Using bolt (52, sheet 11, detail N) and clamp (53), secure fuel manifold (45) onto bracket (68).
Tighten bolt to 60-70 lb in. (6.8-7.9 N·m) of torque. See sheet 6 for location of detail N.
(17) Using bolt (62, sheet 9, detail H) and clamp (53), secure fuel manifold (45) onto bracket (61).
Tighten bolt to 60-70 lb in. (6.8-7.9 N·m) of torque. See sheet 2 for location of detail H.
(18) Triple torque B-nuts at staging valve joints and tube joint as follows:
direction.

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C. Install fuel manifold (44) as follows:
WARNING

(1) Lubricate B-nut threads and ferrules of fuel purge manifold (44, sheet 5) with lubricating oil.
(2) Position fuel tube (44) with two ends adjacent to aft port of C1-STG liquid fuel staging valve (13)
and aft port of C2-PRG liquid fuel staging valve (12) with remaining end pointing forward.
(3) Connect B-nut to secure fuel manifold (44) onto aft port of C1-STG liquid fuel staging valve (13).
(4) Connect B-nut to secure fuel manifold (44, sheet 5) onto aft port of C2-PRG liquid fuel staging
valve (12). Tighten B-nut hand-tight.
(7) Triple torque B-nuts at staging valve joints per step 13.A.(12).
D. Install fuel tube (43) and fuel tube (42) as follows:
(1) Lubricate B-nut threads and ferrules of fuel manifold (43, sheet 5) with lubricating oil. Ensure
orifice cone remains inside B-nut on fuel manifold.
(2) Position fuel tube (43) with one end adjacent to forward port of B1B-PRG liquid fuel staging valve
(14) and remaining end pointing forward.
(3) Connect B-nut to secure fuel manifold (43) and orifice cone onto forward port of B1B-PRG liquid
fuel staging valve (14). Tighten B-nut hand-tight.
(5) Using bolt (55, sheet 15, detail AG) and clamp (82), secure fuel tube (43) onto bracket (65). Tighten
bolt to 60-70 lb in. (6.8-7.9 N·m) of torque. See sheet 5 for location of detail AG.
orifice cone remains inside B-nut on fuel manifold.

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(8) Position ends of fuel tube (42) adjacent to forward port of C2-STG liquid fuel staging valve (11) and
open end of fuel tube (43).
(9) Connect B-nut to secure fuel tube (42) and orifice cone onto forward port of C2-STG liquid fuel
staging valve (11). Tighten B-nut hand-tight.
(10) Connect B-nut to secure fuel tube (43) onto fuel manifold (43). Tighten B-nut hand-tight.
(12) Triple torque B-nut at tube joint per step 13.A.(21).
E. Install fuel manifold (41) as follows:
WARNING

(2) Position short legs of fuel manifold (41) adjacent to forward port of C2-PRG liquid fuel staging
valve (12) and aft port of C2-STG liquid fuel staging valve (11). Route end of long leg up over
staging valves pointing aft.
(3) Connect B-nut to secure fuel manifold (41) onto C2 inlet on lower C2-manifold (18, figure 1,
sheet 5, section G-G). Tighten B-nut hand-tight.
WARNING

(4) Connect electrical connector (50, figure 5) onto sensor (49) on fuel manifold (41) per step
13.A.(10)(a) through step 13.A.(10)(d).
(5) Connect B-nut to secure fuel manifold (41) onto forward port of C2-PRG liquid fuel staging valve
(6) Connect B-nut to secure fuel manifold (41, sheet 2) onto aft port of C2-STG liquid fuel staging
(7) Lightly coat threads and contact faces of bolt (52) and two bolts (55) with thread lubricant.
(8) Using bolt (52, sheet 14, detail AE), and clamp (82), secure fuel manifold (41) onto bracket (83).
Tighten bolt to 60-70 lb in. (6.8-7.9 N·m) of torque. See sheet 3 for location of detail AE.

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NOTE
following step.
(9) Using bolt (55, sheet 14, detail AF) and clamp (82), secure fuel manifold (41) onto bracket (85).
Tighten bolt to 60-70 lb in. (6.8-7.9 N·m) of torque. See sheet 3 for location of detail AF.
(10) Using bolt (55, sheet 10, detail L) and clamp (53), secure fuel tube (41) onto bracket (65). Tighten
bolt to 60-70 lb in. (6.8-7.9 N·m) of torque. See sheet 2 for location of detail L.
(12) Triple torque B-nut at manifold ring joint per step 13.A.(13).
F. Install fuel manifold (40) as follows:
WARNING
(2) Position short legs of fuel manifold (40) adjacent to aft port of A2B-STG liquid fuel staging valve
(10) and forward port of A2B-PRG liquid fuel staging valve (9). Route end of long leg up over
(3) Connect B-nut to secure fuel manifold (40) onto A2B inlet on lower A2A A2B-manifold (6,
figure 1, sheet 3, section C-C). Tighten B-nut hand-tight.
WARNING
(4) Connect electrical connector (50) onto sensor (49) on fuel manifold (40) per step 13.A.(10)(a)
through step 13.A.(1)(d).
(5) Connect B-nut to secure fuel manifold (40) onto aft port of A2B-STG liquid fuel staging valve (10).
(6) Connect B-nut to secure fuel manifold (40) onto forward port of A2B-PRG liquid fuel staging valve

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(8) Using bolt (55, sheet 14, detail AD) and clamp (53), secure fuel manifold (40) onto bracket (65).
Tighten bolt to 60-70 lb in. (6.8-7.9 N·m) of torque. See sheet 2 for location of detail AD.
(9) Triple torque B-nuts at staging valve joints and manifold ring joint as follows:
direction.
G. Install fuel manifold (39) as follows:
WARNING

(2) Position short legs of fuel manifold (39) adjacent to aft port of A2A-STG liquid fuel staging valve
(8) and forward port of A2A-PRG liquid fuel staging valve (7). Route end of long leg up over
(3) Connect B-nut to secure fuel manifold (39) onto A2A inlet on lower A2A A2B-manifold (6,
figure 1, sheet 3, section C-C). Tighten B-nut hand-tight.
(4) Connect B-nut to secure fuel manifold (39, figure 5) onto aft port of A2A-STG liquid fuel staging
(5) Connect B-nut to secure fuel manifold (39, sheet 2) onto forward port of A2A-PRG liquid fuel
WARNING

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(8) Using bolt (55, sheet 10, detail L) and clamp (53), secure fuel manifold (39) onto bracket (65).
Tighten bolt to 60-70 lb in. (6.8-7.9 N·m) of torque. See sheet 2 for location of detail L.
(9) Using bolt (52, sheet 13, detail AB) and clamp (53), secure fuel manifold (39) onto bracket (80).
Tighten bolt to 60-70 lb in. (6.8-7.9 N·m) of torque. See sheet 2 for location of detail AB.
(10) Triple torque B-nuts at staging valve joints and manifold ring joint per step 13.F.(9).
H. Install fuel manifold (38) as follows:
WARNING

(2) Position short legs of fuel manifold (38) adjacent to aft port of A2A-STG liquid fuel staging valve
(8), aft port of A2A-PRG liquid fuel staging valve (7), and aft port of A1-PRG liquid fuel staging
valve (6).
(3) Connect B-nut to secure fuel manifold (38) onto aft port of A2A-STG liquid fuel staging valve (8).
(4) Connect B-nut to secure fuel manifold (38) onto aft port of A2A-PRG liquid fuel staging valve (7).
(5) Connect B-nut to secure fuel manifold (38) onto aft port of A1-PRG liquid fuel staging valve (6).
(6) Lightly coat threads and contact faces of two bolts (52) with thread lubricant.
(7) Using bolt (52, sheet 11, detail R) and clamp (53), secure fuel manifold (38) onto bracket (70).
Tighten bolt to 60-70 lb in. (6.8-7.9 N·m) of torque. See sheet 7 for location of detail R.
(8) Using bolt (52, sheet 14, detail AC) and clamp (53), secure fuel manifold (38) onto bracket (81).
Tighten bolt to 60-70 lb in. (6.8-7.9 N·m) of torque. See sheet 7 for location of detail AC.

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I. Install fuel manifold (37) as follows:
WARNING

(2) Position short legs of fuel manifold (37) adjacent to forward port of A1-PRG liquid fuel staging
valve (6) and aft port of A1-STG liquid fuel staging valve (5). Route end of long leg up over staging
valves pointing aft.
(3) Connect B-nut to secure fuel manifold (37) onto A1 inlet on lower A1-manifold (figure 1, sheet 4,
section E-E). Tighten B-nut hand-tight.
(4) Connect B-nut to secure fuel manifold (37, figure 5) onto forward port of A1-PRG liquid fuel
staging valve (6).
(5) Connect B-nut to secure fuel manifold (37) onto aft port of A1-STG liquid fuel staging valve (5).
(6) Lightly coat threads and contact faces of three bolts (52) and two nuts (77) with thread lubricant.
(7) Using bolt (52, sheet 13, detail AB) and clamp (53), secure fuel manifold (37) onto bracket (80).
Tighten bolt to 60-70 lb in. (6.8-7.9 N·m) of torque. See sheet 2 for location of detail AB.
(8) Using bolt (52, sheet 13, detail AA), nut (77), and clamp (53), secure fuel tube (37) onto clamp (78).
Tighten nut to 60-70 lb in. (6.8-7.9 N·m) of torque. See sheet 3 for location of detail AA.
(9) Using bolt (52, sheet 13, detail Z), nut (77), and clamp (53), secure fuel tube (37) onto clamp (67).
Tighten nut to 60-70 lb in. (6.8-7.9 N·m) of torque. See sheet 3 for location of detail Z.
WARNING

step 13.A.(10)(d).
(12) Using bolt (52, sheet 8, detail C) and clamp (53), secure fuel manifold (37) onto bracket (56).
Tighten bolt to 60-70 lb in. (6.8-7.9 N·m) of torque. See sheet 4 for location of detail C.
(13) Triple torque B-nuts at staging valve joints and manifold ring joint per step 13.F.(9).

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J. Install fuel manifold (36) as follows:
WARNING

orifice cones remain inside B-nuts on fuel manifold (36).
(2) Position legs of fuel manifold (36) adjacent to forward port of A2B-STG liquid fuel staging valve
(10), forward port of A2A-STG liquid fuel staging valve (8), and forward port of A1-STG liquid
fuel staging valve (5).
(3) Connect B-nut to secure fuel manifold (36) and orifice cone onto forward port of A2B-STG liquid
fuel staging valve (10). Tighten B-nut hand-tight.
(4) Connect B-nut to secure fuel manifold (36, sheet 5) and orifice cone onto forward port of A2A-STG
liquid fuel staging valve (8). Tighten B-nut hand-tight.
(5) Connect B-nut to secure fuel manifold (36, sheet 4) and orifice cone onto forward port of A1-STG
liquid fuel staging valve (5). Tighten B-nut hand-tight.
(6) Lightly coat threads and contact faces of two bolts (52) and bolt (55) with thread lubricant.
(7) Using bolt (52, sheet 13, detail Y) and clamp (76), secure fuel manifold (36) onto bracket (79).
Tighten bolt to 60-70 lb in. (6.8-7.9 N·m) of torque. See sheet 5 for location of detail Y.
(8) Using bolt (52, sheet 8, detail D) and clamp (53), secure fuel manifold (36) onto bracket (57).
Tighten bolt to 60-70 lb in. (6.8-7.9 N·m) of torque. See sheet 4 for location of detail D.
NOTE
following step.

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K. Install fuel tube (35) and fuel tube (34) as follows:
WARNING

(1) Lubricate B-nut threads and ferrules of fuel tube (35, sheet 1) with lubricating oil.
(2) Position fuel tube (35) adjacent to bracket (75, sheet 12, detail X) and bracket (73, sheet 12,
detail V) with end of short leg pointing aft. See sheet 1 for location of detail X and sheet 6 for
location of detail V.
(3) Connect B-nut to secure fuel tube (35) onto B1A inlet on lower B1A B1B-manifold (3, figure 1,
sheet 3, section C-C). Tighten B-nut hand-tight.
(5) Using bolt (52, figure 5, sheet 12, detail X) and clamp (53), secure fuel tube (35) onto bracket (75).
Tighten bolt to 60-70 lb in. (6.8-7.9 N·m) of torque. See sheet 1 for location of detail X.
WARNING
step 13.A.(10)(d).
(7) Using bolt (55, sheet 12, detail U) and clamp (53), secure fuel tube (35) onto bracket (72). Tighten
bolt to 60-70 lb in. (6.8-7.9 N·m) of torque. See sheet 6 for location of detail U.
(8) Using bolt (52, sheet 12, detail V) and clamp (53), secure fuel tube (35) onto bracket (73). Tighten
bolt to 60-70 lb in. (6.8-7.9 N·m) of torque. See sheet 6 for location of detail V.
direction.

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WARNING

(11) Position short legs of fuel tube (34, sheet 5) adjacent to forward port of B1A-PRG liquid fuel staging
valve (4) and aft port of B1A-STG liquid fuel staging valve (3) with remaining end adjacent to open
end of fuel tube (35).
(12) Connect B-nut to secure fuel tube (34) onto open end of fuel tube (35). Tighten B-nut hand-tight.
(13) Connect B-nut to secure fuel manifold (34) onto forward port of B1A-PRG liquid fuel staging valve
(14) Connect B-nut to secure fuel manifold (34, sheet 5) onto aft port of B1A-STG liquid fuel staging
(16) Using bolt (52, sheet 12, detail W) and clamp (53), secure fuel tube (34) onto bracket (74). Tighten
bolt to 60-70 lb in. (6.8-7.9 N·m) of torque. See sheet 5 for location of detail W.
(17) Triple torque B-nuts at staging valve joints and tube joint per step 13.B.(18).
L. Install fuel manifold (33), fuel tube (32), fuel manifold (31), fuel tube (30), and fuel manifold (29) as
follows:
(2) Position legs of fuel tube (33, sheet 5) adjacent to aft port of B3-PRG liquid fuel staging valve (2)
and aft port of B1A-PRG liquid fuel staging valve (4) with remaining end pointing downward.
(3) Connect B-nut to secure fuel manifold (33) onto aft port of B3-PRG liquid fuel staging valve (2).
(4) Connect B-nut to secure fuel manifold (33) onto aft port of B1A-PRG liquid fuel staging valve (4).
(7) Position end fuel tube (32, sheet 5) with B-nut adjacent to open end of fuel manifold (33) with
remaining end pointing inboard.

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(10) Using bolt (52, sheet 12, detail V) and clamp (53), secure fuel tube (32) onto bracket (73). Tighten
bolt to 60-70 lb in. (6.8-7.9 N·m) of torque. See sheet 6 for location of detail V.
(11) Using bolt (62, sheet 12, detail U) and clamp (53), secure fuel tube (32) onto bracket (72). Tighten
bolt to 60-70 lb in. (6.8-7.9 N·m) of torque. See sheet 6 for location of detail U.
(12) Triple torque B-nut at tube joint as follows:
direction.
WARNING

(14) Position end fuel manifold (31, sheet 6) with B-nut adjacent to open end of fuel tube (32) and
opposite end pointing outboard with remaining end pointing forward.
(15) Connect B-nut to secure fuel manifold (31) onto fuel tube (32). Tighten B-nut hand-tight.
(17) Using bolt (52, sheet 11, detail T) and clamp (53), secure fuel tube (31) onto bracket (71). Tighten
bolt to 60-70 lb in. (6.8-7.9 N·m) of torque. See sheet 4 for location of detail T.
(18) Using bolt (52, sheet 11, detail R) and clamp (53), secure fuel tube (31) onto bracket (70). Tighten
bolt to 60-70 lb in. (6.8-7.9 N·m) of torque. See sheet 7 for location of detail R.
(19) Triple torque B-nut at tube joint per step 13.L.(12).

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(21) Position end fuel tube (30, sheet 6) with B-nut adjacent to open end of fuel tube (31) and opposite
end pointing upward.
(24) Using bolt (52, sheet 11, detail P) and clamp (53), secure fuel tube (30) onto bracket (69). Tighten
bolt to 60-70 lb in. (6.8-7.9 N·m) of torque. See sheet 7 for location of detail P.
(25) Using bolt (52, sheet 11, detail N) and clamp (53), secure fuel tube (30) onto bracket (68). Tighten
bolt to 60-70 lb in. (6.8-7.9 N·m) of torque. See sheet 6 for location of detail N.
(26) Using bolt (62, sheet 9, detail H) and clamp (53), secure fuel tube (30) onto bracket (61). Tighten
bolt to 60-70 lb in. (6.8-7.9 N·m) of torque. See sheet 2 for location of detail H.
WARNING

(29) Position ends fuel manifold (29, sheet 7) adjacent to aft port of B2-PRG liquid fuel staging valve
(17), aft port of B1B-STG liquid fuel staging valve (15), and open end of fuel tube (30).
(31) Connect B-nut to secure fuel manifold (29) onto aft port of B1B-STG liquid fuel staging valve (15).
(32) Connect B-nut to secure fuel manifold (29) onto aft port of B2-PRG liquid fuel staging valve (17).
M. Install fuel tube (28), fuel tube (27), and fuel manifold (26) as follows:
(2) Position fuel tube (28, sheet 2) with sensor (49) between A2A STG liquid fuel staging valve and
A2B PRG liquid fuel staging valve with long leg pointing aft.
(3) Connect B-nut to secure fuel tube (28) onto B2 inlet on lower B2 B3-manifold (9, figure 1, sheet 4,
section D-D). Tighten B-nut hand-tight.
(4) Lightly coat threads and contact faces of two bolts (52, figure 5) and bolt (55) with thread lubricant.

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(5) Using bolt (52, figure 5, sheet 10, detail M) and clamp (53), secure fuel tube (28) onto bracket (66).
Tighten bolt to 60-70 lb in. (6.8-7.9 N·m) of torque. See sheet 6 for location of detail M.
(6) Using bolt (52, sheet 10, detail M), nut (77), and clamp (53), secure fuel tube (28) onto clamp (67) at
two locations. Tighten bolt to 60-70 lb in. (6.8-7.9 N·m) of torque. See sheet 6 for location of detail
M.
WARNING
step 13.A.(10)(d).
(9) Triple torque B-nut at manifold ring joint per step 13.K.(9).
WARNING
(11) Position end of fuel tube (27, sheet 2) adjacent to open end of fuel tube (28) with remaining end
pointing upward.
(12) Connect B-nut to secure fuel tube (28) onto fuel tube (27). Tighten B-nut hand-tight.
(13) Lightly coat threads and contact faces of three bolts (52) with thread lubricant.
(14) Using bolt (52, sheet 9, detail F) and clamp (53), secure fuel tube (27) onto bracket (59). Tighten
bolt to 60-70 lb in. (6.8-7.9 N·m) of torque. See sheet 4 for location of detail F.
(15) Using bolt (52, sheet 9, detail G) and clamp (53), secure fuel tube (27) onto bracket (60). Tighten
bolt to 60-70 lb in. (6.8-7.9 N·m) of torque. See sheet 4 for location of detail G.
(16) Using bolt (52, sheet 10, detail K) and clamp (53), secure fuel tube (27) onto bracket (64). Tighten
bolt to 60-70 lb in. (6.8-7.9 N·m) of torque. See sheet 2 for location of detail K.

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WARNING

(19) Position short legs of fuel manifold (26, sheet 3) adjacent to forward port of B2-PRG liquid fuel
staging valve (17) and aft port of B2-STG liquid fuel staging valve (18) with remaining end adjacent
to open end of fuel tube (27).
(20) Connect B-nut to secure fuel manifold (26) onto fuel tube (27, sheet 2). Tighten B-nut hand-tight.
(21) Connect B-nut to secure fuel tube (26) onto forward port of B2-PRG liquid fuel staging valve (17).
(22) Connect B-nut to secure fuel manifold (26) onto aft port of B2-STG liquid fuel staging valve (18).
(24) Using bolt (52, sheet 10, detail J) and clamp (53), secure fuel manifold (26) onto bracket (63).
Tighten bolt to 60-70 lb in. (6.8-7.9 N·m) of torque. See sheet 3 for location of detail J.
N. Install fuel tube (25), fuel manifold (24), fuel manifold (23), fuel manifold (22), and fuel tube (21) as
follows:
(1) Lubricate B-nut threads and ferrules of fuel tube (25) with lubricating oil. Ensure orifice cone
remains inside B-nut on fuel tube.
(2) Position long end of fuel tube (25, sheet 3) adjacent to forward port of B2-STG liquid fuel staging
valve (18) with end of short leg pointing outboard.
(3) Connect B-nut to secure fuel tube (25) and orifice cone onto forward port of B2-STG liquid fuel
(5) Using bolt (52, sheet 10, detail J) and clamp (53), secure fuel tube (25) onto bracket (63). Tighten
bolt to 60-70 lb in. (6.8-7.9 N·m) of torque. See sheet 3 for location of detail J.

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WARNING

(7) Lubricate B-nut threads and ferrules of fuel manifold (24) with lubricating oil. Ensure orifice cone
remains inside B-nut on fuel manifold.
(8) Position fuel manifold (24, sheet 2) with ends of short legs of adjacent open end of fuel tube (25)
and forward port of C1-STG liquid fuel staging valve (16). Route end of long leg pointing inboard.
(10) Connect B-nut to secure fuel tube (24) and orifice cone onto forward port of C1-STG liquid fuel
(12) Using bolt (62, sheet 9, detail H) and clamp (53), secure fuel manifold (24) onto bracket (61).
Tighten bolt to 60-70 lb in. (6.8-7.9 N·m) of torque. See sheet 2 for location of detail H.
(14) Triple torque B-nuts at staging valve joint and tube joint per step 13.B.(18).
(16) Position fuel manifold (23, sheet 4) adjacent to bracket (58, sheet 9, detail E) and bracket (59,
sheet 9, detail F) with B-nut end pointing right, forward looking aft.
(17) Connect B-nut to secures fuel manifold (23) onto fuel manifold (24). Tighten B-nut hand-tight.
(19) Using bolt (52, sheet 9, detail F) and clamp (53), secure fuel manifold (23) onto bracket (59).
Tighten bolt to 60-70 lb in. (6.8-7.9 N·m) of torque. See sheet 4 for location of detail F.
(20) Using bolt (52, sheet 9, detail E) and clamp (53), secure fuel manifold (23) onto bracket (58).
Tighten bolt to 60-70 lb in. (6.8-7.9 N·m) of torque. See sheet 4 for location of detail E.

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WARNING

(22) Lubricate B-nut threads and ferrules of fuel manifold (22) with lubricating oil. Ensure orifice cone
remains inside B-nut on fuel manifold.
(23) Position fuel manifold (22, sheet 4) with end of short leg adjacent to forward port of B1A-STG
liquid fuel staging valve (3) and end of long leg adjacent to open end of fuel manifold (23).
(24) Connect B-nut to secure fuel tube (22) and orifice cone to forward port of B1A-STG liquid fuel
(25) Connect B-nut to secure fuel manifold (22) onto fuel manifold (23). Tighten B-nut hand-tight.
(27) Using bolt (52, sheet 8, detail D) and clamp (53), secure fuel manifold (22) onto bracket (57).
Tighten bolt to 60-70 lb in. (6.8-7.9 N·m) of torque. See sheet 4 for location of detail D.
NOTE
following step.
(29) Using bolt (52, sheet 8, detail B) and clamp (53), secure fuel manifold (22) onto bracket (54).
Tighten bolt to 60-70 lb in. (6.8-7.9 N·m) of torque. See sheet 5 for location of detail B.
(30) Triple torque B-nut at staging valve joint and tube joint per step 13.B.(18).
(31) Lubricate B-nut threads and ferrules of fuel tube (21) with lubricating oil. Ensure orifice cone
remains inside B-nut on fuel tube.
(32) Position fuel tube (21, sheet 4) with B-nut end adjacent to forward port of B3-STG liquid fuel
staging valve (1) and remaining end adjacent to open end of fuel manifold (22).

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(34) Connect B-nut to secure fuel tube (21) and orifice cone onto forward port of B3-STG liquid fuel
O. Install fuel manifold (20) and fuel supply tube (19) as follows:
(2) Position fuel manifold (20, sheet 1) with end of short leg adjacent to forward port of B3-PRG liquid
fuel staging valve (2) and remaining end pointing aft.
(3) Connect B-nut to secure fuel manifold (20) onto B3 inlet on upper B2 B3-manifold (8, figure 1,
sheet 4, section D-D).
(4) Connect B-nut to secure fuel manifold (20, figure 5) onto forward port of B3-PRG liquid fuel
staging valve (2).
(6) Using bolt (52, sheet 8, detail A) and clamp (53), secure fuel manifold (20) onto bracket (51).
Tighten bolt to 60-70 lb in. (6.8-7.9 N·m) of torque. See sheet 1 for location of detail A.
WARNING
(8) Triple torque B-nut at staging valve joint and manifold ring joint per step 13.F.(9).
WARNING

(10) Position fuel tube (19, sheet 1) with ends of legs adjacent to aft port of B3-STG liquid fuel staging
valve (1) and open end of fuel manifold (20).
(11) Connect B-nut to secure fuel supply tube (19) onto aft port of B3-STG liquid fuel staging valve (1).

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(12) Connect B-nut to secure fuel manifold (20) onto fuel supply tube (19). Tighten B-nut hand-tight.
14. Liquid Fuel Staging Valve Removal.
A. Remove liquid fuel staging valves (15, figure 6) as follows:
(1) Remove liquid fuel staging valve supply and purge tubes per paragraph 12.
WARNING

(2) Loosen and disconnect electrical harness (19, detail B) connectors from four liquid fuel staging
valves (15) located on left side, forward looking aft (FLA), of bottom support bracket (9).
(3) Loosen bolts (13, view A) that secure four liquid fuel staging valves (15) to left side, FLA, of
bottom support bracket (9). Remove bolts and staging valves.
(4) Loosen and disconnect electrical harness (19) connector from one liquid fuel staging valve (15)
located on lowest position of side support bracket (16).
(5) Loosen bolts (13) that secure one liquid fuel staging valve (15) to lowest position of side support
bracket (16). Remove bolts and staging valve.
(6) Loosen and disconnect electrical harness (17) connectors from three liquid fuel staging valves (15)
located on upper three positions of side support bracket (16).
(7) Loosen bolts (13) that secure three liquid fuel staging valves (15) to upper three positions of side
support bracket (16). Remove bolts and staging valves.
located on bracket (22).
(9) Loosen bolts (13) that secure one liquid fuel staging valve (15) to bracket (22). Remove bolts and
staging valve.
(10) Loosen and disconnect electrical harness (42, detail C) connectors from four liquid fuel staging
valves (15) located on right side, FLA, of bottom support bracket (9).
(11) Loosen bolts (13) that secure four liquid fuel staging valves (15) to right side, FLA, of bottom
support bracket (9). Remove bolts and staging valves.

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Figure 6. Liquid Fuel Staging Valve and Electrical Harness Replacement (Sheet 1 of 3)

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staging valve.
located on side support bracket (29).
(15) Loosen bolts (13) that secure one liquid fuel staging valve (15) to side support bracket (29). Remove
bolts and staging valve.
staging valve.
staging valve.
staging valve.
15. Liquid Fuel Staging Valve Installation.
A. Install liquid fuel staging valves (15, figure 6) as follows:
(1) Lightly coat bolts (13, view A) threads and contact faces with thread lubricant.
(2) Using bolts (13), secure one liquid fuel staging valve (15, detail C), electrical connector forward,
onto bracket (30). Tighten bolts to 60-70 lb in. (6.8-7.9 N·m) of torque.
WARNING

(3) Connect electrical harness (40) connector onto liquid fuel staging valve (15) located on bracket (30)
as follows:
(a) Engage electrical connector with mating threads and turn knurled coupling rings while
wiggling backshells of electrical connector.

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(4) Using bolts (13), secure one liquid fuel staging valve (15), electrical connector forward, onto
bracket (31). Tighten bolts to 60-70 lb in. (6.8-7.9 N·m) of torque.
per step 15.A.(3)(a) through step 15.A.(3)(d).
(8) Using bolts (13), secure one liquid fuel staging valve (15), electrical connector forward, onto side
support bracket (29). Tighten bolts to 60-70 lb in. (6.8-7.9 N·m) of torque.
(9) Connect electrical harness (42) connector onto liquid fuel staging valve (15) located on side support
bracket (29) per step 15.A.(3)(a) through step 15.A.(3)(d).
WARNING
(12) Using bolts (13), secure four liquid fuel staging valves (15), electrical connectors forward, onto right
side, FLA, of bottom support bracket (9). Tighten bolts to 60-70 lb in. (6.8-7.9 N·m) of torque.
(13) Connect electrical harness (42) connectors onto four liquid fuel staging valves (15) located on right
side, FLA, of bottom support bracket (9) per step 15.A.(3)(a) through step 15.A.(3)(d).
(14) Using bolts (13), secure one liquid fuel staging valve (15, detail B), electrical connector forward,
onto bracket (22). Tighten bolts to 60-70 lb in. (6.8-7.9 N·m) of torque.
(16) Using bolts (13), secure three liquid fuel staging valves (15) onto upper three positions of side

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(17) Connect electrical harness (17) connectors onto three liquid fuel staging valves (15) located on
upper three positions of side support bracket (16) per step 15.A.(3)(a) through step 15.A.(3)(d).
(18) Using bolts (13), secure one liquid fuel staging valve (15), electrical connector forward, onto lowest
position of side support bracket (16). Tighten bolts to 60-70 lb in. (6.8-7.9 N·m) of torque.
(19) Connect electrical harness (19) connector onto one liquid fuel staging valve (15) located on lowest
position of side support bracket (16) per step 15.A.(3)(a) through step 15.A.(3)(d).
(20) Using bolts (13), secure four liquid fuel staging valves (15), electrical connectors forward, onto left
side, FLA, of bottom support bracket (9). Tighten bolts to 60-70 lb in. (6.8-7.9 N·m) of torque.
side, FLA, of bottom support bracket (9) per step 15.A.(3)(a) through step 15.A.(3)(d).
(22) Install liquid fuel staging valve supply and purge tubes per paragraph 13.
16. Liquid Fuel Electrical Harness and Temperature Sensor Removal.
A. Remove electrical harness (17, figure 6, detail B) as follows:
(1) Loosen bolt (4) that secures clamp (1) and electrical harness (17) to forward bolthole in bracket (23).
Remove bolt and clamp.
(2) Loosen bolt (4) that secures clamp (1) and electrical harness (17) to forward bolthole in bracket (24).
WARNING

(3) Loosen and disconnect electrical harness (17) connectors from three liquid fuel staging valves (15)
located on upper three positions of side support bracket (16).
(5) Loosen nuts (21) and machine screws (20) securing electrical harness (17) to bracket (25). Remove
nuts, machine screws, and electrical harness (17).
B. Remove electrical harness (18, figure 6, detail B) as follows:
(1) Loosen bolt (4) that secures clamp (1) and electrical harness (18) to aft bolthole in bracket (23).
(2) Loosen bolt (4) that secures clamp (1) and electrical harness (18) to aft bolthole in bracket (24).
(3) Loosen and disconnect electrical harness (18) connector from temperature sensor (11) (one place).

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(4) Loosen bolt (4) that secures clamp (1) and electrical harness (18) to bracket (25). Remove bolt and
clamp.
(5) Loosen nut (5, view A) and bolt (4), that secures clamp (1) and electrical harness (18) to clamp on
fuel manifold (6). Remove nut, bolt, and clamp.
(6) Loosen nuts (5) and bolts (4), that secure clamps (1) and electrical harness (18) to clamps on fuel
manifold (7) (two places). Remove nuts, bolts, and clamps.
WARNING

(7) Loosen and disconnect electrical harness (18) connector from temperature sensor (11) (one place).
(8) Loosen nuts (21, detail B) and machine screws (20) securing electrical harness (18) to bracket (26).
Remove nuts, machine screws, and electrical harness (18).
C. Remove electrical harness (19, detail B) as follows:
clamp.
(2) Loosen and disconnect electrical harness (19) connectors from four liquid fuel staging valves (15)
located on left side, forward looking aft (FLA), of bottom support bracket (9).
located on lower position of side support bracket (16).
D. Remove electrical harness (40, detail C) as follows:
clamp.

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E. Remove electrical harness (41, detail C) as follows:
(1) Loosen nuts (5, view A) and bolts (4), that secure clamps (3) and electrical harness (41) to clamps
on fuel manifold (14) (two places). Remove nuts, bolts, and clamps.
clamp.
(3) Loosen and disconnect electrical harness (18) connectors from temperature sensors (11) (seven
places).
(4) Loosen nuts (21, detail C) and machine screws (20) securing electrical harness (41) to bracket (37).
Remove nuts, machine screws, and electrical harness (41).
F. Remove electrical harness (42, detail C) as follows:
clamp.
clamp.
WARNING

(3) Loosen and disconnect electrical harness (42) connectors from four liquid fuel staging valves (15)
located on right side, FLA, of bottom support bracket (9).
G. Remove temperature sensors (11) from fuel tube connections at eight places (view A) and at one place
(detail B) as follows:
(1) Remove coupling nut (10) that secures temperature sensor (11) to fuel tube connection.
(2) Remove temperature sensor (11) from fuel tube connection.
(3) Remove seal ring (12) from temperature sensor (11) and discard ring.

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17. Liquid Fuel Electrical Harness and Temperature Sensor Installation.
A. Install temperature sensors (11) onto fuel tube connections at eight places (figure 6, view A) and at one
place (detail B) as follows:
(1) Install new seal ring (12) onto temperature sensor (11).
(2) Install temperature sensor (11) onto fuel tube connection.
WARNING
(3) Lightly coat coupling nut (10) threads and contact faces with lubricating oil.
(4) Using coupling nut (10), secure temperature sensor (11) onto fuel tube connection. Tighten coupling
nut to 78-92 lb ft (106-124 N·m) of torque.
B. Install electrical harness (42, detail C) as follows:
(1) Lightly coat machine screws (20) and nuts (21) threads and contact faces with thread lubricant.
(2) Using machine screws (20) and nuts (21), secure electrical harness (42) onto bracket (37). Tighten
WARNING

(3) Connect electrical harness (42) connector onto one liquid fuel staging valve (15) located on bracket
(35) as follows:
(a) Engage electrical connector with mating threads and turn knurled coupling rings while
wiggling backshells of electrical connector.
(4) Connect electrical harness (42) connector onto one liquid fuel staging valve (15) located on side
support bracket (29) per step 17.B.(3)(a) through step 17.B.(3)(d).

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side, FLA, of bottom support bracket (9) per step 17.B.(3)(a) through step 17.B.(3)(d).
(6) Lightly coat two bolts (4) threads and contact faces with thread lubricant.
(7) Using bolt (4), secure clamp (2) and electrical harness (42) onto bracket (38). Tighten bolt to
60-70 lb in. (6.8-7.9 N·m) of torque.
60-70 lb in. (6.8-7.9 N·m) of torque.
C. Install electrical harness (41, detail C) as follows:
WARNING

(3) Connect electrical harness (41) connectors onto seven temperature sensors (11, view A) per
step 17.B.(3)(a) through step 17.B.(3)(d).
(4) Lightly coat three bolts (4) threads and contact faces with thread lubricant.
60-70 lb in. (6.8-7.9 N·m) of torque.
(6) Lightly coat two nuts (5) threads and contact faces with thread lubricant.
(7) Using bolts (4) and nuts (5), secure clamps (3) and electrical harness (41) onto clamps on fuel
manifold (14) (two places). Tighten nuts to 60-70 lb in. (6.8-7.9 N·m) of torque.
D. Install electrical harness (40, detail C) as follows:

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WARNING

(3) Connect electrical harness (40) connector onto one liquid fuel staging valve (15) located on side
support bracket (29) per step 17.B.(3)(a) through step 17.B.(3)(d).
(33) per step 17.B.(3)(a) through step 17.B.(3)(d).
60-70 lb in. (6.8-7.9 N·m) of torque.
E. Install electrical harness (19, detail B) as follows:
(3) Connect electrical harness (19) connector onto one liquid fuel staging valve (15) located on lower
position of side support bracket (16) per step 17.B.(3)(a) through step 17.B.(3)(d).
(4) Connect electrical harness (19) connectors onto four liquid fuel staging valves (15) located on left
side, forward looking aft (FLA), of bottom support bracket (9) per step 17.B.(3)(a) through
step 17.B.(3)(d).
60-70 lb in. (6.8-7.9 N·m) of torque.
F. Install electrical harness (18, detail B) as follows:

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WARNING

(3) Connect electrical harness (18) connector onto one temperature sensor (11, view A) per
step 17.B.(3)(a) through step 17.B.(3)(d).
(4) Lightly coat three nuts (5) and six bolts (4) threads and contact faces with thread lubricant.
(5) Using bolts (4) and nuts (5), secure clamps (1) and electrical harness (18) onto clamps on fuel
manifold (7) (two places). Tighten nuts to 60-70 lb in. (6.8-7.9 N·m) of torque.
(6) Using bolt (4) and nut (5), secure clamp (1) and electrical harness (18) onto clamp on fuel manifold
(6). Tighten nut to 60-70 lb in. (6.8-7.9 N·m) of torque.
(7) Using bolt (4), secure clamp (1) and electrical harness (18) onto bracket (25, detail B). Tighten bolt
(8) Connect electrical harness (18) connector onto one temperature sensor (11) per step 17.B.(3)(a)
through step 17.B.(3)(d).
(9) Using bolt (4), secure clamp (1) and electrical harness (18) onto aft bolthole in bracket (24). Tighten
(10) Using bolt (4), secure clamp (1) and electrical harness (18) onto aft bolthole in bracket (23). Tighten
G. Install electrical harness (17, detail B) as follows:
(4) Connect electrical harness (17) connectors onto three liquid fuel staging valves (15) located on
upper three positions of side support bracket (16) per step 17.B.(3)(a) through step 17.B.(3)(d).
(5) Lightly coat two bolts (4) threads and contact faces with thread lubricant.
(6) Using bolt (4), secure clamp (1) and electrical harness (17) onto forward bolthole in bracket (24).
(7) Using bolt (4), secure clamp (1) and electrical harness (17) onto forward bolthole in bracket (23).

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18. Liquid Fuel Brackets and Electrical Harness Brackets Removal.
A. Remove liquid fuel electrical harnesses per step 16.A. through step 16.F.
B. Remove liquid fuel staging valve supply and purge tubes per paragraph 12, except for step 12.C.(13),
step 12.G.(4), step 12.G.(5), step 12.O.(8), and step 12.O.(10).
C. Remove liquid fuel staging valves per paragraph 14, step 14.A.(3), step 14.A.(5), step 14.A.(7),
step 14.A.(9), step 14.A.(11), step 14.A.(13), step 14.A.(15), step 14.A.(17), step 14.A.(19), and
step 14.A.(21).
D. Loosen two bolts (36, figure 7) that attach tube support bracket (1) to inboard face of side support bracket
(38). Remove bolts and tube support bracket (1).
E. Loosen four bolts (37) that attach valve support bracket (2) to outboard face of side support bracket (38).
Remove bolts and valve support bracket (2).
F. Loosen two bolts (36) that attach harness support bracket (3) to forward flange of side support bracket
(38). Remove bolts and harness support bracket (3).
G. Loosen two bolts (36) that attach harness support bracket (4) to forward flange of side support bracket
H. Loosen two bolts (36) that attach B1A-support bracket (5) to outboard face of side support bracket (38).
Remove bolts and B1A-support bracket (5).
I. Loosen two bolts (36) that attach B1A-support bracket (6) to aft flange of side support bracket (38).
J. Loosen two bolts (36) that attach panel support bracket (7) to forward flange of side support bracket (38).
Remove bolts and panel support bracket (7).
K. Remove bridge bracket (8), B-support bracket (9), and panel support bracket (10) as follows:
(1) Loosen two bolts (37) that attach B-support bracket (9) and bridge bracket (8) to aft flange of side
support bracket (38). Remove bolts and B-support bracket (9).
(2) Loosen two bolts (37) that attach panel support bracket (10) and bridge bracket (8) to forward flange
of side support bracket (38). Remove bolts, panel support bracket (10), and bridge bracket (8).
L. Loosen two bolts (37) that attach A- and B-support bracket (11) to forward flange of bottom support
bracket (40). Remove bolts and A- and B-support bracket (11).
M. Loosen two bolts (36) that attach tube support bracket (12) to aft flange of bottom support bracket (40) and
loosen two bolts (36) that attach tube support bracket (12) to forward flange of bottom support bracket
(40). Remove bolts and tube support bracket (12).

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Figure 7. Liquid Fuel Brackets (Sheet 1 of 2)

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Figure 7. Liquid Fuel Brackets (Sheet 2 of 2)
N. Loosen two bolts (36) that attach purge bracket (13) to aft flange of bottom support bracket (40). Remove
bolts and purge bracket (13).
O. Loosen two bolts (36) that attach B1A-support bracket (14) to aft flange of bottom support bracket (40).
P. Loosen bolt (36) that attaches harness support bracket (15) to left side (forward looking aft [FLA]) of
forward flange of bottom support bracket (40). Remove bolts and harness support bracket (15).
Q. Loosen two bolts (36) that attach B-support bracket (16) to forward flange of bottom support bracket (40).
Remove bolts and B-support bracket (16).
R. Loosen two bolts (36) that attach A-supply bracket (17) to upper face of bottom support bracket (40).
Remove bolts and A-supply bracket (17).

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S. Loosen two bolts (36) that attach purge bracket (18) to forward flange of bottom support bracket (40).
Remove bolts and purge bracket (18).
T. Loosen two bolts (36) that attach A- and B-purge bracket (19) to aft flange of bottom support bracket (40)
and loosen two bolts (36) that attach A- and B-purge bracket (19) to lower face of bottom support bracket
(40). Remove bolts and A- and B-purge bracket (19).
U. Loosen two bolts (36) that attach B1B-support bracket (20) to aft flange of bottom support bracket (40).
Remove bolts and B1B-support bracket (20).
V. Loosen two bolts (36) that attach C-support bracket (21) to upper face of bottom support bracket (40).
Remove bolts and C-support bracket (21).
W. Loosen two bolts (36) that attach B-support bracket (22) to forward flange of bottom support bracket (40).
X. Loosen two bolts (36) that attach B1B and B2-support bracket (23) to aft flange of bottom support bracket
(40). Remove bolts and B1B and B2-support bracket (23).
Y. Loosen bolt (36) that attaches harness support bracket (15) to right side (FLA) of forward flange of bottom
support bracket (40) at two locations. Remove bolts and two harness support brackets (15).
Z. Loosen two bolts (36) that attach C-support bracket (24) to upper face of bottom support bracket (40).
Remove bolts and C-support bracket (24).
AA. Loosen two bolts (36) that attach support bracket (25) to forward flange of bottom support bracket (40).
Remove bolts and support bracket (25).
AB. Loosen two bolts (36) that attach B-support bracket (26) to aft flange of bottom support bracket (40).
AC. Loosen two bolts (37) that attach harness support bracket (27) to forward flange of bottom support bracket
AD. Remove B2-support bracket (28) and valve support bracket (29) as follows:
NOTE
The same two bolts attach the B2-support bracket and the valve support bracket in the
following step.
(1) Loosen two bolts (37) that attach B2-support bracket (28) to outboard face of side support bracket
(39) and that also attach forward side of valve support bracket (29) to inboard face of side support
bracket (39). Remove bolts and B2-support bracket (28).
(2) Loosen two bolts (36) that attach aft side of valve support bracket (29) to inboard face of side
support bracket (39). Remove bolts and valve support bracket (29).
AE. Loosen two bolts (36) that attach harness support bracket (30) to forward flange of side support bracket

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AF. Loosen two bolts (36) that attach panel support bracket (31) to forward flange of side support bracket (39).
Remove bolts and panel support bracket (31).
AG. Loosen four bolts (37) that attach valve support bracket (32) to inboard face of side support bracket (39) at
two locations. Remove bolts and two valve support brackets (32).
AH. Loosen two bolts (36) that attach B2-support bracket (33) to inboard face of side support bracket (39).
Remove bolts and B2-support bracket (33).
AI. Loosen two bolts (36) that attach harness support bracket (34) to forward flange of side support bracket
AJ. Loosen four bolts (37) that attach valve support bracket (35) to inboard face of side support bracket (39).
Remove bolts and valve support bracket (35).
19. Liquid Fuel Brackets and Electrical Harness Brackets Installation.
A. Lightly coat bolts (36 and 37, figure 7) threads and contact faces with thread lubricant.
B. Using four bolts (37), attach valve support bracket (35) onto inboard face of side support bracket (39).
C. Using two bolts (36), attach harness support bracket (34) onto forward flange of side support bracket (39).
D. Using two bolts (36), attach B2-support bracket (33) onto inboard face of side support bracket (39).
E. Using four bolts (37), attach valve support bracket (32) onto inboard face of side support bracket (39) at
two locations. Tighten bolts to 60-70 lb in. (6.8-7.9 N·m) of torque.
F. Using two bolts (36), attach panel support bracket (31) onto forward flange of side support bracket (39).
G. Using two bolts (36), attach harness support bracket (30) onto forward flange of side support bracket (39).
H. Install B2-support bracket (28) and valve support bracket (29) as follows:
(1) Using two bolts (36), attach aft side of valve support bracket (29) onto inboard face of side support
bracket (39). Tighten bolts hand-tight.
NOTE
The same two bolts attach the B2-support bracket and the valve support bracket in the
following step.
(2) Using two bolts (37), attach B2-support bracket (28) onto outboard face of side support bracket (39)
and attach forward side of valve support bracket (29) onto inboard face of side support bracket (39).
(3) Tighten two bolts (36) and two bolts (37) to 60-70 lb in. (6.8-7.9 N·m) of torque.

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I. Using two bolts (37), attach harness support bracket (27) onto forward flange of bottom support bracket
(40). Tighten bolts to 60-70 lb in. (6.8-7.9 N·m) of torque.
J. Using two bolts (36), attach B-support bracket (26) onto aft flange of bottom support bracket (40). Tighten
K. Using two bolts (36), attach support bracket (25) onto forward flange of bottom support bracket (40).
L. Using two bolts (36), attach C-support bracket (24) onto upper face of bottom support bracket (40).
M. Using bolt (36), attach harness support bracket (15) onto right side (forward looking aft [FLA]) of forward
flange of bottom support bracket (40) at two locations. Tighten bolts to 60-70 lb in. (6.8-7.9 N·m) of
torque.
N. Using two bolts (36), attach B1B and B2-support bracket (23) onto aft flange of bottom support bracket
O. Using two bolts (36), attach B-support bracket (22) onto forward flange of bottom support bracket (40).
P. Using two bolts (36), attach C-support bracket (21) onto upper face of bottom support bracket (40).
Q. Using two bolts (36), attach B1B-support bracket (20) onto aft flange of bottom support bracket (40).
R. Using two bolts (36), attach A- and B-purge bracket (19) onto aft flange of bottom support bracket (40)
and using two bolts (36), attach A- and B-purge bracket (19) onto lower face of bottom support bracket
S. Using two bolts (36), attach purge bracket (18) onto forward flange of bottom support bracket (40).
T. Using two bolts (36), attach A-supply bracket (17) onto upper face of bottom support bracket (40). Tighten
U. Using two bolts (36), attach B-support bracket (16) onto forward flange of bottom support bracket (40).
V. Using bolt (36), attach harness support bracket (15) onto left side (FLA) of forward flange of bottom
W. Using two bolts (36), attach B1A-support bracket (14) onto aft flange of bottom support bracket (40).
X. Using two bolts (36), attach purge bracket (13) onto aft flange of bottom support bracket (40). Tighten

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Y. Using two bolts (36), attach tube support bracket (12) onto aft flange of bottom support bracket (40) and
using two bolts (36), attach tube support bracket (12) onto forward flange of bottom support bracket (40).
Z. Using two bolts (37), attach A- and B-support bracket (11) onto forward flange of bottom support bracket
AA. Install bridge bracket (8), B-support bracket (9), and panel support bracket (10) as follows:
NOTE
The same two bolts attach the panel support bracket and the bridge bracket in the
following step.
(1) Using two bolts (37), attach panel support bracket (10) and bridge bracket (8) onto forward flange of
side support bracket (38). Ensure panel support bracket (10) is against aft side of flange and bridge
bracket (8) is against aft side of panel support bracket (10). Tighten bolts hand-tight. The same two
bolts attach the B-support bracket and the bridge bracket in the following step.
(2) Using two bolts (37), attach B-support bracket (9) and bridge bracket (8) onto aft flange of side
support bracket (38). Ensure B-support bracket (9) is against aft side of flange and bridge bracket (8)
is against forward side of flange. Tighten bolts hand-tight.
(3) Tighten four bolts (37) to 60-70 lb in. (6.8-7.9 N·m) of torque.
AB. Using two bolts (36), attach panel support bracket (7) onto forward flange of side support bracket (38).
AC. Using two bolts (36), attach B1A-support bracket (6) onto aft flange of side support bracket (38). Tighten
AD. Using two bolts (36), attach B1A-support bracket (5) onto outboard face of side support bracket (38).
AE. Using two bolts (36), attach harness support bracket (4) onto forward flange of side support bracket (38).
AF. Using two bolts (36), attach harness support bracket (3) onto forward flange of side support bracket (38).
AG. Using four bolts (37), attach valve support bracket (2) onto outboard face of side support bracket (38).
AH. Using two bolts (36), attach tube support bracket (1) onto inboard face of side support bracket (38).
AI. Install liquid fuel staging valves per paragraph 15, step 15.A.(1), step 15.A.(2), step 15.A.(4),
step 15.A.(6), step 15.A.(8), step 15.A.(10), step 15.A.(12), step 15.A.(14), step 15.A.(16), step 15.A.(18),
and step 15.A.(20).

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AJ. Install liquid fuel staging valve supply and purge tubes per paragraph 13, except for step 13.A.(6),
step 13.A.(8), step 13.I.(8), step 13.I.(9), and step 13.M.(6).
AK. Install liquid fuel electrical harnesses per paragraph 17, step 17.B. through step 17.G.
20. Tubular Liquid Fuel Manifold Removal.
A. Disconnect all fuel and electrical connections from fuel system and secure per packager’s manual.
C. Remove enclosure fuel manifold supports per packager’s manual.
D. Remove liquid fuel electrical harnesses per paragraph 16, step 16.A. through step 16.F.
E. Remove liquid fuel staging valve supply and purge tubes per paragraph 12, except for step 12.C.(13),
step 12.G.(4), step 12.G.(5), step 12.O.(8), and step 12.O.(10).
F. Remove liquid fuel staging valves per paragraph 14, step 14.A.(3), step 14.A.(5), step 14.A.(7),
step 14.A.(9), step 14.A.(11), step 14.A.(13), step 14.A.(15), step 14.A.(17), step 14.A.(19), and
step 14.A.(21).
G. Remove liquid fuel brackets and electrical harness brackets per paragraph 18, step 18.D. through
step 18.AC.
H. Remove liquid fuel manifold fuel tubes per paragraph 6.
I. Remove fuel manifold clamps (figure 8) as follows:
(1) Remove fuel manifold clamps at 12:30 o'clock position, forward looking aft (FLA), as follows:
(a) Remove six bolts (12, section B-B), washers (13), springs (14), and washers (15) from center
clamp block (7).
(b) Remove six bolts (16, view C), one clamp block (17), clamp block (18), five clamp blocks (19),
and five clamp blocks (20).
(c) Remove bolt (6, section B-B) that secures center clamp block (7) to angle support (1) and
remove center clamp block (7).
(2) Remove fuel manifold clamps at 2:00 o'clock position, FLA, as follows:
clamp block (7).
(c) Remove bolt (6, section B-B) that secures center clamp block (7) to support bracket (21) and

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Figure 8. Liquid Fuel Manifold Clamps/Brackets (Sheet 1 of 4)

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clamp block (7).
(c) Remove bolt (6, section B-B) that secures center clamp block (7) to left side support bracket
(22) and remove center clamp block (7).
clamp block (7).
(c) Remove bolt (6, section B-B) that secures center clamp block (7) to lower support (29) and

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clamp block (7).
(c) Remove bolt (6, section B-B) that secures center clamp block (7) to lower support (29) and
clamp block (7).
clamp block (7).
clamp block (7).
(c) Remove bolt (6, section B-B) that secures center clamp block (7) to angle support (1) and
(a) Remove two bolts (23, section D-D), and clamp block (25) from center clamp block (26).
(b) Remove two bolts (24, view E), center clamp block (26, section D-D), and clamp block (27)
from support bracket (30).

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(a) Remove two bolts (23, section D-D) and clamp block (25) from center clamp block (26).
(b) Remove two bolts (24, view E), center clamp block (26, section D-D), and clamp block (27)
from support bracket (28).
(a) Remove two bolts (9, section A-A) and clamp block (11) from center clamp block (5).
(b) Remove two bolts (8) and clamp block (10) from center clamp block (5).
(c) Remove bolt (4) that secures center clamp block (5) to angle support (1) and remove center
clamp block (5).
J. Remove angle support (1, view F) as follows:
(1) Remove three bolts (2) that secure angle support (1) to support bracket (32).
(2) Remove two bolts (3) that secure angle support (1) to support bracket (21).
(3) Remove angle support (1).
K. Remove fuel manifold clamp support brackets as follows:
(1) At 2:00 o'clock position, remove three bolts (33, figure 8) that secure support bracket (21) to liquid
manifold side frame (34). Remove bracket.
(2) At 3:00 o'clock position, remove three bolts (33) that secure left side support bracket (22) to liquid
(3) At 4:00 o'clock position, remove three bolts (33) that secure fuel system support bracket (28) to
liquid manifold side frame (34). Remove bracket.
(4) At 8:00 o'clock position, remove three bolts (33) that secure fuel system support bracket (30) to
liquid manifold side frame (35). Remove bracket.
(5) At 9:00 o'clock position, remove three bolts (33) that secure right side support bracket (31) to liquid
(6) At 10:00 o'clock position, remove three bolts (33) that secure support bracket (32) to liquid manifold
side frame (35). Remove bracket.
L. Remove lower support (29) as follows:
(1) Remove bolts (36, detail G) that secure lower support (29) to bracket (38).
(2) Remove bolts (36, detail H) that secure lower support (29) to bracket (39).
(3) Remove lower support (29).

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M. Remove bolts (37, detail G) that secure bracket (38) to liquid manifold side frame (35). Remove bracket
(38).
N. Remove bolts (37, detail H) that secure bracket (39) to liquid manifold side frame (34). Remove bracket
(39).
O. Remove support bracket (40) as follows:
(1) Remove nuts (42, detail J) and bolts (41) that secure support bracket (40) to liquid manifold side
frame (35).
(2) Remove nuts (42, detail K) and bolts (41) that secure support bracket (40) to liquid manifold side
frame (34).
(3) Remove support bracket (40).
P. Remove fuel manifolds (figure 1) as follows:
NOTE
(1) Remove B1A B1B-manifold as follows:
(a) At 8:45 and 2:45 o'clock positions, loosen B-nuts connecting upper B1A B1B-manifold (2) to
lower B1A B1B-manifold (3).
(b) Remove upper B1A B1B-manifold (2) and lower B1A B1B-manifold (3).
NOTE
(2) Remove A2A A2B-manifold as follows:
(a) At 8:45 and 2:45 o'clock positions, loosen B-nuts connecting upper A2A A2B-manifold (5) to
lower A2A A2B-manifold (6).
(b) Remove upper A2A A2B-manifold (5) and lower A2A A2B-manifold (6).
NOTE
(3) Remove B2 B3-manifold as follows:
(a) At 8:45 and 2:45 o'clock positions, loosen B-nuts connecting upper B2 B3-manifold (8) onto
lower B2 B3-manifold (9).
(b) Remove upper B2 B3-manifold (8) and lower B2 B3-manifold (9).

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(4) Remove A1-manifold as follows:
(a) At 8:45 and 2:45 o'clock positions, loosen B-nuts connecting upper A1-manifold (11) onto
lower A1-manifold (12).
(b) Remove upper A1-manifold (11) and lower A1-manifold (12).
(5) Remove C1-manifold as follows:
(a) At 8:45 and 2:45 o'clock positions, loosen B-nuts connecting upper C1-manifold (14) onto
lower C1-manifold (15).
(b) Remove upper C1-manifold (14) and lower C1-manifold (15).
(6) Remove C2-manifold as follows:
(a) At 8:45 and 2:45 o'clock positions, loosen B-nuts connecting upper C2-manifold (17) onto
lower C2-manifold (18).
(b) Remove upper C2-manifold (17) and lower C2-manifold (18).
Q. Remove air purge tube (20, figure 1, view H) as follows:
(1) Remove bolt (21) and clamp (22) from air purge tube (20).
(2) If not previously accomplished, remove bolts (23) and gasket (24) per packager’s manual.
(3) Remove safety wire from bolts (25).
(4) Remove bolts (25), metal gasket (26), and air purge tube (20). Discard metal gasket.
(5) Remove two bolts (27) and purge support bracket (28).
R. Remove dual fuel manifold support fixture, 1C9621, per WP 3015 00.
21. Tubular Liquid Fuel Manifold Installation.
B. Install air purge tube (20, figure 1, view H) as follows:
(2) Install purge support bracket (28) using two bolts (27). Tighten bolts to 60-70 lb in. (6.8-7.9 N·m) of
torque.
(3) Install new metal gasket (26) onto end of air purge tube (20).
(5) Install air purge tube (20) to CRF using four bolts (25). Tighten bolts to 60-70 lb in. (6.8-7.9 N·m) of
torque.

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(6) Safety-wire bolts (25).
(7) Install gasket (24) and bolts (23) per packager’s manual.
(9) Position clamp (22) around air purge tube (20) and install bolt (21). Tighten bolt to 60-70 lb in.
C. Install fuel manifolds (figure 1) as follows:
(1) Install C2-manifold as follows:
WARNING
LUBRICATING OIL, MIL-PRF-23699F (C/I): COMBUSTIBLE. DO
NOT INHALE, INGEST, OR LET THIS MATERIAL TOUCH YOU.
IRRITANT. PERSONAL PROTECTIVE EQUIPMENT REQUIRED.
USE MECHANICAL EXHAUST VENTILATION - IF NOT
AVAILABLE, USE AN APPROVED RESPIRATOR.
(a) Lubricate B-nut threads and ferrules on upper C2-manifold (17) and lower C2-manifold (18)
with lubricating oil.
(b) Position upper C2-manifold (17) adjacent to fuel nozzles, fuel tube nipples forward, with
manifold ends located at 8:45 and 2:45 o'clock positions, forward looking aft (FLA).
(c) Position lower C2-manifold (18) adjacent to fuel nozzles, fuel tube nipples forward, with
manifold ends located at 8:45 and 2:45 o'clock positions, FLA.
(d) Connect upper C2-manifold (17) and lower C2-manifold (18) B-nuts at 8:45 and 2:45 o'clock
positions, FLA. Tighten B-nuts hand-tight.
(2) Install C1-manifold as follows:
(a) Lubricate B-nut threads and ferrules on upper C1-manifold (14) and lower C1-manifold (15)
(b) Position upper C1-manifold (14) adjacent to fuel nozzles, fuel tube nipples forward, with
(c) Position lower C1-manifold (15) adjacent to fuel nozzles, fuel tube nipples forward, with
(d) Connect upper C1-manifold (14) and lower C1-manifold (15) B-nuts at 8:45 and 2:45 o'clock

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(3) Install A1-manifold as follows:
(a) Lubricate B-nut threads and ferrules on upper A1-manifold (11) and lower A1-manifold (12)
(b) Position upper A1-manifold (11) adjacent to fuel nozzles, fuel tube nipples forward, with
(c) Position lower A1-manifold (12) adjacent to fuel nozzles, fuel tube nipples forward, with
(d) Connect upper A1-manifold (11) and lower A1-manifold (12) B-nuts at 8:45 and 2:45 o'clock
NOTE
(4) Install B2 B3-manifold as follows:
WARNING

(a) Lubricate B-nut threads and ferrules on upper B2 B3-manifold (8) and lower B2 B3-manifold
(9) with lubricating oil.
(b) Position upper B2 B3-manifold (8) adjacent to fuel nozzles, fuel tube nipples forward, with
(c) Position lower B2 B3-manifold (9) adjacent to fuel nozzles, fuel tube nipples forward, with
(d) Connect upper B2 B3-manifold (8) and lower B2 B3-manifold (9) B-nuts at 8:45 and
2:45 o'clock positions, FLA. Tighten B-nuts hand-tight.
NOTE
(5) Install A2A A2B-manifold as follows:
(a) Lubricate B-nut threads and ferrules on upper A2A A2B-manifold (5) and lower A2A
A2B-manifold (6) with lubricating oil.

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(b) Position upper A2A A2B-manifold (5) adjacent to fuel nozzles, fuel tube nipples forward, with
manifold ends located at 8:45 and 2:45 o’clock positions, FLA.
(c) Position lower A2A A2B-manifold (6) adjacent to fuel nozzles, fuel tube nipples forward, with
(d) Connect upper A2A A2B-manifold (5) and lower A2A A2B-manifold (6) B-nuts at 8:45 and
2:45 o’clock positions, FLA. Tighten B-nuts hand-tight.
NOTE
(6) Install B1A B1B-manifold as follows:
WARNING

(a) Lubricate B-nut threads and ferrules on upper B1A B1B-manifold (2) and lower B1A
B1B-manifold (3) with lubricating oil.
(b) Position upper B1A B1B-manifold (2) adjacent to fuel nozzles, fuel tube nipples forward, with
(c) Position lower B1A B1B-manifold (3) adjacent to fuel nozzles, fuel tube nipples forward, with
(d) Connect upper B1A B1B-manifold (2) and lower B1A B1B-manifold (3) B-nuts at 8:45 and
2:45 o’clock positions, FLA. Tighten B-nuts hand-tight.
D. Install support bracket (40, figure 8) as follows:
(1) Lightly coat nuts (42, detail J and detail K) and bolts (41) threads and contact faces with thread
lubricant.
(2) Using three nuts (42, detail K) and bolts (41) secure support bracket (40) onto liquid manifold side
frame (34). Tighten nuts hand-tight.
(3) Using three nuts (42, detail J) and bolts (41) secure support bracket (40) onto liquid manifold side
frame (35). Tighten nuts hand-tight.
(4) Tighten six nuts (42) to 202-238 lb in. (22.9-26.8 N·m) of torque.

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E. Install bracket (39, detail H) as follows:
(2) Using two bolts (37) secure bracket (39) onto liquid manifold side frame (34). Tighten bolts to
60-70 lb in. (6.8-7.9 N·m) of torque.
F. Install bracket (38, detail G) as follows:
(2) Using two bolts (37, detail G) secure bracket (38) onto liquid manifold side frame (35). Tighten
G. Install lower support (29) as follows:
(1) Lightly coat bolts (36, detail G and detail H) threads and contact faces with thread lubricant.
(2) Using two bolts (36, detail H) secure lower support (29) onto bracket (39). Tighten bolts hand-tight.
(3) Using two bolts (36, detail G) secure lower support (29) onto bracket (38). Tighten bolts hand-tight.
(4) Tighten four bolts (36) to 60-70 lb in. (6.8-7.9 N·m) of torque.
H. Install fuel manifold clamp support brackets (figure 8) as follows:
(1) Lightly coat eighteen bolts (33) threads and contact faces with thread lubricant.
(2) At 10:00 o'clock position, FLA, secure support bracket (32) onto liquid manifold side frame (35)
using three bolts (33). Tighten bolts to 60-70 lb in. (6.8-7.9 N·m) of torque.
(3) At 9:00 o'clock position, FLA, secure right side support bracket (31) onto liquid manifold side frame
(35) using three bolts (33). Tighten bolts to 60-70 lb in. (6.8-7.9 N·m) of torque.
(4) At 8:00 o'clock position, FLA, secure fuel system support bracket (30) onto liquid manifold side
frame (35) using three bolts (33). Tighten bolts to 60-70 lb in. (6.8-7.9 N·m) of torque.
(5) At 4:00 o'clock position, FLA, secure fuel system support bracket (28) onto liquid manifold side
frame (34) using three bolts (33). Tighten bolts to 60-70 lb in. (6.8-7.9 N·m) of torque.
(6) At 3:00 o'clock position, FLA, secure left side support bracket (22) onto liquid manifold side frame
(34) using three bolts (33). Tighten bolts to 60-70 lb in. (6.8-7.9 N·m) of torque.
(7) At 2:00 o'clock position, FLA, secure support bracket (21) onto liquid manifold side frame (34)
using three bolts (33). Tighten bolts to 60-70 lb in. (6.8-7.9 N·m) of torque.

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I. Install angle support (1, view F) as follows:
(2) Using two bolts (3) secure angle support (1) onto support bracket (21). Tighten bolts hand-tight.
(4) Using three bolts (2) secure angle support (1) onto support bracket (32). Tighten bolts hand-tight.
(5) Tighten two bolts (3) and three bolts (2) to 60-70 lb in. (6.8-7.9 N·m) of torque.
J. Install fuel manifold clamps (figure 8) as follows:
(1) Install fuel manifold clamps at 12:00 o'clock position, FLA, as follows:
(a) Lightly coat bolt (4, section A-A) threads and contact faces with thread lubricant.
(b) Using bolt (4, section A-A), secure center clamp block (5) onto angle support (1). Tighten bolt
hand-tight.
(c) At the forward face of center clamp block (5), position manifold (43) adjacent to the upper
most mounting location, position B2 B3-manifold (44) adjacent to the middle mounting
location, and position C1-manifold (45) adjacent to the lower most mounting location.
(d) Lightly coat bolts (8) threads and contact faces with thread lubricant.
(e) Using two bolts (8) and clamp block (10) secure manifold (43), B2 B3-manifold (44), and
C1-manifold (45) onto the forward face of center clamp block (5). Tighten bolts hand-tight.
(f) At the aft face of center clamp block (5), position manifold (46) adjacent to the upper most
mounting location, position A1-manifold (47) adjacent to the middle mounting location, and
position C2-manifold (48) adjacent to the lower most mounting location.
(g) Lightly coat bolts (9) threads and contact faces with thread lubricant.
(h) Using two bolts (9) and clamp block (11) secure manifold (46), A1-manifold (47), and
C2-manifold (48) onto the aft face of center clamp block (5). Tighten bolts hand-tight.
(a) Lightly coat bolts (24, view E) threads and contact faces with thread lubricant.
(b) Using two bolts (24, view E), clamp block (27, section D-D), and center clamp block (26),
secure B1A B1B-manifold (43), B2 B3-manifold (44), and C1-manifold (45) onto the aft face
of support bracket (28). Tighten bolts hand-tight.
(c) Lightly coat bolts (23) threads and contact faces with thread lubricant.
(d) Using two bolts (23) and clamp block (25), secure A2A A2B-manifold (46), A1-manifold (47),
and C2-manifold (48) onto the aft face of center clamp block (26). Tighten bolts hand-tight.

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(a) Lightly coat bolts (24, view E) threads and contact faces with thread lubricant.
(b) Using two bolts (24, view E), clamp block (27, section D-D), and center clamp block (26),
secure B1A B1B-manifold (43), B2 B3-manifold (44), and C1-manifold (45) onto the aft face
of support bracket (30). Tighten bolts hand-tight.
(c) Lightly coat bolts (23) threads and contact faces with thread lubricant.
(d) Using two bolts (23) and clamp block (25), secure A2A A2B-manifold (46), A1-manifold (47),
and C2-manifold (48) onto the aft face of center clamp block (26). Tighten bolts hand-tight.
(a) Lightly coat bolt (6, section B-B) threads and contact faces with thread lubricant.
(b) Using bolt (6, section B-B) secure center clamp block (7) onto angle support (1). Tighten bolt
hand-tight.
(c) Lightly coat bolts (16, view C) threads and contact faces with thread lubricant.
(d) Using bolt (16, view C), secure clamp block (17), and clamp block (18), onto B1A
B1B-manifold (43, section B-B). Tighten bolt hand-tight.
(e) Using bolt (16, view C), secure one clamp block (19), and one clamp block (20) onto each of
the five remaining manifolds. Tighten bolts hand-tight.
(f) Lightly coat bolts (12, section B-B) threads and contact faces with thread lubricant.
(g) Using bolt (12, section B-B), washer (13), spring (14), and washer (15), secure clamp blocks
(17 and 18, view C), previously attached to B1A B1B-manifold (43, section B-B), onto the
forward face of center clamp block (7). Tighten bolt hand-tight.
(h) Using two bolts (12), washers (13), springs (14), and washers (15), secure clamp blocks
(19 and 20, view C), previously attached to B2 B3-manifold (44, section B-B) and C1-manifold
(45), onto the forward face of center clamp block (7). Tighten bolts hand-tight.
(i) Using three bolts (12), washers (13), springs (14), and washers (15), secure clamp blocks
(19 and 20, view C), previously attached to A2A A2B-manifold (46, section B-B),
A1-manifold (47), and C2-manifold (48), onto the aft face of center clamp block (7). Tighten
bolts hand-tight.
(b) Using bolt (6, section B-B) secure center clamp block (7) onto support bracket (32). Tighten
bolt hand-tight.
(c) Repeat step 21.J.(4)(c) through step 21.J.(4)(i) to install remaining hardware.

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bolt hand-tight.
(b) Using bolt (6, section B-B) secure center clamp block (7) onto lower support (29). Tighten bolt
hand-tight.
(b) Using bolt (6, section B-B) secure center clamp block (7) onto lower support (29). Tighten bolt
hand-tight.
(b) Using bolt (6, section B-B) secure center clamp block (7) onto left side support bracket (22).
Tighten bolt hand-tight.
bolt hand-tight.

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(b) Using bolt (6, section B-B) secure center clamp block (7) onto angle support (1). Tighten bolt
hand-tight.
K. Install liquid fuel manifold fuel tubes as follows:
(1) Remove covers from fuel nozzle and fuel manifold nipples.
(2) Using tape, start at 12:00 o'clock position, indexing CCW, FLA, number each fuel nozzle (19,
figure 1) 1 through 30. The No. 1 fuel nozzle is just CCW of 12:00 o'clock position, FLA.
(3) Lightly coat fuel nozzle nipples with thread lubricant.
(4) Install upper C2-manifold (17) fuel tubes as follows:
WARNING
(a) Lubricate B-nut threads and ferrules of fuel tubes (16) with lubricating oil.
(b) Install straight end of each fuel tube (16, section G-G) onto most CW nipple port, FLA, even
number fuel nozzles No. 26 and No. 28. Tighten B-nuts finger-tight.
(c) Lightly coat upper C2-manifold (17) nipple threads with thread lubricant.
(d) Connect remaining end of each fuel tube (16) onto upper C2-manifold (17). Tighten B-nuts
finger-tight.
(5) Install lower C2-manifold (18) fuel tubes as follows:
(a) Lubricate B-nut threads and ferrules of fuel tube (16) with lubricating oil.
(b) Install straight end of each fuel tube (16) onto most CW nipple port, FLA, even number fuel
(c) Lightly coat lower C2-manifold (18) nipple threads with thread lubricant.
(d) Connect remaining end of each fuel tube (16) onto lower C2-manifold (18). Tighten B-nuts
finger-tight.

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(6) Install upper C1-manifold (14) fuel tubes as follows:
(b) Install straight end of each fuel tube (13, section F-F) onto most CW nipple port, FLA, even
number fuel nozzles Nos. 2, 4, 6, 8, and 30. Tighten B-nuts finger-tight.
(c) Lightly coat upper C1-manifold (14) nipple threads with thread lubricant.
(d) Connect remaining end of each fuel tube (13) onto upper C1-manifold (14). Tighten B-nuts
finger-tight.
(7) Install lower C1-manifold (15) fuel tubes as follows:
WARNING

(b) Install straight end of each fuel tube (13) onto most CW nipple port, FLA, even number fuel
(c) Lightly coat lower C1-manifold (15) nipple threads with thread lubricant.
(d) Connect remaining end of each fuel tube (13) onto lower C1-manifold (15). Tighten B-nuts
finger-tight.
(8) Install upper A1-manifold (11) fuel tubes as follows:
(b) Install straight end of each fuel tube (10, section E-E) onto center nipple port (FLA), fuel
nozzles Nos. 1, 8, 9, and No. 26 through No. 30. Tighten B-nuts finger-tight.
(c) Lightly coat upper A1-manifold (11) nipple threads with thread lubricant.
(d) Connect remaining end of each fuel tube (10) onto upper A1-manifold (11). Tighten B-nuts
finger-tight.
(9) Install lower A1-manifold (12) fuel tubes as follows:
(b) Install straight end of each fuel tube (10) onto center nipple port, FLA, fuel nozzles No. 10
through No. 13.

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(c) Lightly coat lower A1-manifold (12) nipple threads with thread lubricant.
(d) Connect remaining end of each fuel tube (10) onto lower A1-manifold (12). Tighten B-nuts
finger-tight.
(10) Install upper B2 B3-manifold (8) fuel tubes as follows:
WARNING
(b) Install straight end of each fuel tube (7, section D-D) onto least CW nipple port, FLA, even
number fuel nozzles Nos. 2, 4, 24, and 30. Tighten B-nuts finger-tight.
(c) Lightly coat upper B2 B3-manifold (8) nipple threads with thread lubricant.
(d) Connect remaining end of each fuel tube (7) onto upper B2 B3-manifold (8). Tighten B-nuts
finger-tight.
(11) Install lower B2 B3-manifold (9) fuel tubes as follows:
(b) Install straight end of each fuel tube (7) onto least CW center nipple port, FLA, even number
fuel nozzles Nos.14, 16, 18, 20, and 22. Tighten B-nuts finger-tight.
(c) Lightly coat lower B2 B3-manifold (9) nipple threads with thread lubricant.
(d) Connect remaining end of each fuel tube (7) onto lower B2 B3-manifold (9). Tighten B-nuts
finger-tight.
(12) Install upper A2A A2B-manifold (5) fuel tubes as follows:
(b) Install straight end of each fuel tube (4, section C-C) onto center nipple port, FLA, fuel nozzles
No. 2 through No. 7, No. 24 and No. 25. Tighten B-nuts finger-tight.
(c) Lightly coat upper A2A A2B-manifold (5) nipple threads with thread lubricant.
(d) Connect remaining end of each fuel tube (4) onto upper A2A A2B-manifold (5). Tighten
B-nuts finger-tight.

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(13) Install lower A2A A2B-manifold (6) fuel tubes as follows:
WARNING

(b) Install straight end of each fuel tube (4) onto center nipple port, FLA, fuel nozzles No. 14
through No. 23. Tighten B-nuts finger-tight.
(c) Lightly coat lower A2A A2B-manifold (6) nipple threads with thread lubricant.
(d) Connect remaining end of each fuel tube (4) onto lower A2A A2B-manifold (6). Tighten
B-nuts finger-tight.
(14) Install upper B1A B1B-manifold (2) fuel tubes as follows:
(a) Lubricate B-nut threads and ferrules of fuel tube (1) with lubricating oil.
(b) Install straight end of each fuel tube (1, section B-B) onto least CW nipple port, FLA, fuel
nozzles No. 1 and No. 3, No. 5 through No. 8, and No. 25 through No. 29. Tighten B-nuts
finger-tight.
(c) Lightly coat upper B1A B1B-manifold (2) nipple threads with thread lubricant.
(d) Connect remaining end of each fuel tube (1) onto upper B1A B1B-manifold (2). Tighten B-nuts
finger-tight.
(15) Install lower B1A B1B-manifold (3) fuel tubes as follows:
(b) Install straight end of each fuel tube (1) onto least CW nipple port, FLA, fuel nozzles No. 9
through No. 13 and Nos. 15, 17, 19, 21, and 23. Tighten B-nuts finger-tight.
(c) Lightly coat lower B1A B1B-manifold (3) nipple threads with thread lubricant.
(d) Connect remaining end of each fuel tube (1) onto lower B1A B1B-manifold (3). Tighten B-nuts
finger-tight.

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L. Apply final torque to fuel system components as follows:
(1) Tighten bolt (4, figure 8, section A-A) to 202-238 lb in. (22.9-26.8 N·m) of torque, then tighten two
bolts (8), and two bolts (9) to 60-70 lb in. (6.8-7.9 N·m) of torque.
(2) Tighten two bolts (23, section D-D) (two places) and two bolts (24, view E) (two places) to 60-70 lb
in. (6.8-7.9 N·m) of torque.
(3) Tighten six bolts (6, section B-B) (eight places) to 202-238 lb in. (22.9-26.8 N·m) of torque.
(4) Tighten six bolts (16, view C) (eight places) to 60-70 lb in. (6.8-7.9 N·m) of torque, then tighten six
bolts (12, section B-B) (eight places) to 202-238 lb in. (22.9-26.8 N·m) of torque.
(5) Tighten upper C2-manifold (17, figure 1) and lower C2-manifold (18) B-nuts as follows:
(a) Triple torque B-nuts as follows:
1 Tighten B-nut to 460-540 lb in. (52.0-61.0 N·m) of torque.
2 Loosen until B-nut is free running.
3 Retighten B-nut to 460-540 lb in. (52.0-61.0 N·m) of torque.
4 Check the joint by reapplying 460-540 lb in. (52.0-61.0 N·m) of torque to the B-nut in the
(6) Tighten upper C1-manifold (14) and lower C1-manifold (15) B-nuts per step 21.L.(5)(a)1 through
step 21.L.(5)(a)4.
(7) Tighten upper A1-manifold (11) and lower A1-manifold (12) B-nuts per step 21.L.(5)(a)1 through
step 21.L.(5)(a)4.
(8) Tighten upper B2 B3-manifold (8) and lower B2 B3-manifold (9) B-nuts per step 21.L.(5)(a)1
through step 21.L.(5)(a)4.
(9) Tighten upper A2A A2B-manifold (5) and lower A2A A2B-manifold (6) B-nuts per step
21.L.(5)(a)1 through step 21.L.(5)(a)4.
(10) Tighten upper B1A B1B-manifold (2) and lower B1A B1B-manifold (3) B-nuts as follows:
(a) Triple torque B-nuts as follows:
1 Tighten B-nut to 55-65 lb ft (75-88 N·m) of torque.
2 Loosen until B-nut is free running.
3 Retighten B-nut to 55-65 lb ft (75-88 N·m) of torque.
4 Check the joint by reapplying 55-65 lb ft (75-88 N·m) of torque to the B-nut in the

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(11) Tighten fuel tubes (16) B-nuts as follows:
(a) Triple torque B-nuts at fuel nozzle joints as follows:
1 Tighten B-nuts to 262-308 lb in. (29.7-34.7 N·m) of torque at each fuel nozzle joint
torque at each joint sequentially around in a CW direction ALF.
(b) Triple torque B-nuts at manifold joints as follows:
1 Tighten B-nuts to 143-167 lb in. (16.2-18.8 N·m) of torque at each manifold joint
(a) Triple torque B-nuts at fuel nozzle joints per step 21.L.(11)(a)1 through step 21.L.(11)(a)3.
(b) Triple torque B-nuts at manifold joints per step 21.L.(11)(b)1 through step 21.L.(11)(b)3.

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(b) Triple torque B-nuts at manifold joints as follows:
1 Tighten B-nuts to 175-205 lb in. (19.8-23.1 N·m) of torque at each manifold joint
M. Install liquid fuel brackets and electrical harness brackets per paragraph 19, step 19.A. through step 19.AH.
N. Install liquid fuel staging valves per paragraph 15, step 15.A.(1), step 15.A.(2), step 15.A.(4), step
15.A.(6), step 15.A.(8), step 15.A.(10), step 15.A.(12), step 15.A.(14), step 15.A.(16), step 15.A.(18), and
step 15.A.(20).
O. Install liquid fuel staging valve supply and purge tubes per paragraph 13, except for step 13.A.(6),
step 13.A.(8), step 13.I.(8), step 13.I.(9), and step 13.M.(6).
P. Install liquid fuel electrical harnesses per paragraph 17, step 17.B. through step 17.G.
Q. Install enclosure fuel manifold supports per packager's manual.
R. Remove dual fuel manifold support fixture, 1C9621, per WP 3015 00.
S. Make all fuel and electrical connections onto fuel system per packager's manual.

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22. Fuel Hose Assembly Removal.
A. Remove fuel hose assembly at even number fuel nozzle locations as follows:
CAUTION

CONTAMINATION.
NOTE
• Aft-most fuel hoses at even numbered fuel nozzles are connected to
C-manifold.
• Forward-most fuel hoses at even numbered fuel nozzles are connected to
B3-manifold.
NOTE
There is a loop clamp installed on the fuel hose routed to the C-manifold and a
loop clamp installed on the fuel hose routed to the A-manifold. The loop
clamps are attached together to maintain space between the hoses.
(a) If required, remove self-locking nut and bolt that secures two loop clamps together and remove
loop clamp from fuel hose routed to A- or C-manifold.
(b) Loosen B-nut that secures fuel hose to check valve at C-manifold. Disconnect fuel hose from
fuel check valve.
(c) If required, loosen B-nut and remove check valve from C-manifold.
(d) Loosen B-nut that secures fuel hose to A-manifold. Disconnect fuel hose from fuel manifold.
(e) Loosen B-nut that secures fuel hose to B3-manifold. Disconnect fuel hose from manifold.
(2) Remove fuel hose assembly from fuel nozzle pad per paragraph 8, step 8.C.
(4) Repeat step 22.A.(1) through step 22.A.(3) to remove as many fuel hose assemblies as required to

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Figure 9. Fuel Hose Replacement

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B. Remove fuel hose assembly at odd number fuel nozzle locations as follows:
CAUTION

CONTAMINATION.
NOTE
• Aft-most fuel hoses at odd numbered fuel nozzles are connected to
enhanced lean blow out (ELBO) manifold.
• Forward-most fuel hoses at odd numbered fuel nozzles are connected to
B2-manifold.
(a) Loosen B-nut that secures fuel hose to ELBO enhanced manifold. Disconnect fuel hose from
fuel manifold.
(b) Loosen B-nut that secures fuel hose to A-manifold. Disconnect fuel hose from fuel manifold.
(c) Loosen B-nut that secures fuel hose to B2-manifold. Disconnect fuel hose from manifold.
(2) Remove fuel hose assembly from fuel nozzle pad per paragraph 8, step 8.C.
(4) Repeat step 22.B.(1) through step 22.B.(3) to remove as many fuel hose assemblies as required to

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23. Fuel Hose Assembly Installation.
A. Install fuel hose assemblies (figure 9) at odd number fuel nozzle locations as follows:
(1) Remove tape from fuel nozzle port.
(2) Install fuel hose assemblies onto fuel nozzle pads per paragraph 9, step 9.G.
(3) Connect aft most fuel hoses onto ELBO manifold as follows:
WARNING

(a) Lightly coat B-nut fitting on ELBO manifold with lubricating oil.
(b) Slide B-nut back on aft most fuel hose. Lubricate ferrule with lubricating oil.
(c) Install B-nut hand-tight onto ELBO manifold.
(5) Connect forward most fuel hoses onto B2-manifold as follows:
(b) Slide B-nut back on forward most fuel hose. Lubricate ferrule with lubricating oil.
B. Install fuel hose assemblies at even number fuel nozzle locations as follows:
(1) Remove tape from fuel nozzle port.
(2) Install fuel hose assemblies onto fuel nozzle pads per paragraph 9, step 9.G.

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(3) Connect aft most fuel hoses onto C-manifold as follows:
WARNING

(a) Lightly coat B-nut fitting on C-manifold with lubricating oil.
(b) If check valve is removed, lightly coat ferrule on check valve with lubricating oil.
(c) Install check valve onto C-manifold hand-tight.
(d) Slide B-nut back on aft most fuel hose. Lubricate ferrule with lubricating oil.
(e) Install fuel hose B-nut onto check valve hand-tight.
NOTE
There is a loop clamp installed on the fuel hose routed to the C-manifold and a loop clamp
installed on the fuel hose routed to the A-manifold. The loop clamps are attached together
to maintain space between the hoses.
(5) Install loop clamp onto fuel hose routed to C-manifold and install loop clamp onto fuel hose routed
to A-manifold as follows:
(a) Install one loop clamp onto fuel hose midway between C-manifold and fuel nozzle with loop
facing aft.
(b) Install one loop clamp onto fuel hose midway between A-manifold and fuel nozzle with loop
facing forward.
(c) Lightly coat self-locking nut and bolt that secures two loop clamps together with thread
lubricant.
(d) Using self-locking nut and bolt, secure two loop clamps together. Tighten nut hand-tight.
(e) Adjust clamps to maintain space and avoid contact between hoses.
(f) Tighten self-locking nut to 60-70 lb in. (6.8-7.9 N·m) of torque.

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(6) Connect forward most fuel hoses onto B3-manifold as follows:
WARNING

(b) Slide B-nut back on forward most fuel hose. Lubricate ferrule with lubricating oil.
CAUTION
ENSURE ALIGNMENT STRIPE ON FLEX FUEL HOSE IS NOT TWISTED, OR

PREMATURE HOSE FAILURE MAY OCCUR.
C. Final tighten B-nuts that secure fuel hoses onto manifolds as follows:
(1) Final tighten B-nuts that secure fuel hoses onto A-, B2-, B3-, and ELBO manifolds (manifolds with
no check valves) as follows:
(a) Tighten B-nuts to 460-540 lb in. (52.0-61.0 N·m) of torque at each joint sequentially around in
a CW direction ALF.
(2) Final tighten B-nuts that secure check valves onto C-manifold at 15 locations as follows:
(a) Restrain check valve with wrench and tighten B-nuts to 460-540 lb in. (52.0-61.0 N·m) of
(b) Restrain check valve with wrench and loosen until B-nut is free running and retighten to
460-540 lb in. (52.0-61.0 N·m) of torque at each joint sequentially around in a CW direction
ALF.
(c) Restrain check valve with wrench and check joint by reapplying 460-540 lb in.
(52.0-61.0 N·m) of torque to the B-nut in the tightening direction at each joint sequentially

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(3) Final tighten B-nuts that secure fuel hoses onto check valves at 15 locations as follows:
(a) Restrain check valve with wrench and tighten fuel hose B-nuts to 460-540 lb in.
(52.0-61.0 N·m) of torque at each joint sequentially around in a CW direction ALF.
(b) Restrain check valve with wrench and loosen until fuel hose B-nut is free running and retighten
to 460-540 lb in. (52.0-61.0 N·m) of torque at each joint sequentially around in a CW direction
ALF.
(c) Restrain check valve with wrench and check joint by reapplying 460-540 lb in.
(52.0-61.0 N·m) of torque to the fuel hose B-nut in the tightening direction at each joint
24. Gas Staging Valves and Jumper Tube Removal.
A. Remove gas staging valve from valve rack bracket, support bracket, or valve bracket (figure 10) as
follows:
WARNING

(1) Loosen and disconnect electrical harness connector from gas staging valve connector.
(2) Remove four bolts (2) that secure gas staging valve (3) to adapter plate (25).
(4) Remove gas staging valve (3) from adapter plates (25) on valve rack brackets (1 and 9), valve
bracket (35), and support bracket (36).
B. Remove jumper tube from valve bracket as follows:
(1) Remove four bolts (2) that secure jumper tube (52) to adapter plate (25).
(2) Remove jumper tube from adapter plate at valve bracket (51).

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25. Gas Staging Valves and Jumper Tube Installation.
A. Install jumper tube onto valve bracket (figure 10) as follows:
(3) Install new gasket (4) onto jumper tube (52).
(4) Place jumper tube onto adapter plate (25).
(5) Using four bolts (2), secure jumper tube (52) onto adapter plate (25) at valve bracket (51). Tighten
bolts hand-tight.
(6) Using running torque, tighten four bolts (2) in a sequence of bolt No. 2, bolt No. 4, bolt No. 3, and
bolt No. 1. Refer to figure 10, view C for bolt numbers
(7) Loosen bolt No. 2 and retighten to its running torque.
B. Install gas staging valve onto valve rack bracket, support bracket, or valve bracket (figure 10) as follows:
(3) Install new gasket (4) onto gas staging valve (3).
NOTE
• All gas staging valves installed on valve rack brackets and support bracket have
electrical connectors pointing forward.
• Gas staging valves installed on valve brackets attached to B2-manifold have electrical
connectors pointing aft.
(4) Place gas staging valve (3) onto adapter plate (25).

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(5) Using four bolts (2) for each gas staging valve, secure gas staging valves (3) onto adapter plate (25)
at valve rack brackets (1 and 9), valve bracket (35), and support bracket (36). Tighten bolts hand-
tight.
(6) Final tighten bolts per step 25.A.(6) through step 25.A.(11).
WARNING

C. Connect electrical harness onto staging valve as follows:
(1) Engage electrical harness connector onto staging valve connector.
(2) Turn knurled coupling ring while wiggling backshell of electrical connector.
(3) Fully seat electrical harness connector by hand.
(5) Check tightness by wiggling connector backshell. No movement shall occur.
26. Tubular Gas Fuel Manifold Removal.
A. Disconnect all fuel and electrical connections from fuel system and secure per packager's manual.
NOTE
Dual fuel manifold support fixture, 1C9621G01, can only be used on gas turbines with a gas fuel
system. The dual fuel manifold support fixture, 1C9621G03, can be used for either gas turbines with a
gas fuel system or a gas and liquid fuel system.
C. Remove enclosure fuel manifold supports per packager's manual.
D. Remove electrical harnesses (41, 42, and 43, figure 10) and harness support brackets (5 and 8) as follows:
(1) Disconnect electrical harnesses (41, 42, and 43) connectors from staging valves.
(2) Remove self-locking nut (45, view P), bolt (46), and loop clamp (47) that secure electrical harness
(42) to valve rack bracket (9) at 9:30 o'clock position, ALF, then remove loop clamp (50) that
secures electrical harness (41) to valve rack bracket (9).
valve rack bracket (9) at 8:30 o'clock position, ALF, then remove loop clamp (50) that secures
electrical harness (42) to valve rack bracket (9).

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(5) Remove bolt (53, figure 10, view S) and loop clamp (54) that secure electrical harness (42) to fuel
tube (28) integral bracket.
(6) Remove screws (6, view A) and self-locking nuts (7) that secure electrical harness (41) connector to
(7) Remove screws (33) and self-locking nuts (34) that secure electrical harness (42) connector to
(8) Remove electrical harnesses (41 and 42).
(9) Remove self-locking nut (45, view R), bolt (46), and loop clamp (47) that secure electrical harness
(43) to valve rack bracket (1) at 2:30 o'clock position, ALF.
(12) Remove self-locking nut (45, view B), bolt (46), and loop clamp (47) that secure electrical harness
(43) to harness support bracket (5).
(13) Remove screws (6, view B) and self-locking nuts (7) that secure electrical harness (43) connector to
(14) Remove electrical harness (43).
(15) If required, remove bolts (40, view B) that secure harness support bracket (5) to valve rack bracket
(1).
(16) If required, remove bolts (40, view A) that secure harness support bracket (8) to valve rack bracket
(9).
E. Remove gas staging valves per paragraph 24.
F. Remove fuel hoses as follows:
(1) Remove fuel hoses from B2-manifold, B3-manifold, ELBO assembly, C-manifold, and A-manifold
per paragraph 22.
(2) If required, remove fuel hose assembly from fuel nozzle per step 8.C.
G. Remove adapter plates as follows:
(1) Remove adapter plates as follows:
(a) Remove four bolts (26, figure 10) that secure two fuel tubes to each adapter plate (25) at 10
locations on valve rack brackets (1 and 9), two locations on valve brackets (35 and 51), and
support bracket (36).

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(b) Remove four bolts (52) that secure adapter plate (25) to valve rack brackets (1 or 9), support
bracket (36), or valve brackets (35 and 51). Remove adapter plate.
H. Remove A-manifold fuel tubes as follows:
(1) Remove four bolts (2, figure 11) and self-locking nuts (3) that secure fuel tube (5) to A-manifold.
(2) Remove four bolts (2) and self-locking nuts (3) that secure fuel tube (7) to A-manifold. Remove fuel
tube (7) and discard gasket (4).
bracket (3).
(8) Remove U-bolts (13, section A-A) and self-locking nuts (7) that secure fuel tube (12) to bracket (5).
bracket (19).
I. Remove C-manifold fuel tubes as follows:
(1) Remove four bolts (2, figure 13) and self-locking nuts (3) that secure fuel tube (5) to C-manifold.
(2) Remove four bolts (2) and self-locking nuts (3) that secure fuel tube (9) to C-manifold. Remove fuel
tube and discard gasket (4).

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Figure 11. A-Manifold

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Figure 12. Fuel Manifold - Forward Side (Sheet 1 of 2)

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Figure 12. Fuel Manifold - Forward Side (Sheet 2 of 2)
bracket (2).
(8) Remove U-bolt (15, section A-A) and self-locking nuts (7) that secure fuel tube (14) to bracket (4).
bracket (19).
J. Remove bolts (1, figure 12) that secure brackets (2, 3, 4, and 5) to valve rack brackets (6 and 16). Remove
brackets.
K. Remove A-manifold as follows:
(1) Remove bolts (8, figure 11) and self-locking nuts (9) that secure A-manifold fuel tube (1) at
position.

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Figure 13. C-Manifold

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position.
position.
position.
(6) Remove bolts (12, figure 10) and loop clamps (11) that secure A-manifold (13) at two locations
(section G-G).
(7) Remove bolts (12) and loop clamps (11) that secure A-manifold (13) to brackets (10) at two
(8) Remove bolt (12, view J) and loop clamp (11) that secure A-manifold (13) to valve bracket (51).
(9) Remove bolt (12, section H-H) and loop clamp (11) that secure A-manifold (13) to bracket (19).
(10) Remove bolt (12, section F-F) and loop clamp (11) that secure A-manifold (13) to bracket (30).
(11) Remove bolt (12, section N-N) and loop clamp (11) that secure A-manifold (13) to valve bracket
(35).
(12) Remove A-manifold fuel tubes (1, figure 11) from brackets.
L. Remove C-manifold as follows:
(1) Remove bolts (6, figure 13) and self-locking nut (7) that secure C-manifold fuel tube (1) at
position.
position.
position.
position.
(6) Remove bolts (12, figure 10) and loop clamps (11) that secure C-manifold (14) at two locations
(section G-G).
(7) Remove bolts (12) and loop clamps (11) that secure C-manifold (14) to brackets (10) at two
(8) Remove bolt (12, view J) and loop clamp (11) that secure C-manifold (14) to valve bracket (51).

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(9) Remove bolt (12, section H-H) and loop clamp (11) that secure C-manifold (14) to bracket (19).
(10) Remove bolt (12, section F-F) and loop clamp (11) that secure C-manifold (14) to bracket (30).
(11) Remove bolt (12, section N-N) and loop clamp (11) that secure C-manifold (14) to valve bracket
(35).
(12) Remove C-manifold fuel tubes (1, figure 13) from brackets.
M. Remove ELBO assembly as follows:
(1) Remove self-locking nut (8, figure 14), bolt (7), and loop clamp (6) that secure fuel tube (1) to
support bracket (13).
(2) Disconnect fuel tube (1) from ELBO assembly fuel tube (3). Remove fuel tube.
(3) Remove bolt (9), self-locking nut (10), and loop clamp (11) that secure fuel tube (2) to valve rack
bracket (9, figure 10). Remove fuel tube.
(4) Disconnect ELBO assembly fuel tube (3, figure 14) from ELBO assembly fuel tube (4).
NOTE
The ELBO assembly is made with integral loop clamps.
(7) Remove bolts (12, figure 10) that secure ELBO assembly (15) at two locations (section G-G).
NOTE
The same bolt is used to secure both the ELBO assembly and the B3-manifold in the
following steps.
(8) If not previously accomplished, remove bolt (12, section H-H) that secures ELBO assembly (15) to
bracket (19).
(9) If not previously accomplished, remove bolts (12) that secure ELBO assembly (15) to brackets (10)
at two locations (section E-E).
(10) If not previously accomplished, remove bolt (12, section F-F) that secures ELBO assembly (15) to
bracket (30).

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Figure 14. ELBO Assembly

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NOTE
The same bolt and nut are used to secure both ELBO assembly and the B3-manifold in the
following step.
(11) If not previously accomplished, remove bolt (12, section L-L) and self-locking nut (37) that secure
ELBO assembly (15) to B3 manifold (29).
(12) Remove ELBO assembly.
N. Remove B3-supply manifold and fuel tubes as follows:
(1) Remove bolts (38, figure 10) that secure loop clamps (39) to valve rack bracket (9) at two locations.
(2) Remove bolts (38) that secure loop clamps (39) to valve rack bracket (1) at two locations.
(3) Remove bolt (12, section H-H) that secures loop clamp (32) to bracket (19).
(4) Remove bolt (12, section F-F) that secures loop clamp (32) to bracket (30).
(5) Remove four bolts (10, figure 15) and self-locking nuts (11) that secure supply manifold (1) to
supply manifold (2).
(5).
(7) Remove supply manifold (1) and orifice plate (14). Discard gaskets (12 and 13).
(7).
(9) Remove supply manifold (2) and orifice plate (16). Discard gaskets (12).
(11) Remove fuel tube (3) and orifice plate (25). Discard gaskets (12).
(12) Remove bolt (20, view A) and loop clamp (21) that secure fuel tube (4) to bracket (19).
(13) Remove bolts (section B-B) and retaining strap (23) that secure fuel tube (4) to bracket (24).
(15) Remove fuel tube (4) and spacer plate (15). Discard gaskets (12).

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O. Remove B3-manifold as follows:
(1) Remove bolts (17, figure 15) and self-locking nuts (18) that secure fuel manifold (7) to fuel
manifold (8) at 2:00 o'clock position.
(5) Remove bolts (12, figure 10) and loop clamps (11) that secure B3-manifold (29) at two locations
(section G-G).
(6) Remove bolt (12, view J) and loop clamp (11) that secure B3-manifold (29) to valve bracket (51).
(7) Remove bolt (12, section N-N) and loop clamp (11) that secure B3-manifold (29) to valve bracket
(35).
NOTE
The same bolt is used to secure both the B3-manifold and the ELBO assembly in the
following steps.
(8) If not previously accomplished, remove bolt (12, section H-H) and loop clamp (11) that secure
(9) If not previously accomplished, remove bolts (12) and loop clamps (11) that secure B3-manifold
(29) to brackets (10) at two locations (section E-E).
(10) If not previously accomplished, remove bolt (12, section F-F) and loop clamp (11) that secure
NOTE
The same bolt and nut are used to secure both the B3-manifold and the ELBO assembly in
the following step.
(11) If not previously accomplished, remove bolt (12, section L-L), self-locking nut (37), and loop clamp
(11) that secure B3-manifold (29) to ELBO assembly (15).
(12) Remove B3-manifold from brackets.
P. Remove U-bolts (10, figure 16) and self-locking nuts (11) that secure valve brackets (12 and 16) to fuel
tube (6). Remove valve brackets.
Q. Remove U-bolts (18, figure 10) and self-locking nuts (16) that secure two brackets (10, section E-E),
bracket (19, section H-H), and bracket (30, section F-F) to B2-manifold (17). Remove brackets.

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Figure 16. B2-Manifold

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R. Remove B2-manifold as follows:
(1) Remove eight bolts (3, figure 16) and self-locking nuts (5) that secure fuel tube (6) to fuel tube (9).
(3) Remove fuel tube (6) and discard gaskets (4).
(5) Remove self-locking nuts (13, section A-A) and U-bolt (14) that secure fuel tube (9) to bracket (15).
(6) Remove six bolts (2) that secure fuel tube (9) to valve rack bracket (1). Remove fuel tube and
discard gasket (4).
(7) Remove six bolts (2) that secure fuel tube (8) to valve rack bracket (1). Remove fuel tube.
S. Remove two bolts (12, figure 14) that secure support bracket (13) to angle bracket (1, figure 8). Remove
support bracket (13, figure 14).
T. Remove bracket (18, figure 12) and bracket (20) as follows:
(1) Remove six bolts (17) that secure bracket (18) to bracket (6, figure 17). Remove bracket (18,
figure 12).
U. Remove four bolts (7, figure 17) and self-locking nuts (8) that secure support bracket (6) to valve rack
bracket (1). Remove support bracket (6).
V. Remove valve rack brackets from dual fuel manifold support fixture, 1C9621, as follows:
(1) Remove eight capscrews (3, figure 17), flat washers (4), and self-locking nuts (5) that secure two
valve rack brackets (1) to rails (2). Remove valve rack brackets.

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27. Tubular Gas Fuel Manifold Installation.
NOTE
Dual fuel manifold support fixture, 1C9621G01, can only be used on gas turbines with a gas fuel
system. The dual fuel manifold support fixture, 1C9621G03, can be used for either gas turbines with a
gas fuel system or a gas and liquid fuel system.
B. Install two valve rack brackets (1, figure 17) onto dual fuel manifold support fixture, 1C9621, as follows:
(1) Align valve rack brackets (1) with rails (2).
(2) Install four capscrews (3), heads down with flat washers (4) under heads, through each valve rack
bracket (1) and rail (2).
(3) Using eight self-locking nuts (5) secure valve rack brackets (1) onto rails (2). Tighten self-locking
C. Install support bracket (6, figure 17) as follows:
(2) Using four bolts (7) and self-locking nuts (8), secure support bracket (6) onto valve rack bracket (1).
D. Install bracket (18, figure 12) as follows:
(1) Lightly coat bolts (17) with thread lubricant.
(2) Using six bolts (17), secure bracket (18) onto bracket (6, figure 17). Tighten bolts (17, figure 12) to
60-70 lb in. (6.8-7.9 N·m) of torque.
E. Install support bracket (13, figure 14) as follows:
(1) Lightly coat bolts (12) with thread lubricant.
(2) Using two bolts (12), secure support bracket (13) onto upper left side of angle support (1, figure 8).
F. Install B2-manifold as follows:
NOTE
Ensure bracket tabs on fuel tubes point forward.
(1) Align fuel tube (6, figure 16) with aft rail of valve rack bracket (1).
(2) Install new gaskets (4) onto fuel tube (6) flanges at 4:00 and 8:00 o'clock positions.

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(6) Using eight bolts (3), boltheads up, and self-locking nuts (5), secure fuel tube (8) onto fuel tube (6).
(7) Install new gasket (4) onto fuel tube (8) flange at 12:00 o'clock position.
(8) Using eight bolts (3), boltheads up, and self-locking nuts (5), secure fuel tube (9) onto fuel tube (6).
(9) Using eight bolts (3), boltheads right (aft looking forward), and self-locking nuts (5), secure fuel
(11) Lightly coat U-bolt (14, section A-A) threads with thread lubricant.
(12) Using self-locking nuts (13) and U-bolt (14), secure fuel tube (9) onto bracket (15). Tighten nuts
hand-tight.
CAUTION

FLANGES PRIOR TO APPLYING FINAL TORQUE, OR FUEL LEAKAGE MAY
OCCUR.
(13) Tighten nuts (5) at each fuel tube flange as follows:
(a) Using crisscross pattern, tighten nuts (5) to 115-135 lb in. (13.0-15.2 N·m) of torque.
(b) Using crisscross pattern, tighten nuts (5) to 230-270 lb in. (26.0-30.5 N·m) of torque.
(c) Using crisscross pattern, tighten nuts (5) to 345-405 lb in. (39.0-45.7 N·m) of torque.
(d) Using CW sequence, verify final torque of 345-405 lb in. (39.0-45.7 N·m) has been applied to
all nuts.
(15) Tighten self-locking nuts (13, section A-A) to 202-238 lb in. (22.8-26.9 N·m) of torque.
(16) If required, install cap (7) onto fuel tube (6) at 5:00 o'clock position as follows:

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WARNING

(a) Lightly coat fuel tube nipple threads with lubricating oil and install cap onto fuel tube.
(b) Triple torque cap as follows:
1 Tighten cap to 133-157 lb in. (15.1-17.7 N·m) of torque.
2 Loosen cap until free running and retighten to 133-157 lb in. (15.1-17.7 N·m) of torque.
3 Check cap by reapplying 133-157 lb in. (15.1-17.7 N·m) of torque in the tightening
direction.
G. Install valve brackets as follows:
(2) Using U-bolts (10) and self-locking nuts (11) secure valve bracket (12) onto fuel tube (6) at
7:00 o'clock position and secure valve bracket (16) onto fuel tube (6) at 4:00 o'clock position.
H. Install bracket (30, figure 10, section F-F) as follows:
(2) Using U-bolt (18) and self-locking nuts (16), secure bracket (30) onto B2-manifold (17) at
5:30 o'clock position. Tighten self-locking nuts hand-tight.
I. Install B3-manifold (29, figure 15) as follows:
(1) Position fuel manifolds (5 and 8, figure 15) from the 10:00 to 2:00 o'clock position.
(3) Using loop clamps (11), loops forward, and bolts (12), secure B3-manifold (29) onto B2-manifold
(17) support brackets at 11:00 and 1:00 o'clock positions (section G-G). Tighten bolts hand-tight.

/03) *(.
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(9) Using bolt (12, figure 10, view J) and loop clamp (11), secure B3-manifold (29) onto valve bracket
(10) Using bolt (12, section N-N) and loop clamp (11), secure B3-manifold (29) onto valve bracket (35).
(11) Install loop clamp (11), loop forward, onto B3-manifold (29) at 5:30 o'clock position (section F-F).
NOTE
• The ELBO assembly is made with integral loop clamps.
• The same bolt is used to secure both the B3-manifold and ELBO assembly in the
following step.
(12) If ELBO assembly (15, figure 10) is positioned onto bracket (30) at 5:30 o'clock position
(section F-F) per step 27.K.(11), perform the following step.
(a) Using bolt (12), secure both ELBO assembly (15) and loop clamp (11), previously installed
onto B3-manifold (29), onto bracket (30). Ensure ELBO assembly is positioned against bracket
and loop clamp is positioned against bolthead. Tighten bolt hand-tight.
(13) Install loop clamp (12, figure 10, section L-L), loop aft, onto B3-manifold (29).
NOTE
The same bolt and nut are used to secure both the B3-manifold and ELBO assembly in the
following step.
(14) If ELBO assembly is positioned adjacent to B3-manifold per step 27.K.(12), perform the following
step.
(a) Using bolt (12, figure 10, section L-L), bolthead aft, and self-locking nut (37), secure ELBO
assembly (15) onto loop clamp (11), previously installed onto B3-manifold. Ensure ELBO
assembly is positioned against nut and loop clamp is positioned against bolthead. Tighten nut to
60-70 lb in. (6.8-7.9 N·m) of torque.
(17) Tighten self-locking nuts (16, figure 10, section F-F) to 202-238 lb in. (22.9-26.8 N·m) of torque.

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J. Install B3-supply manifold and fuel tubes as follows:
(2) Using bolts (52), secure adapter plate (25) onto valve bracket (51) at 7:30 o'clock position. Tighten
(3) Install preformed packings (27) onto supply manifolds (1 and 2, figure 15) and fuel tubes (3 and 4).
(5) Using loop clamps (39), loops inboard, and bolts (38), secure supply manifold (1, figure 15) onto
valve rack bracket (9, figure 10) at two locations. Tighten bolts hand-tight.
(6) Position supply manifold (1, figure 15) onto fuel manifold (5) and into adapter plate (25, figure 10)
at 7:30 o'clock position. Secure tube onto adapter plate using two bolts (26). Tighten bolts to
60-70 lb in. (6.8-7.9 N·m) of torque.
NOTE
The orifice plate is marked with the words INBOARD and OUTBOARD. The side
marked INBOARD is installed toward the manifold ring. Proper installation is required to
meet engine emissions.
(7) Install two new gaskets (12, figure 15) and orifice plate (14), orifice plate between gaskets, between
supply manifold (1) and fuel manifold (5).
(9) Using four bolts (9), boltheads radially outward, and self-locking nuts (11), secure supply manifold
(1) onto fuel manifold (5). Tighten nuts to 60-70 lb in. (6.8-7.9 N·m) of torque.
(10) Position fuel tube (3) onto fuel manifold (6) and into adapter plate (25, figure 10) at 7:30 o'clock
position. Secure tube onto adapter plate using two bolts (26). Tighten bolts to 60-70 lb in.
(11) Install two new gaskets (12, figure 15) and orifice plate (25), orifice plate between gaskets, between
fuel tube (3) and fuel manifold (6).
(13) Using four bolts (10), boltheads radially outward, and self-locking nuts (11), secure fuel tube (3)
(15) Using bolts (52), secure adapter plate (25) onto valve bracket (35) at 4:00 o'clock position. Tighten

/03) *(.
:3
(16) Using loop clamps (39), loops inboard, and bolts (38), secure fuel tube (4, figure 15) onto valve rack
bracket (1, figure 10) at two locations. Tighten bolts hand-tight.
(17) Position fuel tube (4, figure 15) onto fuel manifold (8) and into adapter plate (25, figure 10) at
4:00 o'clock position. Secure tube onto adapter plate using two bolts (26). Tighten bolts to
60-70 lb in. (6.8-7.9 N·m) of torque.
NOTE
The spacer plate is marked with the words INBOARD and OUTBOARD. The side
marked INBOARD is installed toward the manifold ring.
(18) Install two new gaskets (12, figure 15) and spacer plate (15), orifice plate between gaskets, between
fuel tube (4) and fuel manifold (8).
(19) Using four bolts (9), boltheads radially outward, and self-locking nuts (11), secure fuel tube (4) onto
fuel manifold (8). Tighten nuts to 60-70 lb in. (6.8-7.9 N·m) of torque.
(20) Lightly coat bolts (22, section B-B) with thread lubricant.
(21) Using bolts (22) and retaining strap (23), secure fuel tube (4) onto bracket (24). Tighten bolts to
60-70 lb in. (6.8-7.9 N·m) of torque.
(22) Lightly coat bolt (20, view A) with thread lubricant.
(23) Using bolt (20) and loop clamp (21), secure fuel tube (4) onto bracket (19). Tighten bolt to
60-70 lb in. (6.8-7.9 N·m) of torque.
(24) Using loop clamp (32, figure 10) and bolt (12), secure B3-supply manifold (31) onto bracket (30) at
5:30 o'clock position (section F-F). Tighten bolt hand-tight.
(25) Position supply manifold (2, figure 15) onto supply manifold (1) and fuel manifold (7), and into
adapter plate (25, figure 10) at 4:00 o'clock position. Secure tube onto adapter plate using two bolts
(26) Install new gasket (13, figure 15) between supply manifolds (1 and 2).
(2) onto supply manifold (1). Tighten nuts to 60-70 lb in. (6.8-7.9 N·m) of torque.
NOTE
The orifice plate is marked with the words INBOARD and OUTBOARD. The side
marked INBOARD is installed toward the manifold ring. Proper installation is required to
meet engine emissions.
(28) Install two new gaskets (12) and orifice plate (16), orifice plate between gaskets, between supply
manifold (2) and fuel manifold (7).

*(. /03)
:3
(2) onto fuel manifold (7). Tighten nuts to 60-70 lb in. (6.8-7.9 N·m) of torque.
(31) Tighten bolt (12, section F-F) that secures loop clamp (32) onto bracket (30) to 60-70 lb in.
K. Install ELBO assembly as follows:
WARNING

(1) Slide B-nuts back and lubricate ferrules of ELBO assembly fuel tubes (3 and 5, figure 14) with
lubricating oil.
(2) Lightly coat ELBO assembly fuel tubes (3 and 5) nipple threads with lubricating oil.
(3) Position ELBO assembly fuel tube (3) onto ELBO assembly fuel tube (5).
(4) Secure ELBO assembly fuel tube (3) onto ELBO assembly fuel tube (5). Tighten B-nut hand-tight.
(6) Using two bolts (12), secure ELBO assembly (15) onto B2-manifold (17) support brackets at 11:00
and 1:00 o'clock positions (section G-G). Tighten bolts to 60-70 lb in. (6.8-7.9 N·m) of torque.
(7) Slide B-nut back and lubricate ferrule of ELBO assembly fuel tube (4, figure 14) with lubricating
oil.
(8) Lightly coat ELBO assembly fuel tube (4) nipple threads with lubricating oil.
(9) Position ELBO assembly fuel tube (4) onto ELBO assembly fuel tubes (3 and 5).
(10) Secure ELBO assembly fuel tube (4) onto ELBO assembly fuel tubes (3 and 5). Tighten B-nuts
hand-tight.

/03) *(.
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NOTE
The same bolt is used to secure both the ELBO assembly and B3-manifold to bracket in
the following step.
(11) Ensure loop clamp (11, figure 10) is installed, loop forward, onto B3-manifold (29) per
step 27.I.(10), and is positioned onto bracket (30) at 5:30 o'clock position (section F-F). Position
ELBO assembly (15) onto bracket (30). Using bolt (12), secure both the ELBO assembly (15) and
loop clamp (11) onto bracket (30). Ensure ELBO assembly is positioned against bracket and loop
clamp is positioned against bolthead. Tighten bolt to 60-70 lb in. (6.8-7.9 N·m) of torque.
NOTE
The same bolt and nut are used to secure both the ELBO assembly and B3-manifold in the
following step.
(12) Ensure loop clamp (11, figure 10, section L-L) is installed, loop aft, onto B3-manifold (29) per
step 27.I.(12), and is positioned adjacent to ELBO assembly (15). Using bolt (12), bolthead aft, and
self-locking nut (37), secure ELBO assembly (15) onto loop clamp (11), previously installed onto
B3-manifold. Ensure ELBO assembly is positioned against nut and loop clamp is positioned against
bolthead. Tighten nut to 60-70 lb in. (6.8-7.9 N·m) of torque.
(13) Triple torque B-nuts on ELBO assembly fuel tubes (3, 4, and 5, figure 14) as follows:
(a) Tighten B-nut to 60-70 lb ft (82-94 N·m) of torque at each joint sequentially around in a CW
direction ALF.
(b) Loosen until B-nut is free running and retighten to 60-70 lb ft (82-94 N·m) of torque at each
joint sequentially around in a CW direction ALF.
(c) Check joint by reapplying 60-70 lb ft (82-94 N·m) of torque to the B-nut in the tightening
direction at each joint sequentially around in a CW direction ALF.
(15) Using bolts (52), secure adapter plate (25) onto support bracket (36). Tighten bolts to 60-70 lb in.
(16) Install preformed packings (27, section D-D) onto fuel tubes (1 and 2, figure 14).
WARNING

(17) Slide B-nut back and lubricate ferrule of fuel tube (1) with lubricating oil.
(18) Lightly coat ELBO assembly fuel tube (3) nipple threads (10:00 o'clock position) with lubricating
oil.

*(. /03)
:3
(20) Using bolt (7), self-locking nut (8), and loop clamp (6), secure fuel tube (1) onto support bracket
(13). Tighten nut hand-tight.
(22) Position fuel tube (1, figure 14) onto ELBO assembly fuel tube (3) at 10:00 o'clock position and into
adapter plate (25, figure 10). Secure tube to adapter plate using two bolts (26). Tighten bolts to
60-70 lb in. (6.8-7.9 N·m) of torque.
(24) Triple torque B-nut on fuel tube (1) as follows:
direction.
(26) Using loop clamp (11), bolt (9), and self-locking nut (10), secure fuel tube (2) onto valve rack
bracket (14). Tighten nut hand-tight.
(27) Position fuel tube (2) into adapter plate (25, figure 10). Secure tube onto adapter plate using two
(29) If required, install tube cap (14) onto ELBO assembly fuel tube (4) at 5:30 o'clock position as
follows:
WARNING

(a) Lightly coat ELBO assembly fuel tube nipple threads with lubricating oil and install tube cap
onto fuel tube.

/03) *(.
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direction.
L. Assemble C-manifold as follows:
(2) Using bolts (6) and self-locking nuts (7), join two C-manifold fuel tubes (1). Tighten nuts hand-
tight.
(3) Position C-manifold fuel tubes (1) from 9:30 to 2:00 o'clock position.
(7) Using bolts (6, figure 13) and self-locking nuts (7), secure C-manifold fuel tube (1) section onto
(8) Using bolts (6) and self-locking nuts (7), secure C-manifold fuel tube (1) section onto C-manifold at
(9) Using bolts (6) and self-locking nuts (7), secure C-manifold fuel tube (1) section onto C-manifold at
4:00 and 7:00 o'clock positions. Tighten nuts hand-tight.
(10) Using loop clamp (11, figure 10), loop aft, and bolt (12), secure C-manifold (14) onto bracket (30) at
(11) Using loop clamp (11, view J), loop aft, and bolt (12), secure C-manifold (14) onto valve bracket
(12) Using loop clamp (11, section N-N), loop aft, and bolt (12), secure C-manifold (14) onto valve

*(. /03)
:3
M. Assemble A-manifold as follows:
(2) Using bolts (8) and self-locking nuts (9), join two A-manifold fuel tubes (1). Tighten nuts hand-
tight.
(3) Position A-manifold section from 10:00 to 2:30 o'clock position.
support bracket at 11:00 o'clock position (section G-G). Tighten bolts hand-tight.
(7) Using bolts (8, figure 11) and self-locking nuts (9), secure A-manifold fuel tube (1) section onto
(8) Using bolts (8) and self-locking nuts (9), secure A-manifold fuel tube (1) section onto A-manifold at
(9) Using bolts (8) and self-locking nuts (9), secure A-manifold fuel tube (1) section onto A-manifold at
5:00 and 10:00 o'clock positions. Tighten nuts hand-tight.
(10) Using loop clamp (11, figure 10), loop aft, and bolt (12), secure A-manifold (13) onto bracket (30) at
(11) Using loop clamp (11, view J), loop aft, and bolt (12), secure A-manifold (13) onto valve bracket
(12) Using loop clamp (11, section N-N), loop aft, and bolt (12), secure A-manifold (13) onto valve
N. Install two brackets (10, figure 10, section E-E) onto fuel manifolds as follows:
(2) Using U-bolt (18) and two self-locking nuts (16), secure brackets (10) onto B2-manifold (17) at 3:00
and 9:30 o'clock positions (section E-E). Tighten nuts hand-tight.
(3) Install loop clamps (11), loops forward, onto B3-manifold (29) at 3:00 and 9:30 o'clock positions
(section E-E).

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NOTE
The same bolt is used to secure both the B3-manifold and ELBO assembly in the
following step.
(5) Using bolts (12), secure both ELBO assembly (15) and loop clamps (11), previously installed onto
B3-manifold (29), onto bracket (30) at 3:00 and 9:30 o'clock positions (section E-E). Ensure ELBO
assembly is positioned against brackets and loop clamps are positioned against boltheads. Tighten
bolts hand-tight.
(6) Using loop clamp (11), loop aft, and bolt (12), secure C-manifold (14) onto bracket (10) at 3:00 and
9:30 o'clock positions (section E-E). Tighten bolts hand-tight.
(7) Using loop clamp (11), loop aft, and bolt (12) secure A-manifold (13) onto bracket (10) at 3:00 and
9:30 o'clock positions (section E-E). Tighten bolts hand-tight.
O. If removed, install 10 adapter plates (25, figure 10) onto valve rack brackets (1 or 9) as follows:
(2) Position adapter plate (25) onto valve rack brackets (1 or 9).
(3) Using four bolts (52), secure adapter plate (25) onto valve rack brackets (1 or 9). Tighten bolts to
60-70 lb in. (6.8-7.9 N·m) of torque.
P. Install C-manifold supply tubes and brackets as follows:
(3) Using six bolts (26), secure fuel tube (8, figure 13) onto three adapter plates (25, figure 10) at 2:00,
3:00, and 4:00 o'clock positions. Tighten bolts hand-tight.
60-70 lb in. (6.8-7.9 N·m) of torque.

*(. /03)
:3
(11) Secure fuel tube (8, figure 13) to fuel tube (15) as follows:
60-70 lb in. (6.8-7.9 N·m) of torque.
CAUTION

FLANGES PRIOR TO APPLYING FINAL TORQUE, OR FUEL LEAKAGE
MAY OCCUR.
all nuts.

/03) *(.
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WARNING

(a) Lightly coat fuel tube nipple threads with lubricating oil and install tube cap onto fuel tube.
direction.
(25) Install new gaskets (4, figure 13) between C-manifold fuel tube (1) flanges and fuel tubes (5, 9, 10,
16, and 17) flanges.
(27) Using four bolts (2), boltheads radially outward, and self-locking nuts (3), secure C-manifold fuel

*(. /03)
:3
Q. Install A-manifold supply tubes and brackets as follows:
(8) Using six bolts (26) secure fuel tube (13, figure 11) onto three adapter plates (25, figure 10) at the
8:00, 9:00, and 10:00 o'clock positions. Tighten bolts hand-tight.
(9) Secure fuel tube (13, figure 11) onto fuel tube (6) as follows:
(11) Using U-bolt (9) and self-locking nuts (7), secure fuel tube (8) onto bracket (3). Tighten self-locking
nuts hand-tight.

/03) *(.
:3
CAUTION

FLANGES PRIOR TO APPLYING FINAL TORQUE, OR FUEL LEAKAGE
MAY OCCUR.
(c) Using crisscross pattern., tighten eight nuts (11) to 345-405 lb in. (39.0-45.7 N·m) of torque.
all nuts.
(a) Lightly coat fuel tube nipple threads with lubricating oil and install tube cap onto fuel tube.
(b) Triple torque tube cap per step P.(17)(b).
(21) Install new gaskets (4, figure 11) between A-manifold fuel tube (1) flanges and fuel tubes (5, 7, 14,
15, and 16) flanges.
(23) Using four bolts (2), boltheads radially outward, and self-locking nuts (3), secure A-manifold fuel
tube (1) sections onto fuel tube (5). Tighten nuts hand-tight.

*(. /03)
:3
(28) Tighten bolts (26, figure 10) to 60-66 lb in. (6.8-7.4 N.m) of torque.
R. Install bracket (19, figure 10, section H-H) as follows:
(2) Using U-bolt (18) and self-locking nuts (16), secure bracket (19) onto B2-manifold (17). Tighten
NOTE
The same bolt is used to secure both the ELBO assembly and B3-manifold in the
following step.
(4) Ensure loop clamp (11) is installed, loop forward, onto B3-manifold (29) and is positioned onto
bracket (19) at 6:30 o'clock position. Position ELBO assembly (15) onto bracket (19). Using bolt
(12), secure both the ELBO assembly (15) and loop clamp (11) to bracket (19). Ensure ELBO
assembly is positioned against bracket and loop clamp is positioned against bolthead. Tighten bolt
hand-tight.
(5) Using loop clamp (32), loop forward, and bolt (12), secure B3-supply manifold (31) onto bracket
(7) Using loop clamp (11), loop aft, and bolt (12), secure C-manifold (14) onto bracket (19). Tighten
bolt hand-tight.
(8) Using loop clamp (11), loop aft, and bolt (12), secure A-manifold (13) onto bracket (19). Tighten
bolt hand-tight.

/03) *(.
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(10) Using U-bolt (21) and self-locking nuts (24), secure bracket (19) onto fuel tube (20). Tighten self-
(12) Using U-bolt (23) and self-locking nuts (24), secure bracket (19) onto fuel tube (22). Tighten self-
S. If required, install fuel hoses onto fuel nozzles per paragraph 9, step 9.G.
T. Install fuel hoses onto manifolds per paragraph 23.
U. Install gas staging valves per paragraph 25.
V. Install left (aft looking forward) harness support bracket and electrical harnesses as follows:
(1) If removed, attach harness support bracket (8, figure 10) onto valve rack bracket (9) as follows:
(a) Lightly coat bolt (40, view A) threads and contact faces with thread lubricant.
(b) Using bolts (40), attach harness support bracket (8) onto valve rack bracket (9).
(5) Using four screws (6) and self-locking nuts (7), secure electrical harness connector (41) onto
(10) Route electrical harnesses (41 and 42) to staging valves (3) on valve rack bracket (9).
(11) Lightly coat bolt (53, view S) threads and contact faces with thread lubricant.

*(. /03)
:3
(12) Using bolt (53, view S) and loop clamp (54), secure electrical harness (42) onto fuel tube (28)
integral bracket. Tighten bolt to 60-70 lb in. (6.8-7.9 N·m) of torque.
(14) Using self-locking nut (45, view P), bolt (46), and loop clamp (49), secure electrical harness (41)
onto valve rack bracket (9) at 7:30 o'clock position, ALF. Tighten nut hand-tight.
NOTE
NOTE
(20) Secure electrical harness onto staging valves per step 25.C.(1) through step 25.C.(5).
W. Install right (aft looking forward) harness support bracket and electrical harnesses as follows:
(1) If removed, secure harness support bracket (5, figure 10) onto valve rack bracket (1) as follows:
(a) Lightly coat bolt (40, view B) threads and contact faces with thread lubricant.
(b) Using bolts (40), secure harness support bracket (5) onto valve rack bracket (1).

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(6) Using self-locking nut (45, view B), bolt (46), and loop clamp (47), secure electrical harness (43)
onto harness support bracket (5). Tighten nut hand-tight.
(7) Route electrical harness (43) to staging valves (3) on valve rack bracket (1).
(8) Lightly coat bolts (46, view R) threads and contact faces with thread lubricant.
(9) Using self-locking nut (45), bolt (46), and loop clamp (49), secure electrical harness (43) onto valve
(13) Secure electrical harness onto staging valves per step 25.C.(1) through step 25.C.(5).
(14) Connect electrical harness connectors onto gas staging valves as follows:
(a) Engage electrical harness connector onto gas staging valve connector.
(b) Turn knurled coupling ring while wiggling backshell of electrical connector.
(c) Fully seat electrical harness connector by hand.
(d) After fully seating connector by hand, tighten coupling ring to 70-75 lb in. (7.9-8.5 N·m) of
torque using strap wrench (preferred method). If strap wrench is not available, tighten
connector with Teflon-jawed pliers until slippage occurs.
(e) Check tightness by wiggling connector backshell. No movement shall occur.
X. Install enclosure fuel manifold supports per packager's manual.
Y. Remove dual fuel manifold support fixture, 1C9621, per WP 3015 00.
Z. Make all fuel and electrical connections onto fuel system per packager's manual.
%ODQN
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ULTRAVIOLET FLAME SENSOR, L44819, FLAME
SENSOR SIGHT GLASS, AND FLAME SENSOR
BRACKET REPLACEMENT
())(&7,9,7</03)*$6785%,1(02'(/6

Page No. Change No.
1 - 7 .......................................................................................................................................................... 0
8 Blank ..................................................................................................................................................... 0
Alphabetical Index
Subject Page
Flame Sensor Bracket Installation. .......................................................................................................... 5

Flame Sensor Bracket Removal. .............................................................................................................. 5
Flame Sensor Sight Glass Installation...................................................................................................... 5
Flame Sensor Sight Glass Removal. ........................................................................................................ 5
Ultraviolet Flame Sensor Installation....................................................................................................... 3
Ultraviolet Flame Sensor Removal. ......................................................................................................... 3
*(. /03)
:3
1. Introduction.
This work package contains instructions for removal and installation of ultraviolet flame sensor, L44819, flame
sensor sight glass, and flame sensor bracket. Flame sensors are located at the 4:00 o’clock and 10:00 o’clock
positions.
Title Number
Clamping
None required.

Gasket L43073P01 2
Washer 133A1624P7 2
/03) *(.
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6. Ultraviolet Flame Sensor Removal.

WARNING
A. Disconnect interconnecting cable (figure 1) from packager’s junction box per packager’s manual.
B. Remove bolts and clamps that secure interconnecting cable to brackets.
C. Disconnect interconnecting cable from flame sensor.
CAUTION
D. Disconnect cooling air supply tube from cooling air fitting on air cooling can.
E. Loosen screws that secure cooling can to flame sensor. Slide cooling can off flame sensor.
F. Remove flame sensor.
G. Remove three bolts that secure flame sensor tube mount onto flame sensor bracket. Remove tube mount
and gasket. Discard gasket.
7. Ultraviolet Flame Sensor Installation.
A. Install new gasket and flame sensor tube mount onto flame sensor bracket.
B. Lubricate threads and contact faces of three bolts with thread lubricant.
C. Secure tube mount to flame sensor bracket with three bolts. Tighten bolts to 60-70 lb in. (6.8-7.9 N·m) of
torque.
D. Thread flame sensor onto tube mount. Tighten flame sensor to until snug on tube mount. Loosen flame
sensor and tighten a second time until snug. Tighten flame sensor one-quarter turn past snug.
E. Install air cooling can onto flame sensor and tighten screws on adjustable clamps.
CAUTION

F. Connect cooling air supply tube onto cooling air fitting on cooling can. Tighten coupling nut to
133-157 lb in. (15.1-17.7 N·m) of torque and safety-wire.
*(. /03)
:3
Figure 1. Ultraviolet Flame Sensor
/03) *(.
:3
G. Install interconnecting cable to brackets with clamps and bolts per SWP 1913 02. Tighten bolts to
60-70 lb in. (6.8-7.9 N·m).
WARNING
H. Connect interconnecting cable to packager’s junction box per packager’s manual.
I. Connect interconnecting cable to flame sensor.
8. Flame Sensor Bracket Removal.
A. Remove flame sensor per paragraph 6.
B. Remove bolts that secure flame sensor bracket (figure 2) to compressor rear frame (CRF) flange bracket.
Remove flame sensor bracket.
9. Flame Sensor Bracket Installation.
A. Install flame sensor bracket (figure 2) and secure to CRF flange bracket with three bolts. Tighten bolts to
60-70 lb in. (6.8-7.9 N·m).
B. Install flame sensor per paragraph 7.
10. Flame Sensor Sight Glass Removal.
A. Remove flame sensor per paragraph 6.
B. Remove flame sensor bracket per paragraph 8.
C. Remove flame sensor sight glass from compressor rear frame.
D. If required, remove sight adapter. Discard washer.
11. Flame Sensor Sight Glass Installation.
A. If required, install sight adapter as follows:
(1) Lightly lubricate threads of sight adapter with thread lubricant.
(2) Install sight adapter with new washer into compressor rear frame.
(3) Tighten sight adapter to 115-135 lb in. (13.0-15.2 N·m) of torque. Safety-wire sight adapter.
B. Lubricate threads of sight glass with thread lubricant. Ensure thread lubricant does not contact sight glass
window.
*(. /03)
:3
Figure 2. Flame Sensor Sight Glass and Bracket
/03) *(.
:3
C. Install flame sensor sight glass into compressor rear frame. Tighten sight glass to 276-324 lb in.
(31.2-36.6 N·m) of torque.
D. Install flame sensor bracket per paragraph 9.
E. Install flame sensor per paragraph 7.
%ODQN
/03) *(.
:3
IGNITER PLUG REPLACEMENT
())(&7,9,7</03)*$6785%,1(02'(/6

Page No. Change No.
1 - 9 .......................................................................................................................................................... 0
10 Blank ................................................................................................................................................... 0
Alphabetical Index
Subject Page
Igniter Plug Inspection. ............................................................................................................................ 4

Igniter Plug Installation............................................................................................................................ 7
Igniter Plug Removal. .............................................................................................................................. 3
*(. /03)
:3
1. Introduction.
This work package contains instructions for removal and installation of the igniter plug.
NOTE
Two configurations exist: single igniter plug unit and double igniter plug unit. Single igniter plugs are installed
at the 4:00 position and a blankoff plug is installed at the 10:00 o’clock position. With a double igniter plug
unit, igniter plugs are installed at the 4:00 and 10:00 o’clock positions.
None required.

Gage, Immersion Depth - Igniter Plug 2C6613G01
None required.
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6. Igniter Plug Removal.
WARNING
IGNITION SYSTEM SHALL BE INOPERATIVE FOR AT LEAST 2 MINUTES BEFORE

DISCONNECTING IGNITION LEADS. IGNITION SYSTEM COULD BE CHARGED WITH
LETHAL HIGH VOLTAGE.
CAUTION
• ENSURE IGNITER PLUG ADAPTER IS RESTRAINED WHEN LOOSENING

• IGNITER PLUG MAY FALL OUT WHEN IGNITION LEAD IS DISCONNECTED.
A. Disconnect ignition lead from igniter plug adapter (figure 1). Momentarily ground ignition lead to remove
any residual electrical charge.
B. Remove igniter plug and shims.
Figure 1. Igniter Plug and Lead
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7. Igniter Plug Inspection.
A. Inspect igniter plug per table 1 and figure 2.
Table 1. Igniter Plug Inspection

On-Site Max On-Site Max
Inspect Serviceable Limits Repairable Limits Corrective Action
1. Visible wear or None allowed Not repairable Inspect per step 2
grooving on plug tip
area
2. Depth of wear or Not exceeding 0.015 in. Not repairable Replace plug
groove (0.38 mm) deep or
less than 0.621 in.
(15.78 mm) diameter
3. A clicking sound None allowed Not repairable Replace plug
when the igniter is
shaken moderately
4. Movement of the None allowed Not repairable Replace plug
center electrode
when pushed with
the tip of a blunt
object
5. Visible radial gap 0.005 in. (0.13 mm) gap Not repairable Replace plug
between the center as measured with a gage
electrode and at any single location
insulator
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Figure 2. Igniter Plug Inspection (Sheet 1 of 2)
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Figure 2. Igniter Plug Inspection (Sheet 2 of 2)
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8. Igniter Plug Installation.
A. Determine number of shims required as follows (figure 3):
(1) Measure from outer surface of igniter plug adapter to outer surface of combustor ferrule using
immersion depth gage, 2C6613. Record as dimension A.
(2) Refer to table 2 to determine number of shims required.
B. Install required number of shims on igniter plug.
C. Install igniter plug into igniter plug adapter. Ensure adapter is safety-wired (figure 1).
CAUTION
ENSURE IGNITER PLUG ADAPTER IS RESTRAINED WHEN TIGHTENING COUPLING
D. Install ignition lead over igniter plug adapter. Tighten coupling nut to 23.0-27.0 lb ft (31.2-36.7 N·m) of
torque.
CAUTION
DO NOT OPERATE IGNITER UNIT WITH CAP OR COVER IN PLACE. FAILURE TO

COMPLY MAY RESULT IN DAMAGE TO PART.
E. If installing a single igniter unit in place of a double igniter unit, ensure correct plug and washer are
installed. Apply thread lubricant to thread before installation. Tighten plug to 46-54 lb ft
(63-73 N·m) of torque. Safety-wire blankoff plug (figure 4).
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Figure 3. Igniter Plug Immersion Depth
Table 2. Igniter Plug Shims Requirement

Dimension A Number of Shims Required
2.463-2.494 in. (62.56-63.35 mm) 0
2.431-2.462 in. (61.75-62.53 mm) 1
2.399-2.430 in. (60.93-61.72 mm) 2
2.367-2.398 in. (60.12-60.91 mm) 3
2.335-2.366 in. (59.31-60.10 mm) 4
2.303-2.334 in. (58.50-59.28 mm) 5
2.271-2.32 in. (57.68-58.47 mm) 6
2.239-2.270 inch (56.87-57.66 mm) 7
2.207-2.238 in. (56.06-56.85 mm) 8
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sa
Figure 4. Blankoff Plug Installed - Single Igniter System
%ODQN
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HIGH PRESSURE COMPRESSOR DISCHARGE
TEMPERATURE (T3) SENSOR REPLACEMENT
())(&7,9,7</03)*$6785%,1(02'(/6

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High Pressure Compressor Discharge Temperature (T3) Sensor Installation.......................................... 3

High Pressure Compressor Discharge Temperature (T3) Sensor Removal. ............................................ 3
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1. Introduction.
This work package contains instructions for removing and installing the high pressure compressor (HPC)
discharge temperature (T3) sensors. For detailed routing and clamping, see SWP 1913 02.
Title Number
Clamping


Gasket MS9202-042 1
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6. High Pressure Compressor Discharge Temperature (T3) Sensor Removal.
WARNING
ELECTRICAL POWER SHALL BE OFF BEFORE CONNECTING OR DISCONNECTING ELECTRICAL

CONNECTORS. ELECTRICITY CAUSES SHOCK, BURNS, AND DEATH.
CAUTION

INSTALLATION. FAILURE TO COMPLY MAY CAUSE UNRELIABLE ENGINE OPERATION.
NOTE
There are two T3 sensors on the engine. Procedure to remove T3 sensor is same for both.
A. Tag and disconnect electrical connector from T3 sensor integral lead (figure 1).
B. Remove jamnut that secures T3 sensor integral lead to No. 3 electrical interface panel.
C. Remove bolts that secure T3 sensor integral lead clamps to brackets. Remove clamps from T3 sensor
integral lead.
D. Remove four bolts that secure T3 sensor and T3 sensor support bracket to high pressure compressor (HPC)
rear frame mounting boss.
E. Remove bolt that secures T3 sensor support bracket to fuel nozzle.
F. Remove T3 sensor, T3 sensor support bracket, and gasket. Discard gasket.
G. Repeat step 6.A through step 6.F to remove remaining T3 sensor.
7. High Pressure Compressor Discharge Temperature (T3) Sensor Installation.
NOTE
There are two T3 sensors on the engine. Procedure to install T3 sensor is same for both.
A. Install new gasket and T3 sensor onto HPC rear frame mounting boss. Forward (FWD) marking on T3
sensor must face toward front of engine (figure 1).
B. Install T3 sensor support bracket onto T3 sensor and fuel nozzle.
C. Apply thread lubricant to threads and contact faces of bolts.
D. Using four bolts, secure T3 sensor and T3 sensor support bracket onto HPC rear frame. Tighten bolts to
60-70 lb in. (6.8-7.9 N·m) of torque. Safety-wire bolts.
E. Using bolt, secure T3 sensor support bracket onto fuel nozzle. Tighten bolt to 368-432 lb in.
(41.6-48.8 N·m) of torque and safety-wire.
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NOTE
Maintain 5.0 inch (127 mm) minimum bend radius during routing of T3 sensor integral lead.
F. Install clamps onto T3 sensor integral lead.
G. Secure clamps onto brackets using bolts. Tighten bolts to 60-70 lb in. (6.8-7.9 N·m) of torque.
H. Secure T3 sensor integral lead to No. 3 electrical interface panel with jamnut. Tighten jamnut one-quarter
turn past finger-tight. Safety-wire jamnut.
I. Connect electrical connector to T3 sensor integral lead as follows:
WARNING

assembly.
mating connector.
NOTE
(4) Repeat step 7.I.(2) and step 7.I.(3), as required. It may be necessary to loosen lead clamps that
restrict mating.
J. Repeat step 7.A through step 7.I to install remaining T3 sensor.
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Figure 1. High Pressure Compressor Discharge Temperature (T3) Sensor
%ODQN
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COMPRESSOR DISCHARGE PRESSURE (CDP) AND
STAGE 8 BLEED VALVES REPLACEMENT
())(&7,9,7</03)*$6785%,1(02'(/6

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Alphabetical Index
Subject Page
Compressor Discharge Pressure (CDP) Bleed Valve Installation............................................................ 5

Compressor Discharge Pressure (CDP) Bleed Valve Removal ............................................................... 3
Stage 8 Bleed Valve Installation............................................................................................................... 8
Stage 8 Bleed Valve Removal .................................................................................................................. 6
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1. Introduction.
This work package contains instructions for removing and installing the compressor discharge pressure (CDP)
and stage 8 bleed valves.
Title Number

(Optional)
None required.

Seal, Ring 0946 (FSCM 15284) 2
Seal, Ring 2873-600 (FSCM 15284) 2
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6. Compressor Discharge Pressure (CDP) Bleed Valve Removal
WARNING

CAUTION

OPERATION.
A. Tag and disconnect electrical connector from CDP bleed valve (figure 1).
B. Disconnect tubing from CDP bleed valve as follows:
(1) Position a waste fluid container beneath CDP bleed valve.
WARNING
CAUTION

(2) Disconnect drain line coupling nut from CDP bleed valve fitting.
(3) Disconnect supply tube and return tube coupling nuts from CDP bleed valve fittings.
C. Remove V-clamps and ring seals that secure CDP bleed valve onto CDP bleed air tubes. Discard ring seals.
D. Remove four bolts that secure CDP bleed valve onto mounting bracket. Remove CDP bleed valve.
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Figure 1. CDP Bleed Valve
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7. Compressor Discharge Pressure (CDP) Bleed Valve Installation

NOTE
Bleed valve interfacing hardware may be installation specific. Refer to packager’s manual for specific
procedure.
NOTE
Position bleed valve so that the flow arrow on the valve is oriented so the bleed air flows away from
the gas turbine. Ensure pneumatic vents are not obstructed.
A. Position CDP bleed valve (figure 1) onto mounting bracket and install bolts. Tighten bolts to 106-124 lb in.
(12.0-14.0 N·m) of torque.
B. Install new ring seals, P/N 0946, between CDP bleed valve and CDP bleed air tubes and secure with two
V-clamps. Tighten V-clamps to 115-125 lb in. (13.0-14.1 N·m) of torque.
C. Connect tubing onto CDP bleed valve as follows:

CAUTION

(1) Connect drain line coupling nut onto CDP bleed valve fitting. Tighten coupling nut to 133-157 lb in.
(15.1-17.7 N·m) of torque.
(2) Connect supply tube coupling nut onto CDP bleed valve fitting. Tighten coupling nut to
262-308 lb in. (29.7-34.7 N·m) of torque.
(3) Connect return tube coupling nut onto CDP bleed valve fitting. Tighten coupling nut to
460-540 lb in. (52.0-61.0 N·m) of torque.
D. Connect electrical connector onto CDP bleed valve as follows:
WARNING

assembly.
mating connector.
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NOTE
It may be necessary to loosen clamps that restrict mating.
(4) Repeat step 7.D.(2) and step 7.D.(3), as required. It may be necessary to loosen clamps that restrict
mating.
8. Stage 8 Bleed Valve Removal
WARNING

CAUTION
OPERATION.
A. Tag and disconnect electrical connector from stage 8 bleed valve (figure 2).
B. Disconnect tubing from stage 8 bleed valve as follows:
(1) Position a waste fluid container beneath stage 8 bleed valve.
WARNING

VENTILATION - IF NOT AVAILABLE, USE AN APPROVED RESPIRATOR
CAUTION
(2) Disconnect drain line coupling nut from stage 8 bleed valve fitting.
(3) Disconnect supply tube and return tube coupling nuts from stage 8 bleed valve fittings.
C. Remove V-clamps and ring seals that secure stage 8 bleed valve to stage 8 bleed air tubes. Remove stage 8
bleed valve. Discard ring seals.
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Figure 2. Stage 8 Bleed Valve
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9. Stage 8 Bleed Valve Installation
NOTE
Bleed valve interfacing hardware may be installation specific. Refer to packager’s manual for specific
procedure.
NOTE
Position bleed valve so that the flow arrow on the valve is oriented so the bleed air flows away from
the gas turbine. Ensure pneumatic vents are not obstructed.
A. Install new ring seals, P/N 2873–600, between stage 8 bleed valve and stage 8 bleed air tubes (figure 2).
Position stage 8 bleed valve and secure with two V-clamps. Tighten V-clamps to 115-125 lb in.
(13.0-14.1 N·m) of torque.
B. Connect tubing to stage 8 bleed valve as follows:
CAUTION
(1) Connect drain line coupling nut onto stage 8 bleed valve fitting. Tighten coupling nut to
133-157 lb in. (15.1-17.7 N·m) of torque.
(2) Connect supply tube coupling nut onto stage 8 bleed valve fitting. Tighten coupling nut to
262-308 lb in. (29.7-34.7 N·m) of torque.
(3) Connect return tube coupling nut onto stage 8 bleed valve fitting. Tighten coupling nut to
460-540 lb in. (52.0-61.0 N·m) of torque.
C. Connect electrical connector to stage 8 bleed valve as follows:
WARNING

assembly.
mating connector.
NOTE
It may be necessary to loosen clamps that restrict mating.
(4) Repeat step 9.C.(2) and step 9.C.(3), as required. It may be necessary to loosen clamps that restrict
mating.
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ACOUSTIC SENSOR REPLACEMENT
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Subject Page
Acoustic Sensor Installation..................................................................................................................... 9

Acoustic Sensor Removal. ....................................................................................................................... 3
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1. Introduction.
This work package provides instructions for the removal and installation of two acoustic sensors located on the
compressor rear frame (CRF) of the engine.
Title Number
None required.

Seal Ring, Metal 4058T39P02 2
Washer, Flat 133A1624P37 2
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6. Acoustic Sensor Removal.

NOTE
There are two acoustic sensors installed on engine. Procedure to remove acoustic sensor from
compressor rear frame is same for both. Remove integral lead for acoustic sensor per appropriate step.
A. Remove integral lead for acoustic sensor (1, figure 1) from brackets and air tube as follows:
WARNING
(1) Disconnect packager supplied cable from acoustic sensor (1) integral lead per packager's manual.
(2) Remove jamnut that secures acoustic sensor (1, view A) integral lead to No. 3 electrical interface
panel (3). Remove integral lead from panel.
NOTE
The same bolt secures two acoustic sensor integral leads onto bracket (6). Acoustic sensor
(1) integral lead is aft.
(3) Remove bolt (4, view B) and hinged cushioned loop clamp (5) that secure acoustic sensor (1)
integral lead to bracket (6). Remove integral lead from bracket.
NOTE
The same nut and bolt secure two acoustic sensor integral leads onto bracket (7). Acoustic
sensor (1) integral lead is outboard.
(4) Remove bolt (4, sheet 1) and hinged cushioned loop clamp (5) that secure acoustic sensor (1)
NOTE
The same bolt secures two acoustic sensor integral leads onto bracket (8) at two locations.
Acoustic sensor (1) integral lead is outboard.
(5) Remove bolt (4) and hinged cushioned loop clamp (5) (two locations) that secure acoustic sensor (1)
(6) Remove bolt (4) and hinged cushioned loop clamp (5) that secure acoustic sensor (1) integral lead to
bracket (8) at most aft location. Remove integral lead from bracket.
(7) Remove bolt (4, view A) and hinged cushioned loop clamp (5) that secure acoustic sensor (1)
bracket (10). Remove integral lead from bracket.
(9) Remove bolt (4) and loop clamp (13) (three locations) that secure acoustic sensor (1) integral lead to
integral brackets on air tube (11). Remove integral lead from air tube.

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Figure 1. Acoustic Sensor Removal/Installation (Sheet 1 of 4)
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(10) Procede to step 6.C. to remove acoustic sensor from compressor rear frame (CRF) (12).
B. Remove integral lead for acoustic sensor (2) from brackets and air tube as follows:
WARNING

(1) Disconnect packager supplied cable from acoustic sensor (2) integral lead per packager’s manual.
(2) Remove jamnut that secures acoustic sensor (2, view A) integral lead to No. 3 electrical interface
panel (3). Remove integral lead from panel.
NOTE
(2) integral lead is forward.
(3) Remove bolt (4, view B) and hinged cushioned loop clamp (5) that secure acoustic sensor (2)
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NOTE
(2) integral lead is inboard.
(4) Remove bolt (4, sheet 1) and hinged cushioned loop clamp (5) that secure acoustic sensor (2)
NOTE
Acoustic sensor (2) integral lead is inboard.
(5) Remove bolt (4) and hinged cushioned loop clamp (5) (two locations) that secure acoustic sensor (2)
NOTE
The same bolt and self-locking nut secure acoustic sensor (2) integral lead and
accelerometer lead onto bracket (14). Acoustic sensor (2) integral lead is forward.
(6) Remove self-locking nut (20), bolt (4), and hinged cushioned loop clamp (5) that secure acoustic
sensor (2) integral lead to bracket (14). Remove integral lead from bracket.
NOTE
bracket (17). Remove integral lead from bracket.
(10) Remove self-locking nut (20), bolt (4), and loop clamp (13) that secure acoustic sensor (2) to
cushioned loop clamp (19) at oil tube (18). See view C for alternate view. Remove integral lead
from oil tube.
(11) Remove bolt (4, view C) and loop clamp (13) that secure acoustic sensor (2) integral lead to integral
bracket on air tube (21). Remove integral lead from air tube.
(12) Procede to step 6.C. to remove acoustic sensor from CRF (12).
C. Remove acoustic sensor (1 or 2) from adapter (24) as follows:
(1) Remove safety wire, then remove bolts (22, section D-D) that secure acoustic sensor (1 or 2) to
adapter (24).
(2) Remove acoustic sensor (1 or 2) from adapter (24). Remove and discard metal seal ring (23).
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D. If required, remove adapter (24) from CRF (12) as follows:
(1) Remove safety wire, then remove adapter (24) and flat washer (25). Discard flat washer.
7. Acoustic Sensor Installation
A. If required, install adapter (24, figure 1) onto CRF (12) as follows:
(1) Coat threads of adapter (24, section D-D) and contact faces of flat washer (25) with thread lubricant.
(2) Install adapter (24) and flat washer (25) into CRF (12). Tighten adapter to 138-162 lb in.
(15.6-18.3 Nm) of torque. Safety-wire adapter.
NOTE
There are two acoustic sensors installed on engine. Procedure to install acoustic sensor
onto compressor rear frame is same for both. Install integral lead for acoustic sensor per
appropriate step.
B. Install acoustic sensor (1 or 2) into adapter (24) as follows:
(1) Install one metal seal ring (23) into adapter (24) groove.
CAUTION
• ENSURE ONLY ONE METAL SEAL RING IS INSTALLED. IF MORE THAN

ONE SEAL RING IS INSTALLED, THE ACOUSTIC SENSOR PROBE WILL
BECOME STUCK, RESULTING IN PERMANENT DAMAGE TO THE
SENSOR AT REMOVAL.
• ENSURE METAL SEAL RING REMAINS PROPERLY SEATED IN

ADAPTER GROOVE DURING INSERTION OF ACOUSTIC SENSOR, OR A
FALSE SENSOR SIGNAL MAY RESULT.
(2) Carefully install acoustic sensor (1 or 2) into adapter (24).
(3) Lightly coat threads and contact faces of bolts (22) with thread lubricant.
(4) Using bolts (22), secure acoustic sensor (1 or 2) into adapter (24). Tighten bolts to 380-420 lb in.
(43.0-47.4 Nm) of torque. Safety-wire bolts.
C. Install integral lead for acoustic sensor (1) onto brackets and air tube as follows:
CAUTION
ENSURE PLACEMENT OF CLAMPS MAINTAINS 0.50 INCH (12.7 MM)
CLEARANCE BETWEEN INTEGRAL LEAD AND ADJACENT HARDWARE.
(2) Using bolt (4, view A) and loop clamp (13) (three locations), secure acoustic sensor (1) integral lead
onto integral brackets on air tube (11). Tighten bolts to 60-70 lb in. (6.8-7.9 Nm) of torque.
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(3) Using bolt (4) and hinged cushioned loop clamp (5), secure acoustic sensor (1) integral lead onto
bracket (10). Tighten bolt to 60-70 lb in. (6.8-7.9 Nm) of torque.
(5) Using bolt (4, sheet 1) and hinged cushioned loop clamp (5), secure acoustic sensor (1) integral lead
onto bracket (8) at most aft location. Tighten bolt to 60-70 lb in. (6.8-7.9 Nm) of torque.
NOTE
Acoustic sensor (1) integral lead is outboard.
(6) Using bolt (4) and hinged cushioned loop clamp (5) (two locations), secure acoustic sensor (1)
integral lead onto bracket (8). Tighten bolts to 60-70 lb in. (6.8-7.9 Nm) of torque.
NOTE
The same nut and bolt secure two acoustic sensor integral leads onto bracket (7). Acoustic
sensor (1) integral lead is outboard.
NOTE
(1) integral lead is aft.
(8) Using bolt (4, view B) and hinged cushioned loop clamp (5), secure acoustic sensor (1) integral lead
onto bracket (6). Tighten bolt to 60-70 lb in. (6.8-7.9 Nm) of torque.
(9) Using jamnut, secure acoustic sensor (1, view A) integral lead onto No. 3 electrical interface panel
(3). Tighten jamnut 1/4 turn beyond finger-tight.
(10) Inspect alignment of acoustic sensor (1) integral lead. Ensure bend radius of integral lead exhibits
smooth transition with no evidence of kinking. Adjust integral lead as required.
WARNING
(11) Connect packager supplied cable onto acoustic sensor (1) integral lead per packager’s manual.
D. Install integral lead for acoustic sensor (2) onto brackets and air tube as follows:

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CAUTION
ENSURE PLACEMENT OF CLAMPS MAINTAINS 0.50 INCH (12.7 MM)

CLEARANCE BETWEEN INTEGRAL LEAD AND ADJACENT HARDWARE.
(2) Using bolt (4, view C) and loop clamp (13), secure acoustic sensor (2) integral lead onto integral
bracket on air tube (21). Tighten bolt to 60-70 lb in. (6.8-7.9 Nm) of torque.
(3) Lightly coat threads and contact faces of self-locking nuts (20) with thread lubricant.
(4) Using self-locking nut (20), bolt (4), and loop clamp (13), secure acoustic sensor (2) integral lead
onto cushioned loop clamp (19) at oil tube (18). See sheet 1 for alternate view. Tighten nut to 60-70
lb in. (6.8-7.9 Nm) of torque.
(5) Using bolt (4, sheet 1) and hinged cushioned loop clamp (5), secure acoustic sensor (2) integral lead
onto bracket (17). Tighten bolt to 60-70 lb in. (6.8-7.9 Nm) of torque.
(6) Using self-locking nut (20), bolt (4), and hinged cushioned loop clamp (5), secure acoustic sensor
(2) integral lead onto bracket (16). Tighten nut to 60-70 lb in. (6.8-7.9 Nm) of torque.
NOTE
NOTE
NOTE
Acoustic sensor (2) integral lead is inboard.
(9) Using bolt (4) and hinged cushioned loop clamp (5) (two locations), secure acoustic sensor (2)
integral lead onto bracket (8). Tighten bolt to 60-70 lb in. (6.8-7.9 Nm) of torque.
NOTE
(2) integral lead is inboard.

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NOTE
(2) integral lead is forward.
(11) Using bolt (4, view B) and hinged cushioned loop clamp (5), secure acoustic sensor (2) integral lead
to bracket (6). Tighten bolt to 60-70 lb in. (6.8-7.9 Nm) of torque.
(12) Using jamnut, secure acoustic sensor (2, view A) integral lead onto No. 3 electrical interface panel
(3). Tighten jamnut 1/4 turn beyond finger-tight.
(13) Inspect alignment of acoustic sensor (2) integral lead. Ensure bend radius of integral lead exhibits
smooth transition with no evidence of kinking. Adjust integral lead as required.
WARNING

(14) Connect packager supplied cable onto acoustic sensor (2) integral lead per packager’s manual.

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LOW PRESSURE ROTOR SPEED (XNSD) SENSOR
REPLACEMENT
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Low Pressure Rotor Speed (XNSD) Sensor Installation.......................................................................... 6

Low Pressure Rotor Speed (XNSD) Sensor Removal. ............................................................................ 3
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1. Introduction.
This work package contains instructions for removing and installing the low pressure rotor speed (XNSD)
sensor. There are two XNSD sensors on the low pressure turbine (LPT) rotor, one at 2:30 o’clock position, and
one at 9:30 o’clock position. For detailed routing and clamping, see SWP 1913 03.
Title Number
Low Pressure Turbine (LPT) Module External Tubing, SWP 1913 03
Harnesses, and Clamping

Puller Tool, LP Speed Probe Sensor Local Manufacture
Slide Hammer, 5 lb (2.3 kg) Local Purchase
Penetrating Oil GE Spec A50TF54, CL-A

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6. Low Pressure Rotor Speed (XNSD) Sensor Removal.
WARNING

CAUTION

OPERATION.
A. Tag and disconnect electrical connector from XNSD sensor (figure 1).
WARNING
USE EXTREME CARE WHEN WORKING WITH SPRINGS UNDER COMPRESSION. SERIOUS
INJURY COULD RESULT IF SPRING IS SUDDENLY RELEASED.
B. Remove nuts and bolts that secure spring retainer to adapter strut.
C. Remove spring retainer and spring from adapter strut.
CAUTION
SHIM SPACERS MUST BE SEPARATED OR PULLED AWAY FROM XNSD SENSOR TO

ALLOW REMOVAL OF SENSOR, OR DAMAGE TO SENSOR WILL OCCUR.
D. Loosen four bolts and nuts attaching adapter strut to TRF strut. Do not remove bolts and nuts.
NOTE
If XNSD sensor cannot be moved by hand go to step 6.I.
E. Pull XNSD sensor out about 0.25 inch (6.4 mm).
F. Pull shim spacers, located between adapter strut and TRF strut, out as far as possible. Shim spacers are not
removable (figure 2).
CAUTION
USE CARE WHEN REMOVING SENSOR TO AVOID DAMAGE TO SENSOR TIP.
G. Pull XNSD sensor straight out of strut.
H. Remove and discard preformed packings from sensor tip.
I. If XNSD sensor cannot be moved by hand:
(1) Soak the XNSD sensor with penetrating oil for a minimum of two hours.
(2) Obtain or locally manufacture puller tool per figure 3.
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(3) Remove four bolts and nuts attaching adapter strut to TRF strut.
(4) Remove strut adapter and shim spacers, noting shim location and orientation for reassembly.
(5) Thread slide hammer into puller tool. See figure 4.
(6) Install puller tool under end of XNSD sensor.
WARNING
DO NOT PINCH SKIN OR FINGERS WHEN OPERATING SLIDE HAMMER.
CAUTION
USE CARE WHEN REMOVING SENSOR TO AVOID DAMAGE TO SENSOR TIP.
(7) Operate slide hammer to loosen XNSD sensor.
(8) Pull XNSD sensor straight out of strut.
(9) Remove and discard preformed packings from sensor tip.
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Figure 1. Low Pressure Rotor Speed (XNSD) Sensor
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Figure 2. Shim Spacers Pulled Out for XNSD Sensor Removal/Installation
7. Low Pressure Rotor Speed (XNSD) Sensor Installation.
A. If slide hammer was used to remove XNSD sensor, put shim spacers in their original location and
orientation and loosely attach adapter strut to TRF strut with four bolts and nuts.
CAUTION
USE CARE WHEN INSTALLING SENSOR TO AVOID DAMAGE TO SENSOR TIP.
B. Lubricate new preformed packings with petrolatum and install onto XNSD sensor (figure 1).
NOTE
SHIM SPACERS MUST BE PULLED OUT AS FAR AS POSSIBLE OR SENSOR CANNOT BE
INSTALLED.
C. Ensure shim spacers, located between adapter strut and TRF strut, are pulled out as far as possible or
sensor cannot be installed (figure 2).
D. Slide XNSD sensor straight down into strut.
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Figure 3. Locally Manufactured Puller Tool
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Figure 4. Puller Tool - Installation
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E. Slide shim spacers together around XNSD sensor and secure with four bolts and nuts. Tighten nuts to
106-124 lb in. (12.0-14.0 N·m) of torque.
F. Install spring onto XNSD sensor (figure 1).
WARNING
USE EXTREME CARE WHEN WORKING WITH SPRINGS UNDER COMPRESSION. SERIOUS
INJURY COULD RESULT IF SPRING IS SUDDENLY RELEASED.
NOTE
Pressure must be kept on spring retainer until nuts are tightened.
G. Install spring retainer onto adapter strut and secure with bolts and nuts. Tighten nuts to 55-70 lb in. (6.3-7.9
N·m) of torque.
H. Connect electrical connector to XNSD sensor as follows:
WARNING

NOTE
It may be necessary to loosen lead clamps that restrict seating of electrical connector.
(1) Engage connector with mating sensor connector and turn knurled coupling ring while wiggling
backshell assembly.
(2) Tighten connector until self-locking feature is fully engaged with locking plate on XNSD speed
sensor connector.
mating connector.
(4) Repeat step 7.H.(2) thru step 7.H.(3) as required, to ensure electrical connector is seated.
%ODQN
/03) *(.
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LOW PRESSURE TURBINE INLET TEMPERATURE (T48)
THERMOCOUPLE REPLACEMENT/INSPECTION
())(&7,9,7</03)*$6785%,1(02'(/6

Page No. Change No.
1 - 8 .......................................................................................................................................................... 0
Alphabetical Index
Subject Page
Low Pressure Turbine Inlet Temperature (T48) Thermocouple Inspection............................................. 3

Low Pressure Turbine Inlet Temperature (T48) Thermocouple Installation. .......................................... 8
Low Pressure Turbine Inlet Temperature (T48) Thermocouple Removal. .............................................. 3
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1. Introduction.
This work package contains instructions for removal, inspection, and installation of the low pressure turbine
(LPT) inlet temperature (T48) thermocouple. Refer to SWP 1913 03 for routing of T48 harnesses.
Title Number

Deleted
Fixture, Puller - Exhaust Gas Temperature Probe 9429M49G01
Heat Gun Local Purchase
Safety Wire (0.032 inch) R297P04 (ALT)

Gasket 9379M93P01 8 (1 per probe)
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6. Low Pressure Turbine Inlet Temperature (T48) Thermocouple Removal.
A. Loosen nuts that secure thermocouple harness to T48 thermocouple. Disconnect thermocouple harness
from T48 thermocouple (figure 1).
B. Remove bolts that secure T48 thermocouple to LPT case. Remove T48 thermocouple.
C. Use puller fixture, 2C14898, if probe is difficult to remove (figure 2).
D. Remove and discard gasket.
7. Low Pressure Turbine Inlet Temperature (T48) Thermocouple Inspection.
A. Inspect thermocouples per table 1 and figure 3.
B. Preferred method of measuring insulation resistance:
(1) Heat probe in oven at 400°F (204°C) for 1 hour.
WARNING
WEAR INSULATED GLOVES TO PREVENT INJURY WHEN HANDLING HOT

PARTS.
(2) Place probe into a container of demineralized water. Ensure water fills inside of all cavities.
(3) Remove temperature probe from water and dry for 5 minutes in air, heating to 200 to 300°F
(93.3 to 148.9°C) using heat gun.
(4) Individually measure resistance, using hi-pot megohmmeter, of each threaded stud to probe body.
C. Alternate method of measuring insulation resistance:
(1) Place probe in a container of demineralized water. Ensure water fills inside of all cavities.
(2) Individually measure resistance, using ohmmeter, of each threaded stud to probe body.
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Figure 1. Low Pressure Turbine Inlet Temperature (T48) Thermocouple
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Figure 2. Temperature Probe Puller Fixture, 9429M49
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Table 1. Thermocouple Inspection Criteria

On-Site Max On-Site Max On-Site
1. Support and sheath for:
a. Corrosion/oxidation 0.228 in. (5.79 mm) Not repairable Replace probe
diameter at mid point
inlet gas port
b. Missing material None allowed Not repairable Replace probe
(including tip)
c. Bowed support 0.090 in. (2.29 mm) Not repairable Replace probe
at end of support
d. Cracks None allowed Not repairable Replace probe
2. Electrical circuitry for:
(thermocouple elements)
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
WARNING
WHEN USING COMPRESSED AIR FOR ANY COOLING, CLEANING, OR DRYING OPERATION, DO
NOT EXCEED 30 PSIG AT THE NOZZLE. EYES CAN BE PERMANENTLY DAMAGED BY
CONTACT WITH LIQUID OR LARGE PARTICLES PROPELLED BY COMPRESSED AIR.
INHALATION OF AIR-BLOWN PARTICLES OR SOLVENT CAN DAMAGE LUNGS.
NOTE
Clean probe with clean cloth and isopropyl alcohol. Dry with jet of dry, filtered compressed air. Disconnect
electrical harness. Measure resistance with one ohmmeter lead on each threaded stud, then reverse ohmmeter
leads and average resistance values.
a. KP to KN circuit resistance 2.4 to 4.1 ohms Not repairable Replace probe

b. Insulation resistance (refer to >10 Mohms each Not repairable Replace probe
step 7.B and step 7.C.)
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Figure 3. Low Pressure Turbine Inlet Temperature (T48) Thermocouple Inspection
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8. Low Pressure Turbine Inlet Temperature (T48) Thermocouple Installation.
A. Install new gasket onto LPT case (figure 1).
B. Install T48 thermocouple into LPT case with flat side of flange facing aft. Using thread lubricant,
lubricate threads and friction surfaces of bolts and secure thermocouple with bolts. Tighten bolts to
60-70 lb in. (6.8-7.9 N·m) of torque and safety-cable/wire.
C. Ensure curved spring washer is in place, and connect thermocouple harness to T48 thermocouple and
secure with nuts.
CAUTION
DO NOT OVERTIGHTEN THERMOCOUPLE HARNESS NUTS. FAILURE TO COMPLY

MAY RESULT IN PART DAMAGE.
D. Tighten largest diameter nut to 29-33 lb in. (3.3-3.7 N·m) of torque. Tighten smallest diameter nut to
16-18 lb in. (1.9-2.0 N·m) of torque.
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LOW PRESSURE TURBINE INLET PRESSURE (P48)
PROBE REPLACEMENT
())(&7,9,7</03)*$6785%,1(02'(/6

Page No. Change No.
1 - 4 .......................................................................................................................................................... 0
Alphabetical Index
Subject Page
Low Pressure Turbine Inlet Pressure (P48) Probe Inspection.................................................................. 3

Low Pressure Turbine Inlet Pressure (P48) Probe Installation. ............................................................... 4
Low Pressure Turbine Inlet Pressure (P48) Probe Removal.................................................................... 3
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1. Introduction.
This work package contains instructions for removing and installing the low pressure turbine (LPT) inlet
pressure (P48) probe.
Title Number
None required.

Gasket 1538M42P01 1
Gasket 1538M42P02 (ALT)
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6. Low Pressure Turbine Inlet Pressure (P48) Probe Removal.
A. Disconnect pressure sensing tube from P48 pressure probe (figure 1).
B. Remove safety wire. Remove bolts and washers that secure P48 probe onto LPT case. Remove P48 probe.
C. Remove and discard gasket.
7. Low Pressure Turbine Inlet Pressure (P48) Probe Inspection.
WARNING

A. Clean probe using isopropyl alcohol to remove external dirt. Total probe immersion is permitted.
B. Inspect probe per table 1 and figure 1.
Table 1. LPT Pressure Probe

1. Sheath area for:
a. Corrosion/oxidation Minimum 0.223 in. (5.66 mm) Not repairable Replace probe
diameter at gas port inlet
b. Missing material None allowed Not repairable Replace probe
(including tip)
c. Bowed support 0.090 in. (2.29 mm) at end Not repairable Replace probe
of support
d. Cracks None allowed Not repairable Replace probe
2. Probe sensing holes for:
a. Hole diameters 0.045-0.048 in. Not repairable Replace probe
(1.15-1.21 mm) diameter
b. Blockage None allowed Not repairable Replace probe
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8. Low Pressure Turbine Inlet Pressure (P48) Probe Installation.
A. Install new gasket onto LPT case (figure 1).
B. Install P48 pressure probe in LPT case so that holes in probe face forward. Secure probe with two washers
and bolts. Tighten bolts to 57-67 lb in. (6.5-7.5 N·m) of torque. Safety-wire bolts.
C. Connect pressure sensing tube to P48 probe per packager’s manual.
Figure 1. Low Pressure Turbine Inlet Pressure (P48) Probe
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BALANCE PISTON ORIFICE PLATE REPLACEMENT
())(&7,9,7</03)*$6785%,1(02'(/6

Page No. Change No.
1 - 4 .......................................................................................................................................................... 0
Alphabetical Index
Subject Page
Thrust Balance Orifice Plate Installation. ................................................................................................ 3

Thrust Balance Orifice Plate Removal..................................................................................................... 3
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1. Introduction.
This work package contains instructions for removing and installing the thrust balance orifice plate.
Title Number
Engine Operation Chapter 8
Troubleshooting Chapter 10
None required.

Gasket, Square, Seal 9608M08G48 2
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6. Thrust Balance Orifice Plate Removal.
A. Apply penetrating oil to nuts (6, figure 1) and bolts (5).
B. Remove four nuts (6) and four bolts (5) from balance piston air tube (1) flange and ejector nozzle (2)
flange. Retain nuts and bolts for reuse.
C. Remove two square seal gaskets (3) and orifice plate (4) from between flanges. Retain orifice plate.
Discard gaskets.
7. Thrust Balance Orifice Plate Installation.
WARNING
LUBRICATING OIL, MIL-PRF-23699F (C/I): COMBUSTIBLE. DO NOT INHALE, INGEST OR

A. Apply lubricating oil to threads and contact faces of four self-locking nuts (6) and four bolts (5).
B. Position two new square seal gaskets (3) and orifice plate (4) between balance piston air tube (1) flange
and ejector nozzle (2) flange. Ensure orifice plate is between gaskets.
C. Using four bolts (5) and four self-locking nuts (6) secure balance piston air tube (1) flange onto ejector
nozzle (2) flange. Tighten self-locking nuts to 106-124 lb in. (12.0-14.0 N·m) of torque.
D. Perform low pressure thrust balance operational check per Chapter 8. Replace orifice plate if necessary.
See Chapter 10 for correct orifice plate.
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Figure 1. Thrust Balance Orifice Plate, Removal and Installation
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HYDRAULIC CONTROL UNIT (HCU) AND HYDRAULIC
FILTER ASSEMBLY REPLACEMENT
())(&7,9,7</03)*$6785%,1(02'(/6

Page No. Change No.
1 - 10 ........................................................................................................................................................ 0
Alphabetical Index
Subject Page
Hydraulic Control Unit (HCU) Installation. ............................................................................................ 6

Hydraulic Control Unit (HCU) Removal. ................................................................................................ 3
Hydraulic Filter Assembly Installation. ................................................................................................... 9
Hydraulic Filter Assembly Removal........................................................................................................ 9

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1. Introduction.
This work package contains instructions for removing and installing the hydraulic control unit (HCU) and
hydraulic filter assembly.
Title Number

(Optional)

Gasket, Seal J219P03 1
Gasket, Seal L28004P01 1
Gasket, Seal L28004P03 (ALT)
Gasket, Seal - Fuel Filter 9011M60P01 1
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6. Hydraulic Control Unit (HCU) Removal.
WARNING

CAUTION

OPERATION.
A. Tag and disconnect electrical connectors (figure 1).
B. Position waste fluid container under hydraulic control unit (HCU).
NOTE
C. Disconnect tubing as follows (figure 2):
WARNING

(1) Remove bolts and washers that secure variable bypass valve (VBV) head and rod hoses to HCU.
Remove and inspect seal gaskets for serviceability. Discard damaged seal gasket.
CAUTION
ENSURE THAT CONNECTING FITTING IS RESTRAINED WHEN LOOSENING
(2) Disconnect variable inlet guide vane (VIGV) head and rod tubes from HCU.
(3) Disconnect variable stator vane (VSV) head and rod tubes from HCU.
(4) Disconnect thrust balance vane (TBV) head and rod tubes from HCU.
(5) On left side of HCU, disconnect bleed supply and bleed return tubes from HCU (figure 3).

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Figure 1. HCU Electrical Connectors
NOTE
Ensure HCU is supported while removing nuts and washers. HCU weighs approximately 75 lbs
(34 kg).
D. Remove nuts and washers that secure HCU to variable geometry (VG) hydraulic pump. Slide HCU off
mounting studs (figure 4).
E. Remove and discard gasket.
NOTE
If same HCU will be installed, disregard step 6.F.
F. Remove all fittings. Remove and discard preformed packings.
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Figure 3. HCU Bleed Tubes
7. Hydraulic Control Unit (HCU) Installation.
NOTE
If HCU fittings are already installed, proceed to step 7.B.
A. Install HCU fittings as follows (figure 2):
WARNING

(1) Lubricate new packings using lubricating oil.
(2) Install new packings, PN J221P910, onto VIGV, VSV, and TBV head port fittings. Install fittings on
HCU. Tighten fittings to 350-410 lb in. (39.6-46.3 N·m) of torque.
(3) Install new packings, PN J221P908, onto VIGV, VSV, and TBV rod port fittings. Install fittings on
HCU. Tighten fittings to 262-308 lb in. (29.7-34.7 N·m) of torque.
B. Install new seal gasket, PN L28004P01, onto VG hydraulic pump (figure 4).
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Figure 4. HCU

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NOTE
Ensure HCU is supported while installing washers and nuts. HCU weighs approximately 75 lbs
(34 kg).
C. Install HCU onto VG hydraulic pump and secure with washers and nuts. Tighten nuts to 106-124 lb in.
(12.0-14.0 N·m) of torque.
D. Connect tubing as follows (figure 2):
CAUTION

(1) Connect TBV, VSV, and VIGV head tubes onto HCU. Tighten head tube coupling nuts to 55-65 lb ft
(2) Connect TBV, VSV, and VIGV rod tubes onto HCU. Tighten rod tube coupling nuts to
460-540 lb in. (52.0-61.0 N·m) of torque.
(3) Install new or serviceable seal gasket, PN J219P03, onto VBV rod-end port. Using washers and
bolts, secure VBV rod hose onto HCU. Tighten bolts to 32-38 lb in. (3.7-4.2 N·m) of torque.
(4) Install seal gasket, PN J219P04, onto VBV head-end port. Using washers and bolts, secure VBV
head hose onto HCU. Tighten bolts to 32-38 lb in. (3.7-4.2 N·m) of torque.
(5) Connect bleed supply tube onto HCU (figure 3). Tighten supply tube coupling nut to 55-65 lb ft
(6) Connect bleed return tube onto HCU. Tighten return tube coupling nut to 78-92 lb ft (106-124 N·m)
of torque.
CAUTION
ENSURE ELECTRICAL CONNECTORS ARE INSTALLED AT THE PROPER POSITIONS.
FAILURE TO COMPLY WILL CAUSE UNRELIABLE ENGINE OPERATION.
E. Connect electrical connectors as follows (figure 1):
WARNING

assembly.
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mating connector.
NOTE
(4) Repeat step 7.E.(2) and step 7.E.(3), as required. It may be necessary to loosen lead clamps that
restrict mating.
8. Hydraulic Filter Assembly Removal.
A. Position waste fluid container under hydraulic filter assembly (figure 5).
WARNING

B. Remove bolts, nuts, and washers that secure hydraulic filter assembly to HCU. Pull hydraulic filter
assembly away from HCU.
C. Remove and discard gasket.
9. Hydraulic Filter Assembly Installation.
A. Install new gasket, PN 9011M60P01, onto hydraulic filter assembly.
B. Install hydraulic filter assembly to HCU and secure with bolts, nuts, and washers. Tighten bolts and nuts to
106-124 lb in. (12.0-14.0 N·m) of torque.

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Figure 5. Hydraulic Filter Assembly

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81&21752//(':+(135,17('2575$160,77('(/(&7521,&$//<
/03) *(.
:3
VARIABLE GEOMETRY HYDRAULIC PUMP
REPLACEMENT
())(&7,9,7</03)*$6785%,1(02'(/6

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Alphabetical Index
Subject Page
Variable Geometry Hydraulic Pump Installation. .................................................................................... 3

Variable Geometry Hydraulic Pump Removal......................................................................................... 3
81&21752//(':+(135,17('2575$160,77('(/(&7521,&$//<
*(. /03)
:3
1. Introduction.
This work package contains instructions for removing and installing the variable geometry hydraulic pump.
A. Remove hydraulic control unit (HCU) per WP 1811 00.
B. At the operator’s option, the variable geometry hydraulic pump and the HCU may be removed as a unit. in
this case, all steps of WP 1811 00 must be performed, except for separating the HCU from the pump.
Title Number
Hydraulic Control Unit (HCU) and Hydraulic Filter Assembly Replacement WP 1811 00
None required.

81&21752//(':+(135,17('2575$160,77('(/(&7521,&$//<
/03) *(.
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6. Variable Geometry Hydraulic Pump Removal.
A. Position waste fluid container under pump (figure 1).
WARNING

B. Remove nuts and washers that secure oil supply tube onto pump.
C. Remove nuts and washers that secure oil supply tube onto eductor block. Remove tube and seal gaskets.
Inspect gaskets for serviceability. Discard damaged gasket.
D. Remove nuts and washers that secure eductor tube onto pump.
E. Remove nuts and washers that secure eductor tube onto eductor block. Remove tube and seal gaskets.
Inspect gaskets for serviceability. Discard damaged gasket.
F. Remove nuts and washers that secure pump onto gearbox adapter. Remove and discard preformed packing.
7. Variable Geometry Hydraulic Pump Installation.
A. Lubricate new preformed packing, PN J221P260, with petrolatum. Install preformed packing into pump
packing groove.
B. Align pump alignment pin with hole in gearbox flange. Engage pump spline in gearshaft. Push pump into
position against gearbox adapter and secure with washers and nuts. Tighten nuts evenly, in small
increments, in a crisscross pattern to draw pump to gearbox adapter flange. Tighten nuts to 106-124 lb in.
(12.0-14.0 N·m) of torque.
C. Position two new or serviceable oil supply tube seal gaskets, PN J219P07, one at pump and one at eductor
block. Install oil supply tube and secure with nuts and washers. Tighten nuts to 57-67 lb in. (6.5-7.5 N·m)
of torque.
D. Position new or serviceable eductor tube seal gaskets, PN J219P05 and PN J219P04, at pump and eductor
block. Install eductor tube and secure with nuts and washers. Tighten nuts to 57-67 lb in. (6.5-7.5 N·m) of
torque.
81&21752//(':+(135,17('2575$160,77('(/(&7521,&$//<
*(. /03)
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Figure 1. Variable Geometry Hydraulic Pump
81&21752//(':+(135,17('2575$160,77('(/(&7521,&$//<
/03) *(.
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LUBE AND SCAVENGE PUMP REPLACEMENT
())(&7,9,7</03)*$6785%,1(02'(/6

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Alphabetical Index
Subject Page
Lube and Scavenge Pump Installation. .................................................................................................... 7

Lube and Scavenge Pump Removal......................................................................................................... 3
*(. /03)
:3
1. Introduction.
This work package contains instructions for removing and installing the lube and scavenge pump.
Title Number
Magnetic Chip Detector Replacement WP 1910 00

(Optional)

Gasket Packager-Supplied 3
Gasket, Round 9608M12P04 1
Gasket, Seal 9013M28P02 1
Gasket, Seal 9013M28P01 (ALT)
Gasket, Seal 9013M29P01 (ALT)
/03) *(.
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6. Lube and Scavenge Pump Removal.
A. Remove lube and scavenge pump as follows:
(1) Remove electrical cables from clips on electrical bracket.
WARNING

CAUTION

OPERATION.
(2) Tag and disconnect electrical connectors from chip detectors and resistance temperature detector
(RTD) (figure 1).
(3) Position waste fluid container under lube and scavenge pump.
WARNING

CAUTION
NOTE
Ensure lube oil supply is shut off before disconnecting tubing.
(4) Disconnect tubes and hoses from lube and scavenge pump and oil manifolds.
NOTE
Ensure lube and scavenge pump is supported when removing V-band clamp. Lube and
scavenge pump weighs approximately 25 lbs (11 kg).
(5) Remove V-band clamp that secures lube and scavenge pump (figure 2). Pull pump straight out until
drive spline clears gearbox. Remove round gasket and inspect for serviceability. Discard damaged
gasket.
*(. /03)
:3
Figure 1. Lube and Scavenge Pump and Oil Manifold Ports (Sheet 1 of 2)
/03) *(.
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Figure 1. Lube and Scavenge Pump and Oil Manifold Ports (Sheet 2 of 2)
*(. /03)
:3
Figure 2. Lube and Scavenge Pump
/03) *(.
:3
NOTE
If same lube and scavenge pump will be installed, disregard step 6.B, step 6.C, and step 6.D
B. Remove oil manifolds as follows (figure 3):
(1) Remove bolts (1 and 9) and washers (2 and 10) that secure oil supply manifold (3), oil lube and
scavenge manifold (11), and scavenge oil manifold (14) onto lube and scavenge pump (20). Remove
manifolds.
(2) Disconnect coupling nut on air/oil separator tube (5). Remove air/oil separator fitting (8). Remove
and discard preformed packing (7).
(3) Remove bolts (4) that secure air/oil separator tube (5) onto lube and scavenge pump (20) lube and
scavenge. Remove air/oil separator tube.
(4) Remove bolts (16) and washers (17) that secure E-sump scavenge oil manifold (18) onto lube and
scavenge pump (20). Remove manifold.
(5) Remove gaskets (6, 12, 13, 15, and 19) and inspect for serviceability. Discard damaged gaskets.
C. Remove spline lube and seal drain fittings. Remove and discard packings.
D. Remove chip detectors from lube and scavenge pump per WP 1910 00.
7. Lube and Scavenge Pump Installation.
NOTE
If chip detectors, spline lube and seal drain fittings, and oil manifolds are installed, disregard step 7.A,
step 7.B, and step 7.C.
A. Install chip detectors into lube and scavenge pump per WP 1910 00.
B. Install fittings as follows (figure 2):
WARNING
(1) Lubricate new preformed packings, PN J221P904, with lubricating oil. Install preformed packings
onto spline lube and seal drain fittings.
(2) Install spline lube and seal drain fittings into spline lube and seal drain ports. Tighten fittings to
135-157 lb in. (15.1-17.7 N·m) of torque.
*(. /03)
:3
Figure 3. Typical Oil Manifolds
/03) *(.
:3
C. Install oil manifolds as follows (figure 3):
(1) Install new or serviceable gaskets, PN 9013M29P02 (12), PN 9013M28P02 (13), and PN
9013M30P02 (15), onto lube and scavenge pump (20).
(2) Position oil supply manifold (3), oil lube and scavenge manifold (11), and scavenge oil manifold
(14) onto lube and scavenge pump (20) and secure with washers (2 and 10) and bolts (1 and 9).
(3) Install new or serviceable gasket, PN J219P04 (19), onto rear of lube and scavenge pump (20).
Install E-sump scavenge oil manifold (18) and secure with washers (17) and bolts (16). Tighten bolts
(4) Install new gasket, PN J219P02 (6), onto air/oil separator tube (5). Connect air/oil separator tube (5)
onto lube and scavenge pump (20) and secure with bolts (4). Tighten bolts to 32-38 lb in.
WARNING

(5) Lubricate new preformed packing (7), PN J221P910, with lubricating oil. Install preformed packing
onto air/oil separator fitting (8).
CAUTION

(6) Connect air/oil separator tube (5) to air/oil separator fitting (8). Tighten coupling nut to 55-65 lb ft
D. Install lube and scavenge pump as follows:
(1) Install round gasket, PN 9608M12P04, onto lube and scavenge pump. Align hole in gasket with
antitorque pin on pump.
(2) Position lube and scavenge pump in front of gearbox, aligning drive shaft splines and antitorque pin.
Slide pump into gearbox until housing seats.
NOTE
Ensure lube and scavenge pump is supported while installing V-band clamp. Lube and
scavenge pump weighs approximately 25 lbs (11 kg).
(3) Secure lube and scavenge pump onto gearbox using V-band clamp. Tighten clamp to 70-90 lb in.
*(. /03)
:3
E. Connect oil tubes and hoses as follows (figure 2):
(1) Install packager-supplied gasket. Connect oil tube onto lube supply outlet (L3) port and secure with
bolts. Tighten bolts to 325-425 lb in. (36.8-48.0 N·m) of torque.
(2) Install packager-supplied gasket. Connect oil tube onto lube supply inlet (L1) port and secure with
bolts. Tighten bolts to 500-700 lb in. (56.5-79.0 N·m) of torque.
(3) Install packager-supplied gasket. Connect oil tube onto scavenge discharge (L2) port and secure
with bolts. Tighten bolts to 425-550 lb in. (48.1-62.1 N·m) of torque.
CAUTION

(4) Connect lube oil tube onto lube discharge port fitting. Tighten coupling nut to 78-92 lb in.
(5) Connect oil tube onto supply pressure (L4) port fitting. Tighten coupling nut to 262-308 lb in.
(29.7-34.7 N·m) of torque.
(6) Connect scavenge tube onto scavenge discharge pressure (L5) port fitting. Tighten coupling nut to
262-308 lb in. (29.7-34.7 N·m) of torque.
(7) Connect oil manifold tube onto gearbox oil supply port fitting. Tighten coupling nut to
262-308 lb in. (29.7-34.7 N·m) of torque.
(8) Connect oil tube onto compressor rear frame (CRF) oil supply port fitting. Tighten coupling nut to
460-540 lb in. (52.0-61.0 N·m) of torque.
(9) Connect oil tube onto turbine rear frame (TRF) oil supply port fitting. Tighten coupling nut to
900-1090 lb in. (101.7-123.1 N·m) of torque.
(10) Connect accessory gearbox scavenge tube/hose onto accessory gearbox (AGB) scavenge in port
fitting. Tighten coupling nut to 55-65 lb ft (75-88 N·m) of torque.
(11) Connect D-sump lube scavenge tube onto D-sump scavenge in port fitting. Tighten coupling nut to
(12) Connect E-sump lube scavenge tube onto E-sump scavenge in port fitting. Tighten coupling nut to
(13) Install new gasket, PN J219P05, onto transfer gearbox scavenge tube. Connect tube onto transfer
gearbox scavenge in port and secure with bolts. Tighten bolts to 57-67 lb in. (6.5-7.5 N·m) of torque.
(14) Install new gasket, PN J219P05, onto B-sump scavenge tube. Connect tube onto B-sump scavenge
in port and secure with bolts. Tighten bolts to 57-67 lb in. (6.5-7.5 N·m) of torque.
(15) Install new gasket, PN J219P05, onto C-sump scavenge tube. Install tube onto C sump scavenge in
port and secure with bolts. Tighten bolts to 57-67 lb in. (6.5-7.5 N·m) of torque.

/03) *(.
:3
(16) Connect oil tube onto spline lube port fitting. Tighten coupling nut to 133-157 lb in.
(15.1-17.7 N·m) of torque.
(17) Connect hose assembly onto seal drain port fitting. Tighten coupling nut to 133-157 lb in.
(15.1-17.7 N·m) of torque.
F. Connect electrical connectors to RTDs and chip detectors as follows:
WARNING

assembly.
mating connector.
NOTE
(4) Repeat step 7.F.(2) and step 7.F.(3), as required. It may be necessary to loosen lead clamps that
restrict mating.
G. Install electrical cables into clips on electrical bracket.
%ODQN
/03) *(.
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PNEUMATIC STARTER REPLACEMENT
())(&7,9,7</03)*$6785%,1(02'(/6

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Pneumatic Starter Installation. ................................................................................................................. 5

Pneumatic Starter Removal...................................................................................................................... 3
*(. /03)
:3
1. Introduction.
A. This work package contains instructions for removing and installing the pneumatic starter (reference kit,
PN 682L184).
Title Number
Pneumatic Starter Servicing WP 4022 00

(Optional)
Gasket 9107M23P01 1
Gasket L22281P02 1
/03) *(.
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6. Pneumatic Starter Removal.
WARNING

CAUTION

OPERATION.
A. Tag and disconnect electrical connector from pneumatic starter (figure 1).
CAUTION
ENSURE AIR SUPPLY IS SHUT OFF BEFORE DISCONNECTING AIR/GAS INLET HOSE.
FAILURE TO COMPLY MAY RESULT IN PART DAMAGE.
B. Remove V-band clamp that secures air/gas inlet hose onto pneumatic starter. Remove and discard gasket.
C. Disconnect air/gas outlet hose from pneumatic starter per packager’s manual.
D. Position waste fluid container under pneumatic starter.
WARNING

CAUTION
FAILURE TO COMPLY CAN RESULT IN PART DAMAGE.
E. Disconnect tubes and hoses from pneumatic starter fittings.
*(. /03)
:3
Figure 1. Pneumatic Starter
/03) *(.
:3
Figure 2. Pneumatic Starter Fittings
NOTE
Ensure pneumatic starter is supported when removing nuts. Pneumatic starter weighs approximately
50 lbs (23 kg).
F. Remove nuts that secure pneumatic starter to transfer gearbox (TGB). Reposition oil scavenge tube
bracket. Remove pneumatic starter.
G. Remove and discard gasket.
H. Remove and discard preformed packings from starter drive shaft.
NOTE
If same pneumatic starter will be installed, proceed to paragraph 7.
I. Remove fittings and discard packings (figure 2).
7. Pneumatic Starter Installation.
A. If a new pneumatic starter is installed, service starter per WP 4022 00.
NOTE
If fittings are already installed, proceed to step 7.C.
B. Install fittings as follows:
*(. /03)
:3
WARNING
LUBRICATING OIL, MIL-PRF-23699F (C/I), IS TOXIC TO SKIN, EYES, AND

RESPIRATORY TRACT. SKIN AND EYE PROTECTION IS REQUIRED. AVOID
REPEATED OR PROLONGED CONTACT. USE IN WELL-VENTILATED AREA.
(1) Lubricate all new preformed packings using lubricating oil.
(2) Install new preformed packing, PN J221P906, onto reducer. Install reducer into air supply port.
(3) Install new preformed packing, PN J221P904, onto elbow. Install elbow into oil scavenge port.
Tighten jamnut finger-tight.
(4) Install new preformed packing, PN J221P908, onto union. Install union into oil scavenge port.
Tighten union to 262-308 lb in. (29.7-34.7 N·m) of torque.
C. Install new preformed packing, PN J221P222, onto pneumatic starter drive shaft (figure 1).
D. Install new gasket, PN 9107M23P01, onto TGB starter adapter.
NOTE
Ensure pneumatic starter is supported when installing nuts. Pneumatic starter weighs approximately
50 lbs (23 kg).
E. Align pneumatic starter so maintenance drain plug is at 6:00 o’clock position and install onto TGB. Install
oil scavenge tube bracket onto TGB studs. Secure starter and bracket using nuts. Tighten nuts to
193-227 lb in. (21.9-25.6 N·m) of torque.
F. Connect tubes and hoses as follows:
CAUTION

(1) Connect tube/hose onto air supply reducer. Tighten coupling nut to 460-540 lb in. (52.0-61.0 N·m)
of torque.
(2) Align oil in elbow with oil tube. Tighten jamnut on elbow to 133-157 lb in. (15.1-17.7 N·m) of
torque. Connect oil tube onto oil in elbow. Tighten coupling nut to 133-157 lb in. (15.1-17.7 N·m)
of torque.
(3) Connect oil scavenge tube to oil scavenge union. Tighten coupling nut to 460-540 lb in.
(52.0-61.0 N·m) of torque.
(4) Install new gasket, PN L22281P02, on air/gas inlet hose. Using V-band clamp, secure air/gas inlet
hose to pneumatic starter. Tighten V-band clamp as follows:
(a) Tighten V-band clamp to approximately 48 lb in. (5.4 N·m) of torque.
(b) Inspect and ensure V-band clamp is seated over both flanges equally.
/03) *(.
:3
(c) Using plastic or non-metallic mallet, tap V-band clamp around circumference, to distribute
band tension.
(d) Tighten V-band clamp to 87-103 lb in. (9.9-11.6 N·m) final torque. Continue to lightly tap
V-band clamp to prevent unequal loading.
(e) After full value torque is applied, tap circumference of V-band clamp again. Reapply torque to
ensure V-band is properly tightened.
(5) Install air/gas outlet hose onto pneumatic starter per packager’s manual.
G. Connect electrical connector to pneumatic starter as follows:
WARNING

assembly.
mating connector.
NOTE
(4) Repeat step 7.G.(2) and step 7.G.(3), as required. It may be necessary to loosen lead clamps that
restrict mating.
%ODQN
/03) *(.
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HIGH PRESSURE COMPRESSOR SPEED (XN25) SENSOR
REPLACEMENT
())(&7,9,7</03)*$6785%,1(02'(/6

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High Pressure Compressor Speed (XN25) Sensor Installation................................................................ 3

High Pressure Compressor Speed (XN25) Sensor Removal. .................................................................. 3
*(. /03)
:3
1. Introduction.
This work package contains instructions for removing and installing the high pressure compressor speed
(XN25) sensor.
Title Number

(Optional)

Gasket J219P04 1
/03) *(.
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6. High Pressure Compressor Speed (XN25) Sensor Removal.
WARNING

CAUTION

OPERATION.
NOTE
There are two identical XN25 sensors on left side of gearbox.
A. Tag and disconnect electrical connector from XN25 sensor (figure 1).
B. Loosen jamnut and remove XN25 sensor from gearbox port. Remove and retain jamnut.
WARNING

CAUTION
USE CARE TO ENSURE OLD SILICONE RUBBER ADHESIVE DOES NOT FALL INTO
GEARBOX. FAILURE TO COMPLY MAY CAUSE PART DAMAGE.
C. Using isopropyl alcohol, clean old silicone rubber adhesive from gearbox.
7. High Pressure Compressor Speed (XN25) Sensor Installation.
A. Remove bolts that secure gearbox access cover or AGB vent tube(s). Remove access cover or move AGB
vent tube(s) out of the way, and remove gasket. Inspect gasket for serviceability. Discard damaged gasket.
B. Install jamnut onto XN25 sensor.
C. Install and adjust XN25 sensor to meet required gap of 0.010-0.015 inch (0.25-0.38 mm) between sensor
tip and tooth crown of gear. Using feeler gage inserted through gearbox opening, check for required gap.
*(. /03)
:3
Figure 1. High Pressure Compressor Speed (XN25) Sensor
/03) *(.
:3
WARNING
VENTILATED AREA.
D. Apply a thin bead of silicone rubber adhesive around XN25 sensor at gearbox. Diameter of bead shall be
approximately 0.06 inch (1.5 mm).
NOTE
Tighten jamnut while silicone rubber adhesive is still wet.
E. Hold XN25 sensor and tighten jamnut to 90-110 lb in. (10.2-12.4 N·m) of torque.
F. Using feeler gage, recheck gap between sensor tip and tooth crown of gear. Gap shall be between
0.010-0.015 inch (0.25-0.38 mm). Safety-wire jamnut.
NOTE
Package vent system may have been installed as part of the package installation. Refer to the
packager’s information for proper installation.
G. Install new or serviceable gasket, PN J219P04, and cover or connect vent tube(s) with gasket, PN
MS27196-16 onto gearbox access opening, and secure using bolts. Tighten bolts to 32-38 lb in.
(3.7-4.2 N·m) of torque. Safety-wire bolts.
H. Connect electrical connector to XN25 sensor as follows:
WARNING

assembly.
mating connector.
NOTE
(4) Repeat step 7.H.(2) and step 7.H.(3), as required. It may be necessary to loosen lead clamps that
restrict mating.
(5) Safety-wire electrical connector.
%ODQN
/03) *(.
:3
LUBE RESISTANCE TEMPERATURE DETECTOR
(RTD) REPLACEMENT
())(&7,9,7</03)*$6785%,1(02'(/6

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Lube Resistance Temperature Detector Installation................................................................................. 3

Lube Resistance Temperature Detector Removal. ................................................................................... 3
*(. /03)
:3
1. Introduction.
This work package contains instructions for removing and installing lube resistance temperature detector
(RTD).
Title Number

Wrench, Strap (1/2” drive, 90° angle, BT-BS-625, Daniels Mfg Corp.
1/2” strap) (Optional)

/03) *(.
:3
6. Lube Resistance Temperature Detector Removal.
WARNING

CAUTION

OPERATION.
A. Tag and disconnect electrical connector from resistance temperature detector (RTD) (figure 1).
B. Position waste fluid container under lube and scavenge pump.
WARNING

C. Remove RTD from lube and scavenge pump manifold or boss on transfer gearbox (TGB) scavenge tube.
Remove and discard preformed packing.
7. Lube Resistance Temperature Detector Installation.
A. Lubricate new preformed packing with lubricating oil and install into RTD packing groove.
CAUTION
USE CARE TO PREVENT DAMAGE TO RTD TIP.
B. Install RTD into lube and scavenge pump manifold or boss on TGB scavenge tube. Tighten RTD to
133-157 lb in. (15.1-17.7 N·m) of torque.
*(. /03)
:3
Figure 1. Resistance Temperature Detector
/03) *(.
:3
C. Connect electrical connector to RTD as follows:
WARNING

assembly.
mating connector.
NOTE
restrict mating.
%ODQN
/03) *(.
:3
MAGNETIC CHIP DETECTOR REPLACEMENT
())(&7,9,7</03)*$6785%,1(02'(/6

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Subject Page
Magnetic Chip Detector Installation. ....................................................................................................... 3

Magnetic Chip Detector Removal............................................................................................................ 3
81&21752//(':+(135,17('2575$160,77('(/(&7521,&$//<
*(. /03)
:3
1. Introduction.
This work package contains instructions for removal and installation of the magnetic chip detector.
Title Number

Wrench, Strap (1/2” drive, 90° angle, 1/2” BT-BS-625, Daniels Mfg Corp.
strap) (Optional)

81&21752//(':+(135,17('2575$160,77('(/(&7521,&$//<
/03) *(.
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6. Magnetic Chip Detector Removal.
A. Position waste fluid container under lube and scavenge pump (figure 1).
WARNING

CAUTION

OPERATION.
B. Tag and disconnect electrical connector from chip detector.
WARNING

C. Remove chip detector from lube and scavenge pump or oil manifold block. Remove and discard preformed
packing.
7. Magnetic Chip Detector Installation.
A. Lubricate new preformed packing with lubricating oil. Install new preformed packing onto chip detector.
B. Install chip detector into lube and scavenge pump or oil manifold block. Tighten chip detector to
60-80 lb in. (6.8-9.0 N·m) of torque.
C. Safety-wire chip detector.
D. Connect electrical connector to chip detector as follows:
assembly.
mating connector.
NOTE
(4) Repeat step 7.D.(2) and step 7.D.(3) as required. It may be necessary to loosen lead clamps that
restrict mating.
81&21752//(':+(135,17('2575$160,77('(/(&7521,&$//<
*(. /03)
:3
Figure 1. Magnetic Chip Detector
81&21752//(':+(135,17('2575$160,77('(/(&7521,&$//<
/03) *(.
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ACCELEROMETER REPLACEMENT
())(&7,9,7</03)*$6785%,1(02'(/6

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Subject Page
Compressor Rear Frame Accelerometer Installation. .............................................................................. 3

Compressor Rear Frame Accelerometer Removal................................................................................... 3
Turbine Rear Frame Accelerometer Installation. ..................................................................................... 7
Turbine Rear Frame Accelerometer Removal.......................................................................................... 5
81&21752//(':+(135,17('2575$160,77('(/(&7521,&$//<
*(. /03)
:3
1. Introduction.
This work package contains instructions for removing and installing the compressor rear frame (CRF) and
turbine rear frame (TRF) accelerometers.
None required.

(Optional)
Thread Lubricant GE Spec. A50TF201
None required.
81&21752//(':+(135,17('2575$160,77('(/(&7521,&$//<
/03) *(.
:3
6. Compressor Rear Frame Accelerometer Removal.
WARNING

CAUTION
ENSURE LOCATION OF ELECTRICAL CONNECTOR IS NOTED TO AID INSTALLATION.

FAILURE TO COMPLY MAY CAUSE UNRELIABLE ENGINE OPERATION.
A. Tag packager electrical connector and disconnect from compressor rear frame (CRF) accelerometer
(1, figure 1) integral lead.
B. Remove jamnut (2) that secures CRF accelerometer (1) integral lead to No. 3 electrical panel (3). Remove
lead from panel.
C. Remove bolt (4) and loop clamp (5) that secure CRF accelerometer (1) integral lead to tray bracket (6) at
three locations.
D. Remove self-locking nuts (7), bolts (4), and loop clamps (5) that secure CRF accelerometer (1) integral
lead to two brackets (8).
E. Remove four bolts (9) that secure CRF accelerometer (1) to accelerometer bracket (10). Reposition PX36
bracket (11). Remove CRF accelerometer.
7. Compressor Rear Frame Accelerometer Installation.
A. Apply thread lubricant to threads and contact faces of bolts (9, figure 1).
B. Position CRF accelerometer (1) onto accelerometer bracket (10) and position PX36 bracket (11) onto CRF
accelerometer.
C. Using four bolts (9), secure CRF accelerometer (1) onto accelerometer bracket (10). Tighten bolts to
60-70 lb in. (6.8-7.9 N·m) of torque.
D. Apply thread lubricant to threads and contact faces of bolts (4) and self-locking nuts (7).
E. Using self-locking nuts (7), bolts (4) (boltheads inboard), and loop clamps (5), secure CRF accelerometer
(1) integral lead onto two brackets (8). Tighten nuts to 60-70 lb in. (6.8-7.9 N·m) of torque.
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Figure 1. CRF Accelerometer
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F. Using bolt (4) and loop clamp (5), secure CRF accelerometer (1) integral lead onto tray bracket (6) at three
locations. Tighten bolts to 60-70 lb in. (6.8-7.9 N·m) of torque.
G. Using jamnut (2), secure CRF accelerometer (1) integral lead onto No. 3 electrical panel (3). Tighten
jamnut one-quarter turn past hand-tight.
WARNING

H. Use tag to identify correct packager electrical connector and connect onto CRF accelerometer (1) integral
lead as follows:
assembly.
mating connector.
NOTE
(4) Repeat step 7.H.(2) and step 7.H.(3) as required. It may be necessary to loosen integral lead clamps
that restrict mating.
8. Turbine Rear Frame Accelerometer Removal.
WARNING
CAUTION
ENSURE LOCATION OF ELECTRICAL CONNECTOR IS NOTED TO AID INSTALLATION.

FAILURE TO COMPLY MAY CAUSE UNRELIABLE ENGINE OPERATION.
A. Tag packager electrical connector and disconnect from turbine rear frame (TRF) accelerometer
(1, figure 2) integral lead.
B. Remove jamnut (2) that secures TRF accelerometer (1) integral lead to No. 4 electrical panel (3). Remove
lead from panel.
C. Remove bolt (4, view B) and loop clamp (5) that secure TRF accelerometer (1) integral lead to cable
bracket (6).
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Figure 2. TRF Accelerometer
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D. Remove bolt (4) and loop clamp (5) that secure TRF accelerometer (1) integral lead to cable bracket (7).
E. Remove bolt (4) and loop clamp (5) that secure TRF accelerometer (1) integral lead to lube supply bracket
(8).
F. Remove bolt (4) and loop clamp (5) that secure TRF accelerometer (1) integral lead to oil scavenge bracket
(9) at two locations.
G. Remove four bolts (10, view A) that secure TRF accelerometer (1) to accelerometer bracket (11).
Reposition XNSD bracket (12). Remove TRF accelerometer.
9. Turbine Rear Frame Accelerometer Installation.
A. Apply thread lubricant to threads and contact faces of bolts (10, figure 2).
B. Position TRF accelerometer (1, view A) onto accelerometer bracket (11) and position XNSD bracket (12)
onto TRF accelerometer.
C. Using four bolts (10), secure TRF accelerometer (1) onto accelerometer bracket (11). Tighten bolts to
60-70 lb in. (6.8-7.9 N·m) of torque.
D. Apply thread lubricant to threads and contact faces of bolts (4).
E. Using bolt (4), and loop clamp (5), secure TRF accelerometer (1) integral lead onto oil scavenge bracket
(9) at two locations. Tighten bolts to 60-70 lb in. (6.8-7.9 N·m) of torque.
F. Using bolt (4), and loop clamp (5), secure TRF accelerometer (1) integral lead onto lube supply bracket
(8). Tighten bolt to 60-70 lb in. (6.8-7.9 N·m) of torque.
G. Using bolt (4) and loop clamp (5), secure TRF accelerometer (1) integral lead onto cable bracket (7).
H. Using bolt (4, view B) and loop clamp (5), secure TRF accelerometer (1) integral lead onto cable bracket
(6). Tighten bolt to 60-70 lb in. (6.8-7.9 N·m) of torque.
I. Using jamnut (2), secure TRF accelerometer (1) integral lead onto No. 4 electrical panel (3). Tighten
jamnut one-quarter turn past hand-tight.
WARNING

J. Use tag to identify correct packager electrical connector and connect onto TRF accelerometer (1) integral
lead as follows:
assembly.
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mating connector.
NOTE
(4) Repeat step 9.J.(2) and step 9.J.(3) as required. It may be necessary to loosen integral lead clamps
that restrict mating.
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EXTERNAL PIPING, HOSES, AND ELECTRICAL HARNESS
REPLACEMENT
())(&7,9,7</03)*$6785%,1(02'(/6

Page No. Change No.
1 - 3 .......................................................................................................................................................... 0
4 Blank ..................................................................................................................................................... 0
Alphabetical Index
Subject Page
Arrangement............................................................................................................................................. 3
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1. Introduction.
This work package introduces the external configuration work packages. For specific work instructions, refer
to paragraph 2. Reference Material.
Title Number
Front Frame Module External Tubing, Harnesses, and Clamping SWP 1913 01
Core Module External Tubing, Electrical Leads, and Clamping SWP 1913 02
Low Pressure Turbine (LPT) Module External Tubing, Harnesses, and Clamping SWP 1913 03
Engine Assembly External Tubing, Harnesses, and Clamping SWP 1913 04
None required.
Reference the SWPs listed above for a list of consumable materials.
Due to the variety of gaskets, packings, seals, etc. used during installation of external tubing, expendable
materials are not listed. Refer to Illustrated Parts Breakdown (IPB), GEK 119320, for required parts.
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6. Arrangement.
A. SWP 1913 01 contains information for installation of front frame module external tubing, harnesses, and
clamping.
B. SWP 1913 02 contains information for installation of core module external tubing, harnesses, and
clamping.
C. SWP 1913 03 contains information for installation of engine assembly external tubing, harnesses, and
clamping.
D. SWP 1913 04 contains information for final installation of engine assembly external tubing, harnesses, and
clamping.
%ODQN
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SUBORDINATE WORK PACKAGE SWP 1913 01
FRONT FRAME MODULE EXTERNAL TUBING,
HARNESSES, AND CLAMPING
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LIST OF EFFECTIVE SWP PAGES

Total Number of Pages in this SWP is 36
Page No. Change No.
1 - 36 ........................................................................................................................................................ 0
Alphabetical Index
Subject Page
Air Collector Brackets Installation........................................................................................................... 4

Front Frame Module Brackets Installation. ............................................................................................. 4
Front Frame Module Electrical Cables Installation. ................................................................................ 4
Front Frame Module Tubing and Clamping Installation. ........................................................................ 4
Transfer Gearbox Assembly Brackets Installation................................................................................... 4
Transfer Gearbox Assembly Tubing and Clamping Installation.............................................................. 4
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1. Introduction.
A. This subordinate work package contains information concerning installation of front frame module
external tubing, harnesses, and clamping.
B. The following general instructions shall be met any time tubing, electrical leads, harnesses, or cables are
disturbed:
(1) Unless otherwise specified, bend radii for an electrical lead, cable, or harness must exhibit a smooth
transition. No kinks allowed.
(2) Electrical connections of leads and harnesses shall conform to the following assembly points:
(a) Engage connector with its mating interface and turn knurled coupling ring, while wiggling
backshell assembly.
(b) After fully seating connector by hand, tighten connector with Teflon-jawed pliers until slippage
(c) Check for full seating by wiggling accessory assembly. There shall be no movement with
respect to mating connector.
NOTE
(d) Repeat step 1.B.(2)(b) and step 1.B.(2)(c), as required. It may be necessary to loosen lead
clamps that restrict mating.
(3) Torque all remaining nuts of misalignment fittings as follows:
Tube Size Outer Diameter (OD) Torque

(inches) (lb ft) (N·m)
0.75-1.00 24-26 (32.5-35.2)
1.125-1.50 20-40 (27.1-54.2)
1.625-2.00 40-50 (54.2-67.8)
2.125 and up 50-60 (67.8-81.3)
(4) Unless otherwise noted, install all bolts with boltheads forward.
(5) If any external tube or manifold does not fit in the free state at assembly within 0.060 inch
(1.52 mm) and is known to be within manufacturing tolerance, it shall be modified by bending as
required. After bending, to obtain the required free-state fit, the following shall apply:
(a) Part shall conform to original specification and pressure requirements.
(b) Bend radii shall not be less than manufacturing limits.
(c) Coupling nuts shall thread freely by hand.
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(d) End flange fittings shall seat flush within 0.005 inch (0.13 mm).
(e) End points of tube or manifold shall align with mating connector with 0.060 inch (1.52 mm) in
all planes.
(f) A minimum clearance of 0.125 inch (3.18 mm) shall be maintained between tube OD and
adjacent parts.
Title Number

Wrench, Strap (1/2” drive, 90° angle, BT-BS-625, Daniels Mfg Corp.
1/2” strap) (Optional)
Molybdenum Disulfide Lubricant MIL-L-25681
Silicone Tape MIL-I-46852
Zinc Chromate Primer Fed Spec TT-P-1757
materials are not listed. Refer to Illustrated Parts Breakdown (IPB), GEK 119320, for required parts.
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6. Air Collector Brackets Installation.

Set figure 1 and table 1.
7. Transfer Gearbox Assembly Brackets Installation.

See figure 2 and table 2.
8. Transfer Gearbox Assembly Tubing and Clamping Installation.

9. Front Frame Module Brackets Installation.

10. Front Frame Module Tubing and Clamping Installation.

11. Front Frame Module Electrical Cables Installation.

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Figure 1. Air Collector Brackets
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Table 1. Air Collector Brackets (Figure 1)

Attach Item To Item Secure With Torque Notes
VSV/VBV bracket (1) Air collector/front Bolts (2), Spacer (18) 57-67 lb in. (b) (e)
frame aft flange (6.5-7.5 N·m)
VSV/VBV bracket (3) Air collector/front Bolts (2), Spacer (18) 57-67 lb in. (b) (e)
Electrical bracket (4) Air collector/front Bolts (2), Spacer (18) 57-67 lb in. (b) (e)
Electrical bracket (5) Aft lower right flange Bolts (6), Nuts (7) 483-567 lb in. (a) (c)
(54.6-64.0 N·m)
Panel bracket (8) Forward lower right Bolts (6), Nuts (7) 483-567 lb in. (a) (c)
flange (54.6-64.0 N·m)
Panel bracket (9) Air collector/front Bolts (10), Nuts (11) 57-67 lb in. (a) (d)
frame forward flange (6.5-7.5 N·m)
Electrical bracket (12) Aft lower left flange Bolts (6), Nuts (7) 483-567 lb in. (a) (c)
(54.6-64.0 N·m)
Electrical bracket (13) Aft lower left flange Bolts (6), Nuts (7) 483-567 lb in. (a) (c)
(54.6-64.0 N·m)
VSV/VBV Air collector aft face Bolts (15) 57-67 lb in.
Bracket (14) (6.5-7.5 N·m)
VSV/VBV Air collector right side Bolts (15), 57-67 lb in.
Bracket (16) Washers (17) (6.5-7.5 N·m)
WARNING
SOLID FILM LUBRICANT IS TOXIC TO SKIN, EYES, AND RESPIRATORY TRACT. SKIN, EYE,
AND RESPIRATORY PROTECTION IS REQUIRED.
NOTES:
(a) Lubricate threads and washer faces of bolts/nuts using molybdenum disulfide lubricant.
(b) Safety-wire with safety cable, 736L680.
(c) Boltheads face outboard.
(d) Boltheads face aft.
(e) Lubricate threads and washer faces of bolts using thread lubricant.
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Figure 2. Transfer Gearbox Assembly Brackets (Sheet 1 of 2)
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Figure 2. Transfer Gearbox Assembly Brackets (Sheet 2 of 2)
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Table 2. Transfer Gearbox Assembly Brackets (Figure 2)

Mounting bracket (1) Gearbox housing Bolts (2), Washers (3), 193-227 lb in. (a)
Nuts (4) (21.9-25.6 N·m)
Electrical bracket (5) Gearbox housing Washers (6), Nuts (7) 57-67 lb in.
(6.5-7.5 N·m)
Mounting bracket (8) Gearbox housing Bolts (10) 193-227 lb in. (a) (b)
and Tubing (21.9-25.6 N·m)
bracket (9)
Electrical bracket (11) Bevel gear housing Washers (12), Bolts (13) 193-227 lb in. (b)
(21.9-25.6 N·m)
Electrical bracket (14) Bevel gear housing Washers (12), Bolts (25) 57-67 lb in. (b)
(6.5-7.5 N·m)
Oil bracket (15) VG hydraulic pump Bolts (16) 57-67 lb in. (b)
adapter (6.5-7.5 N·m)
Lube bracket (17) VG hydraulic pump Bolts (16) 57-67 lb in. (b) (c)
adapter (6.5-7.5 N·m)
Lube bracket (18) Gearbox housing Bolts (19) 32-38 lb in.
(3.7-4.2 N·m)
Lube bracket (18) Gearbox housing Bolts (20), Washers (21), 304-356 lb in.
Nuts (22) (34.4-40.2 N·m)
Electrical bracket (23) Manual drive adapter Washers (6), Bolts (16) 57-67 lb in. (b)
assembly (6.5-7.5 N·m)
Electrical bracket (24) Manual drive adapter Washers (6), Bolts (16) 57-67 lb in. (b)
assembly (6.5-7.5 N·m)
Mounting bracket (8) Gearbox housing Bolts (10) 193-227 lb in. (a) (b)
(21.9-25.6 N·m)
Manifold bracket (26) Gearbox housing Bolts (27) 193-227 lb in.
(21.9-25.6 N·m)
WARNING
ZINC CHROMATE PRIMER, TT-P-1757, IS HIGHLY TOXIC TO SKIN, EYES, AND RESPIRATORY
TRACT. SKIN AND EYE PROTECTION, AND VAPOR CONTROL ARE REQUIRED. AVOID ALL
CONTACT.
NOTES:
(a) Coat mating surfaces of bracket and gearbox housing using zinc chromate primer.
(b) Safety-wire.
(c) Nut plates face aft.
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Figure 3. Transfer Gearbox Assembly Tubing and Clamping (Sheet 1 of 3)

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Table 3. Transfer Gearbox Assembly Tubing and Clamping (Figure 3)

Electrical bracket (1) Oil supply manifold Bolts (2) 57-67 lb in.
(6.5-7.5 N·m)
Preformed packing (3), Oil manifold 175-205 lb in. (a)
Union (4) (19.8-23.1 N·m)
Preformed packing (5), Oil supply manifold 133-157 lb in. (a)
Plug (6) (15.1-17.7 N·m)
Union (8) (19.8-23.1 N·m)
Preformed packing (9), Lube and scavenge 133-157 lb in. (a)
Plug (10) manifold (15.1-17.7 N·m)
Preformed packing (11), Lube and scavenge 350-410 lb in.
Union (12) manifold (39.6-46.3 N·m)
Gasket (13), Oil tube (14) Oil scavenge manifold Bolts (15) 57-67 lb in.
(6.5-7.5 N·m)
Union (17) (39.6-46.3 N·m)
Gasket (18), AGB Gearbox housing Bolts (21) 32-38 lb in.
tube/hose (19), Oil drain (3.7-4.2 N·m)
bracket (20)
AGB tube/hose (19) Union (17) Coupling nut 55-65 lb ft
(75-88 N·m)
AGB tube/hose (19) Manual drive adapter Clamp (22), 32-38 lb in.
Bolt (23) (3.7-4.2 N·m)
Preformed packing (24), AGB tube/hose (19) 133-157 lb in. (a) (b)
Plug (25) (15.1-17.7 N·m)
Preformed packing (26), Fuel pump adapter 133-157 lb in. (a)
Union (27) (15.1-17.7 N·m)
Preformed packing (28), Gearbox housing fuel 133-157 lb in. (a)
Union (29) pump pad (15.1-17.7 N·m)
Hose assembly (30) Union (29) Coupling nut 133-157 lb in.
(15.1-17.7 N·m)
Preformed packing (31), Gearbox housing starter Coupling nut 133-157 lb in. (a)
Oil drain tube (32) pad (15.1-17.7 N·m)
Oil manifold (33 Union (27), Hose assembly Coupling nuts 133-157 lb in.
(30), Oil drain tube (32) (15.1-17.7 N·m)
Oil manifold (33) Manifold bracket Clamp (34), 32-38 lb in.
(26, figure 2) Bolt (35), Nut (36) (3.7-4.2 N·m)
Oil manifold (33) Oil drain bracket (20) Clamp (37), 32-38 lb in.
Bolt (35), Nut (36) (3.7-4.2 N·m)

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Table 3. Transfer Gearbox Assembly Tubing and Clamping (Figure 3) (Continued)

Union (39) pump (15.1-17.7 N·m)
Hose assembly (40) Oil manifold (33), Coupling nuts 133-157 lb in.
Union (39) (15.1-17.7 N·m)
Hose assembly (40) Electrical bracket Clamp (41), 57-67 lb in.
(23, figure 2) Bolts (42) (6.5-7.5 N·m)
Hose assembly (40) AGB tube/hose (19) Clamps (43, 44), 32-38 lb in.
Bolts (35), (3.7-4.2 N·m)
Nuts (36)
Union (46) pump (15.1-17.7 N·m)
Union (48) (39.6-46.3 N·m)
Preformed packing (49), AGB tube/hose (19) 133-157 lb in. (a)
RTD sensor (50) (15.1-17.7 N·m)
Preformed packing (51), Oil supply manifold 46-54 lb ft (a)
Union (52) (63-73 N·m)
Union (54) (29.7-34.7 N·m)
Plug (56) (15.1-17.7 N·m)
Plug (58) (15.1-17.7 N·m)
Union (60) (39.6-46.3 N·m)
Gasket (61), Air/Oil Lube and scavenge Bolts (63) 32-38 lb in. (a)
separator tube (62) pump (3.7-4.2 N·m)
Air/Oil separator tube (62) Union (60) Coupling nut 55-65 lb ft
(75-88 N·m)
Preformed packing (64), Oil manifold 46-54 lb ft (a)
Union (65) (63-73 N·m)
Preformed packing (66), Oil manifold 46-54 lb ft (a)
Oil tube (67) (63-73 N·m)
Oil tube (68) Oil tube (67), Coupling nut 78-92 lb ft
Union (65) (106-124 N·m)
Plug (70) (15.1-17.7 N·m)
Union (72) (19.8-23.1 N·m)

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Oil manifold (73) Union (72) Coupling nut 262-308 lb in.
(29.7-34.7 N·m)
Oil manifold (73) Tubing bracket Clamp (37), 57-67 lb in.
(9, figure 2) Bolts (42) (6.5-7.5 N·m)
Gasket (74), VG hydraulic pump Washers (76), 32-38 lb in.
Lube tube (75) Nuts (36) (3.7-4.2 N·m)
Gasket (77), Oil manifold Bolts (42) 57-67 lb in.
Lube tube (75) (6.5-7.5 N·m)
Lube tube (75) Lube bracket Clamp (41), 57-67 lb in.
(18, figure 2) Bolts (42) (6.5-7.5 N·m)
Gasket (78), VG hydraulic pump Washers (80), 57-67 lb in.
Lube tube (79) Nuts (81) (6.5-7.5 N·m)
Gasket (82), Oil manifold Bolts (42) 57-67 lb in.
Lube tube (79) (6.5-7.5 N·m)
Preformed packing (83), HCU, TBV Head 350-410 lb in. (a)
Union (84) (39.6-46.3 N·m)
Preformed packing (85), HCU, TBV Rod 262-308 lb in. (a)
Union (86) (29.7-34.7 N·m)
Preformed packing (87), HCU, VSV and VIGV 350-410 lb in. (a)
Union (88) Head (39.6-46.3 N·m)
Gasket (91), Oil tube (14) Bolts (93), 57-67 lb in. (a)
Oil tube (92) Nuts (94) (6.5-7.5 N·m)
Gasket (95), Oil tube (92) Transfer gearbox housing Bolts (35) 57-67 lb in.
(6.5-7.5 N·m)
Preformed packing (89), HCU, VSV and VIGV Rod 262-308 lb in.
Union (90) (29.7-34.7 N·m)
Oil tube (92) Lube bracket (17, figure 2) Clamp (96), 57-67 lb in.
Bolt (42) (6.5-7.5 N·m)
Oil tube (92) Oil bracket (15, figure 2) Clamp (96), 57-67 lb in.
Bolt (42), (6.5-7.5 N·m)
Washer (97),
Nut (94)
Oil tube (98) Oil manifold (73) Coupling nut 133-157 lb in.
(15.1-17.7 N·m)
Oil tube (98) Union (46) Coupling nut 133-157 lb in.
(15.1-17.7 N·m)
Oil tube (98) Lube bracket (18, figure 2) Clamp (34), 32-38 lb in.
Bolt (99), (3.7-4.2 N·m)
Washer (100),
Nut (36)

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Cap assembly (101) Oil tube (98) 133-157 lb in.
(15.1-17.7 N·m)
Preformed packing (102), Accessory gearbox housing 152-178 lb in. (a)
Reducer (103) (17.2-20.1 N·m)
Oil manifold (104) Reducer (103) Coupling nut 175-205 lb in.
(19.8-23.1 N·m)
Oil manifold (104) Oil manifold (73) Coupling nut 175-205 lb in.
(19.8-23.1 N·m)
Oil manifold (104) Accessory gearbox housing Clamp (105), 57-67 lb in.
Bolt (106) (6.5-7.5 N·m)
Preformed packing (107), Transfer gearbox housing 155-175 lb in. (a)
Reducer (108) (17.6-19.7 N·m)
Oil tube (109) Reducer (108) Coupling nut 133-157 lb in.
(15.1-17.7 N·m)
(15.1-17.7 N·m)
Preformed packing (71), VG hydraulic pump 175-205 lb in.
Plug (110) (19.8-23.1 N·m)
WARNING
LUBRICATING OIL, MIL-PRF-23699F (C/I): COMBUSTIBLE. DO NOT INHALE, INGEST, OR LET

THIS MATERIAL TOUCH YOU. IRRITANT. PERSONAL PROTECTIVE EQUIPMENT REQUIRED.
USE MECHANICAL EXHAUST VENTILATION - IF NOT AVAILABLE, USE AN APPROVED
RESPIRATOR.
NOTES:
(a) Lubricate preformed packing using lubricating oil.
(b) Safety-wire.

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Figure 4. Front Frame Module Brackets

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Table 4. Front Frame Module Brackets (Figure 4)

Mount pad (1) Front frame Bolts (2) 483-567 lb in. (a)
(54.6-64.0 N·m)
VBV bracket (3) Front frame Washers (4), Bolts (5) 57-67 lb in.
(6.5-7.5 N·m)
VSV/VBV bracket (6) Front frame Washers (4), Bolts (5) 57-67 lb in.
(6.5-7.5 N·m)
Electrical bracket (7) Transfer gearbox mount Washers (4), Bolts (8) 57-67 lb in. (b)
plate (6.5-7.5 N·m)
plate (6.5-7.5 N·m)
plate (6.5-7.5 N·m)
Oil bracket (11) Electrical bracket (10) Bolts (5) 57-67 lb in.
(6.5-7.5 N·m)
No. 2 electrical interface Electrical brackets (9, 10) Bolts (13) 57-67 lb in.
panel (12) (6.5-7.5 N·m)
No. 2 electrical interface Transfer gearbox mount Washers (4), 193-227 lb in.
panel (12) bracket Bolts (14) (21.9-25.6 N·m)
(6.5-7.5 N·m)
(6.5-7.5 N·m)
Electrical bracket (17) Front frame Bolts (18) 57-67 lb in.
(6.5-7.5 N·m)
WARNING
SOLID FILM LUBRICANT IS TOXIC TO SKIN, EYES, AND RESPIRATORY TRACT. SKIN, EYE,
AND RESPIRATORY PROTECTION IS REQUIRED.
NOTES:
(a) Coat threads of bolts with molybdenum disulfide lubricant.
(b) Safety-wire.

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Figure 5. Front Frame Module Tubing and Clamping (Sheet 1 of 5)

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Table 5. Front Frame Module Tubing and Clamping (Figure 5)

Gasket (2), Front frame Bolts (4) 57-67 lb in. (a)
Air elbow (3) (6.5-7.5 N·m)
Oil manifold (5) VSV/VBV bracket, Clamp (6), Bolt (4), 57-67 lb in.
(16, figure 4) Washer (7), Nut (1) (6.5-7.5 N·m)
Oil manifold (8) VSV/VBV bracket Clamp (6), Bolt (4), 57-67 lb in.
Preformed packing (9), VBV actuator rod end 133-157 lb in. (b)
Reducer (10) port (6 places) (15.1-17.7 N·m
)
VBV oil tube (11) Oil manifold (8) Coupling nut 262-308 lb in.
(29.7-34.7 N·m
)
VBV oil tube (11) Reducer (10) Coupling nut 262-308 lb in.
(29.7-34.7 N·m
)
Preformed packing (12), VBV actuator head end 133-157 lb in. (b)
Reducer (13) port (6 places) (15.1-17.7 N·m
)
Preformed packings Oil tube (17) (b)
(14, 15), Drain can (16)
(29.7-34.7 N·m
)
(29.7-34.7 N·m
)
Drain can (16) VBV actuator head end Hand-tight (c)
port
Oil drain tube (18) Drain can (16) Coupling nut 262-308 lb in.
(29.7-34.7 N·m
)
Oil manifold (19) Oil manifold (8) Coupling nut 55-65 lb ft
(75-88 N·m)

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Table 5. Front Frame Module Tubing and Clamping (Figure 5) (Continued)

(29.7-34.7 N·m
)
(12, 15), Drain can (16)
(75-88 N·m)
(29.7-34.7 N·m
)
port
(29.7-34.7 N·m
)
Oil drain tube (21) Oil drain tube (18) Coupling nut 262-308 lb in.
(29.7-34.7 N·m
)
Oil manifolds (19, 20), VSV/VBV bracket Clamp (22), Bolt (23), 57-67 lb in.
Oil drain tube (21) (3, figure 1) Washer (7), Nut (1) (6.5-7.5 N·m)
Oil drain tube (21) VSV/VBV bracket Clamp (24), Bolt (4), 57-67 lb in.
Oil manifold (25) VBV bracket Clamp (6), Bolt (4), 57-67 lb in.
Oil manifold (27) VBV bracket Clamp (6), Bolt (4), 57-67 lb in.
VBV oil tube (28) Oil manifold (25) Coupling nut 262-308 lb in.
(29.7-34.7 N·m
)
VBV oil tube (28) Reducer (10) Coupling nut 262-308 lb in.
(29.7-34.7 N·m
)
(14, 15), Drain can (16)

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(29.7-34.7 N·m
)
(29.7-34.7 N·m
)
port
(29.7-34.7 N·m
)
(75-88 N·m)
(29.7-34.7 N·m
)
(14, 15), Drain can (16)
Oil tube (32) Oil manifold (27) Coupling nut 55-65 lb ft
(75-88 N·m)
(29.7-34.7 N·m
)
port
(29.7-34.7 N·m
)
Oil drain tube (33) Oil drain tube (30) Coupling nut 262-308 lb in.
(29.7-34.7 N·m
)
Oil manifold (31), VSV/VBV bracket Clamp (22), Bolt (23), 57-67 lb in.
Oil tube (32), (1, figure 1) Washer (7), Nut (1) (6.5-7.5 N·m)
Oil drain tube (33)
Oil drain tube (33) VBV bracket Clamp (24), Bolt (4), 57-67 lb in.
Preformed Oil tube (34) (b)
packings (14, 15),
Drain can (16)

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(29.7-34.7 N·m
)
Drain can (16) VBV actuator head Coupling nut Hand-tight (c)
end port
(29.7-34.7 N·m
)
(29.7-34.7 N·m
)
Preformed Oil tube (37) (b)
packings (14, 15),
Drain can (16)
(29.7-34.7 N·m
)
Drain can (16) VBV actuator head Hand-tight (c)
end port
VSV teflon hose (38) Union (88, figure 3) Coupling nut 55-65 lb ft
(75-88 N·m)
VBV teflon hose (39) HCU Bolts (42), Washers (43), 32-38 lb in.
Gasket (44) (3.7-4.2 N·m)
VBV teflon hose (40) HCU Bolts (42), Washers (43), 32-38 lb in.
Gasket (45), (3.7-4.2 N·m)
Reducer (46)
VSV teflon hose (41) Union (90, figure 3) Coupling nut 460-540 lb in.
(52.0-61.0 N·m
)
VSV teflon hose (38, 41), Together Clamps (47, 48, 49), 57-67 lb in.
VBV teflon hose (39, 40) Bolt (52), Nut (53) (6.5-7.5 N·m)
VSV teflon hose (38, 41), VSV/VBV bracket Clamps (47, 48, 49), 57-67 lb in.
VBV teflon hose (39, 40) (68) (16, figure 1) Bolt (52), Nut (53) (6.5-7.5 N·m)

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VSV/VBV bracket Front frame Bolts (51) 57-67 lb in.
(6.5-7.5 N·m)
WARNING

USE MECHANICAL EXHAUST VENTILATION - IF NOT AVAILABLE, USE AN APPROVED
RESPIRATOR.
NOTES:
(a) Safety-wire.
(b) Lubricate packings using lubricating oil.
(c) Align drain fittings before tightening.

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Figure 6. Front Frame Module Electrical Cables (Sheet 1 of 5)

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Table 6. Front Frame Module Electrical Cables (Figure 6)

Preformed packing (19), T25 sensor 87-103 lb in. (a) (b)
Plug (20) (9.9-11.6 N·m)
T25 sensor/Integral lead (1) Air collector upper Bolt (21) 32-38 lb in. (b)
left (3.7-4.2 N·m)
T25 sensor/Integral lead (1) VSV/VBV bracket (3, Clamp (9), Bolt (11) 57-67 lb in. (a)
figure 1) (6.5-7.5 N·m)
Electrical bracket Clamp (9), Bolt (11) 57-67 lb in. (a)
(4, figure 1) (6.5-7.5 N·m)
Electrical bracket (17, Clamps (14), 57-67 lb in. (a)
figure 4) Bolts (11) (6.5-7.5 N·m)
Electrical bracket Spring clip (a)
(7, figure 4)
No. 2 electrical Jamnut Hand-tight, then (c)
interface panel 1/4-1/2 turn
(12, figure 4)
CAUTION
ROUTING OF HARNESS IS COMPLETED DURING FINAL ENGINE ASSEMBLY. ENSURE

LOOSE CONNECTOR IS SECURED TO AVOID DAMAGE DURING TRANSPORT.
Left side VSV/VBV/LVDT VBV actuator Connector ring Hand-tight
electrical cable (2) (11:00 o'clock)
VSV/VBV bracket (3, Clamp (14), 57-67 lb in. (a)
figure 1) Bolt (11) (6.5-7.5 N·m)
Electrical bracket (4, Clamp (14), 57-67 lb in. (a)
figure 1) Bolt (11) (6.5-7.5 N·m)
Electrical bracket (17, Clamps (14), 57-67 lb in. (a)
figure 4) Bolts (11) (6.5-7.5 N·m)
Electrical bracket Clamps (13), 57-67 lb in. (a)
(7, figure 4) Bolt (11) (6.5-7.5 N·m)
(12, figure 4)
Gas generator speed electrical XN25 sensor Connector ring Hand-tight (c)
cable (3)
(7, figure 4)
(12, figure 4)

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Table 6. Front Frame Module Electrical Cables (Figure 6) (Continued)

Gas generator speed electrical XN25 sensor Connector ring Hand-tight (b)
cable (4)
Electrical bracket (12, Spring clip (a)
figure 1)
(12, figure 4)
T25 sensor/Integral lead (1), Electrical bracket (13, Clamps (9, 10, 13), 57-67 lb in. (c)
left side VBV/VSV LVDT figure 1) Bolt (11), Nut (12) (6.5-7.5 N·m)
electrical cable (2), Gas
generator speed electrical cable
(4)
Chip detector electrical Common scavenge Connector ring Hand-tight
cable (5) chip detector
Tubing bracket Spring clip (a)
(9, figure 2)
Lube bracket Spring clip (a)
(17, figure 2) (2 places)
B-sump scavenge Connector ring Hand-tight
chip detector
TGB/A-sump Connector ring Hand-tight
scavenge chip
detector
Electrical bracket (23, Spring clips (a)
figure 2)
Electrical bracket (14, Spring clip (a)
figure 2)
Chip detector electrical Electrical bracket Spring clip (a)
cable (5) (5, figure 2)
(7, figure 4)
(12, figure 4)
TGB/A, AGB, B, C lube RTD AGB scavenge RTD Connector ring Hand-tight
electrical cable (6)
figure 2) Bolt (11) (6.5-7.5 N·m)

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Table 6. Front Frame Module Electrical Cables (Figure 6) (Continued)

TGB/A sump Connector ring Hand-tight
scavenge RTD
B-sump scavenge Connector ring Hand-tight
RTD
C-sump scavenge Connector ring Hand-tight
RTD
figure 2) Bolt (11) (6.5-7.5 N·m)
Electrical bracket Clamp (17), 57-67 lb in. (a)
(7, figure 4) Bolt (11) (6.5-7.5 N·m)
No. 2 electrical Jamnut Hand-tight, then (b)
(12, figure 4)
D, E, supply lube RTD D, E-sump scavenge, Connector ring Hand-tight
electrical cable (7) supply RTD
D-sump branch of electrical D-sump scavenge Connector ring Hand-tight
cable (7) RTD
(7, figure 4) Bolt (11) (6.5-7.5 N·m)
(5, figure 1) Bolt (11), Nut (12) (6.5-7.5 N·m)
Oil bracket Clamp (16), 57-67 lb in. (a)
(15, figure 2) Bolt (11) (6.5-7.5 N·m)
E-sump and supply branch of Oil bracket Clamp (18), 57-67 lb in. (a)
electrical cable (7) (11, figure 4) Bolt (11) (6.5-7.5 N·m)
E-sump branch of electrical Oil bracket Clamp (16), 57-67 lb in. (a)
cable (7) (11, figure 4) Bolt (11) (6.5-7.5 N·m)
(1, figure 3 Bolt (11) (6.5-7.5 N·m)
Main cable No. 2 electrical Jamnut Hand-tight, then (c)
(12, figure 4)
CAUTION
ROUTING OF HARNESS IS COMPLETED DURING FINAL ENGINE ASSEMBLY. ENSURE

LOOSE CONNECTOR IS SECURED TO AVOID DAMAGE DURING TRANSPORT.
Right side VBV/VSV VBV actuator Connector ring Hand-tight

LVDT electrical cable (8) (5:00 o’clock
position)
(7, figure 4) Bolt (11) (6.5-7.5 N·m)

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CORE MODULE EXTERNAL TUBING, ELECTRICAL
LEADS, AND CLAMPING
())(&7,9,7</03)*$6785%,1(02'(/6

Page No. Change No.
1 - 40 ........................................................................................................................................................ 0
Alphabetical Index
Subject Page
Core Module Brackets Installation........................................................................................................... 4

Core Module Electrical Leads Installation............................................................................................... 4
Core Module Tubing and Clamping Installation...................................................................................... 4
CRF Aft Case to CRF Brackets Installation. ........................................................................................... 4
CRF Fuel Nozzle Pad and Strut Pad Brackets Installation. ..................................................................... 4
CRF/HPT Flange Brackets Installation.................................................................................................... 4
HPC/CRF Flange Brackets Installation. .................................................................................................. 4
HPT Tubing Installation........................................................................................................................... 4
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1. Introduction.
A. This subordinate work package contains information concerning installation of core module external
tubing, harnesses, and clamping, including high pressure compressor (HPC), compressor rear frame
(CRF), and high pressure turbine (HPT).
disturbed:
(1) Unless otherwise specified, the bend radii for an electrical lead, cable, or harness must exhibit a
smooth transition. No kinks allowed.
(2) Electrical connections of heads and harnesses shall conform to the following assembly points:
(a) Engage the connector with its mating interface and turn knurled coupling ring, while wiggling
the backshell assembly.
(b) After fully seating connector by hand, tighten connector with Teflon-jawed pliers until
slippage occurs. Tighten connector with strap wrench (optional method).
NOTE

0.75-1.00 24-26 (32.6-35.2)
1.125-1.50 20-40 (27.2-54.2)
1.625-2.00 40-50 (54.3-67.7)
2.125 and up 50-60 (67.8-81.3)
(1.52 mm) and is known to be within manufacturing tolerance, it shall be modified by bending, as
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all planes.
adjacent parts.
Title Number
Heat Shields Replacement WP 1915 00
(Optional)

Due to the variety of gaskets, packings, seals, etc., used during installation of external tubing, expendable
materials are not listed. Refer to Illustrated Parts Breakdown, GEK 119320, for required parts.
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6. HPC/CRF Flange Brackets Installation.

7. CRF/HPT Flange Brackets Installation.

8. CRF Aft Case to CRF Brackets Installation.

9. CRF Fuel Nozzle Pad and Strut Pad Brackets Installation.

10. Core Module Brackets Installation.

11. HPT Tubing Installation.

12. Core Module Tubing and Clamping Installation.

13. Core Module Electrical Leads Installation.

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Figure 1. HPC/CRF Flange Brackets (Sheet 1 of 2)
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Figure 1. HPC/CRF Flange Brackets (Sheet 2 of 2)
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Table 1. HPC/CRF Flange Brackets (Figure 1)

Ejector bracket (9) Boltholes 2, 3, 4, 90 Bolts (1), Nuts (6) 368-432 lb in. (a) (b)
(41.6-48.8 N·m)
Ejector support bracket (10) Ejector bracket (9) Bolts (7) 106-124 lb in. (a) (c)
(on aft side) (12.0-14.0 N·m)
Air/oil bracket (11) Boltholes 6, 8 Bolts (2), Nuts (6) 368-432 lb in. (a) (b)
(41.6-48.8 N·m)
Support bracket (12) Boltholes 9, 11, 12 Bolts (1), Nuts (6) 368-432 lb in. (a) (b)
(41.6-48.8 N·m)
(41.6-48.8 N·m)
NOTE
Cooling bracket (13) and ejector support bracket (14) share bolthole 18.
Cooling bracket (13) Bolthole 18 Bolt (1), Nut (6) 368-432 lb in. (a) (b)
Bolthole 21 Bolt (2), Nut (6) (41.6-48.8 N·m) (a) (b)
Ejector support bracket (14) Cooling bracket (13) (on Bolt (1), Nut (6) (a) (b)
forward side at bolthole 18)
Bolthole 17 Bolt (1), Nut (6) (a) (b)
Support bracket (15) Cooling bracket (13) Bolts (8) 106-124 lb in. (a) (b)
(on forward side) (12.0-14.0 N·m)
Flange cooling bracket (16) Boltholes 22, 25 Bolts (3), Nuts (6) 368-432 lb in. (a) (c)
(41.6-48.8 N·m) (d)
Support bracket (17) Boltholes 27, 30 Bolts (2), Nuts (6) 368-432 lb in. (a) (b)
(41.6-48.8 N·m)
Support bracket (18) Support bracket (17) Bolts (8) 106-124 lb in. (a) (c)
(12.0-14.0 N·m)
(41.6-48.8 N·m)
Cable bracket (19) Boltholes 39, 41 Bolts (2), Nuts (6) 368-432 lb in. (a) (b)
(41.6-48.8 N·m)
(41.6-48.8 N·m)
Accelerometer bracket (20) Boltholes 45, 47 Bolts (2), Nuts (6) 368-432 lb in. (a) (b)
(41.6-48.8 N·m)
(41.6-48.8 N·m)
Tube bracket (21) Air/oil bracket (11) Bolts (8), Nuts (28) 106-124 lb in. (a) (b)
(on aft side) (12.0-14.0 N·m)
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Table 1. HPC/CRF Flange Brackets (Figure 1) (Continued)

Accelerometer bracket (22) Boltholes 51, 53 Bolts (2), Nuts (6) 368-432 lb in. (a) (b)
(41.6-48.8 N·m)
(41.6-48.8 N·m)
Cooling bracket (13) Boltholes 63, 66 Bolts (2), Nuts (6) 368-432 lb in. (a) (b)
(41.6-48.8 N·m)
Tube bracket (23) Cooling bracket (13) Bolts (8) 106-124 lb in. (a) (c)
(on aft side) (12.0-14.0 N·m)
Flange cooling bracket (16) Boltholes 67, 70 Bolts (3), Nuts (6) 368-432 lb in. (a) (c)
(41.6-48.8 N·m) (d)
Support bracket (17) Boltholes 71, 74 Bolts (2), Nuts (6) 368-432 lb in. (a) (b)
(41.6-48.8 N·m)
Support bracket (24) Support bracket (17) Bolts (8) 106-124 lb in. (a) (c)
(on aft side) (12.0-14.0 N·m)
Support bracket (25) Boltholes 75, 77, 79 Bolts (4), Nuts (6) 368-432 lb in. (a) (b)
(41.6-48.8 N·m)
Cooling bracket (26) Support bracket (25) Bolts (8) 106-124 lb in. (a) (b)
(on forward side) (12.0-14.0 N·m)
Tube support bracket (27) Boltholes 81, 83, 84 Bolts (5), Nuts (6) 368-432 lb in. (a) (b)
(41.6-48.8 N·m)
(41.6-48.8 N·m)
NOTES:
(a) Lubricate threads and washer faces of bolts/nuts using thread lubricant.
(b) Boltheads face aft.
(c) Boltheads face forward.
(d) Safety-wire.
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8
Figure 2. CRF/HPT Flange Brackets
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Table 2. CRF/HPT Flange Brackets (Figure 2)

Support bracket (1) Boltholes 27, 28, 29, 30 Bolts (2), Nuts (4) 202-238 lb in. (a)
(22.9-26.8 N·m)
Electrical bracket (5) Boltholes 41, 42, 43, 44 Bolts (3), Nuts (4) 202-238 lb in. (a)
(22.9-26.8 N·m)
Support bracket (6) Boltholes 80, 81, 84, 85 Bolts (3), Nuts (4) 202-238 lb in. (a)
(22.9-26.8 N·m)
Support bracket (7) Boltholes 105, 106, 107, Bolts (2), Nuts (4) 202-238 lb in. (a)
108 (22.9-26.8 N·m)
Support bracket (7) Boltholes 131, 132, 133, Bolts (2), Nuts (4) 202-238 lb in. (a)
134 (22.9-26.8 N·m)
NOTES

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Figure 3. CRF Aft Case to CRF Brackets (Sheet 1 of 2)

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Figure 3. CRF Aft Case to CRF Brackets (Sheet 2 of 2)

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Table 3. CRF Aft Case To CRF Brackets (Figure 3)

Extended flange bracket (1) Boltholes 3-7 Bolts (2), Nuts (3) 69-81 lb ft (a) (b)
(93.6-109.8 N·m)
(93.6-109.8 N·m)
(93.6-109.8 N·m)
(93.6-109.8 N·m)
(93.6-109.8 N·m)
(93.6-109.8 N·m)
(93.6-109.8 N·m)
(93.6-109.8 N·m)
(93.6-109.8 N·m)
(93.6-109.8 N·m)
(93.6-109.8 N·m)
(93.6-109.8 N·m)
(93.6-109.8 N·m)
(93.6-109.8 N·m)
(93.6-109.8 N·m)
(93.6-109.8 N·m)
(93.6-109.8 N·m)
(93.6-109.8 N·m)

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Table 3. CRF Aft Case To CRF Brackets (Figure 3) (Continued)

(93.6-109.8 N·m)
(93.6-109.8 N·m)
(93.6-109.8 N·m)
(93.6-109.8 N·m)
(93.6-109.8 N·m)
(93.6-109.8 N·m)
(93.6-109.8 N·m)
(93.6-109.8 N·m)
(93.6-109.8 N·m)
Extended flange bracket (30) Boltholes 137, 1, 2 Bolts (2), Nuts (3) 69-81 lb ft (a) (b)
(93.6-109.8 N·m)
NOTE
Forward and mid heat shields are removed and installed in WP 1915 00.
CDP support bracket (31) Extended flange bracket Bolts (32) 106-124 lb in. (a) (b)
(4) (on forward side) (12.0-14.0 N·m)
CDF support bracket (33) Extended flange bracket Bolts (34) 106-124 lb in. (a) (b)
CDP air bracket (35) Extended flange bracket Bolts (32) 106-124 lb in. (a) (b)
(10) (on aft side) (12.0-14.0 N·m)
CDP air bracket (36) Extended flange bracket
(a) (b)
(10) (on forward side)
Support bracket (37) Extended flange bracket Bolts (39) 106-124 lb in. (a) (b)
Flame detector bracket (38) Support bracket (37) (on
forward side)
Cooling bracket (40) Extended flange bracket Bolts (32), Bolt (41), 106-124 lb in. (a) (c)
(13) (on aft side) Spacer (42), Spring (12.0-14.0 N·m)
washer (43)

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Table 3. CRF Aft Case To CRF Brackets (Figure 3) (Continued)

Recoup support bracket (44) Extended flange bracket Bolts (32) 106-124 lb in. (a) (c)
(14) (on aft side) (12.0-14.0 N·m)
Oil bracket (45) Extended flange bracket Bolts (32) 106-124 lb in. (a) (b)
Recoup support bracket (46) Extended flange bracket Bolts (34) 106-124 lb in. (a) (b)
Igniter harness bracket (49) Extended flange bracket Bolts (32) 106-124 lb in. (a) (b)
Recoup support bracket (50) Extended flange bracket Bolts (39) 106-124 lb in. (a) (c)
(24) (on aft side) (12.0-14.0 N·m)
Cooling bracket (51) Extended flange bracket Bolts (39) 106-124 lb in. (a) (c)
(25) (on aft side) (12.0-14.0 N·m)
Flame detector bracket (52) Extended flange bracket
(25) (on forward side)
Recoup support bracket (53) Extended flange brackets Bolts (32) 106-124 lb in. (a) (b)
(27 and 28) (on forward (12.0-14.0 N·m)
side)
Ejector support bracket (54) Extended flange bracket Bolt (32), Bolt (41), 106-124 lb in. (a) (b)
(30) (on forward side) Spacer (42), Spring (12.0-14.0 N·m)
washer (43)
NOTES:
(b) Boltheads face aft.
(c) Boltheads face forward.

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Figure 4. CRF Fuel Nozzle Pad and Strut Pad Brackets

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Table 4. CRF Fuel Nozzle Pad and Strut Pad Brackets (Figure 4)
NOTE
Fuel nozzles are numbered 1 through 30, counterclockwise (CCW), forward looking aft
(FLA). Strut pads are numbered 1 through 10, CCW, FLA.
LPT cooling bracket (1) Fuel nozzle pads Bolts (6) 106-124 lb in. (a)
Nos. 26 and 27 (12.0-14.0 N·m)
LPT cooling bracket (2) Fuel nozzle pads Bolts (6) 106-124 lb in. (a)
Nos. 14 and 15 (12.0-14.0 N·m)
Oil supply bracket (3) Fuel nozzle pads No. 16 Bolts (6) 106-124 lb in. (a)
(12.0-14.0 N·m)
T3 cable bracket (4) Strut pad No. 3 (upper side) Bolts (6) 106-124 lb in. (a)
(12.0-14.0 N·m)
T3 cable bracket (5) Strut pad No. 3 (lower side) Bolts (6) 106-124 lb in. (a)
(12.0-14.0 N·m)
T3 cable bracket (5) Strut pad No. 4 (upper side) Bolts (6) 106-124 lb in. (a)
(12.0-14.0 N·m)
NOTES:

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Figure 5. Core Module Brackets (Sheet 1 of 3)

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Table 5. Core Module Brackets (Figure 5)

Tube bracket (1) HPC case stage 2 Bolts (2) 106-124 lb in. (a) (b)
(12.0-14.0 N·m)
B-sump bracket (3), HPC case stage 2 Bolts (5) 106-124 lb in. (a) (b)
LPT cooling bracket (4) (12.0-14.0 N·m)
LPT cooling bracket (6) HPC case stage 2 Bolts (7) 106-124 lb in. (a) (b)
(12.0-14.0 N·m)
Electrical bracket (8) HPC case stage 2 Bolts (9) 106-124 lb in. (a) (b)
(12.0-14.0 N·m)
Vent bracket (10) HPC case stage 4 Bolts (11) 106-124 lb in. (a) (b)
(12.0-14.0 N·m)
(12.0-14.0 N·m)
(12.0-14.0 N·m)
(12.0-14.0 N·m)
(12.0-14.0 N·m)
Support bracket (18) HPC case stage 6 Bolts (19) 106-124 lb in. (a) (b)
(12.0-14.0 N·m)
Cooling bracket (20), HPC case stage 6 Bolts (22) 106-124 lb in. (a) (b)
Tube bracket (21) (12.0-14.0 N·m)
Cooling bracket (24) HPC case stage 6 Bolts (25) 106-124 lb in. (a) (b)
(12.0-14.0 N·m)
(12.0-14.0 N·m)
Support bracket (28) HPC case stage 6 Bolts (29) 106-124 lb in. (a) (b)
(12.0-14.0 N·m)
Electrical bracket (30) HPC case stage 6 Bolts (31) 106-124 lb in. (a) (b)
(12.0-14.0 N·m)
Bridge bracket (33) Bridge mount Bolts (32) 106-124 lb in. (a)
bracket (23) (12.0-14.0 N·m)
Bridge bracket (33) Electrical bracket (30) Bolts (34) 106-124 lb in. (a)
(12.0-14.0 N·m)
Electrical bracket (35) Electrical bracket (8) Bolts (36) 106-124 lb in. (a)
(12.0-14.0 N·m)
Electrical bracket (35) Electrical bracket (30) Bolts (36) 106-124 lb in. (a)
(12.0-14.0 N·m)
No. 3 electrical panel (37) Electrical bracket (8) Bolts (38) 106-124 lb in. (a)
(12.0-14.0 N·m)

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Table 5. Core Module Brackets (Figure 5) (Continued)

No. 3 electrical panel (37) Electrical bracket (30) Bolts (36) 106-124 lb in. (a)
(12.0-14.0 N·m)
Electrical bracket (35) No. 3 electrical Bolts (36) 106-124 lb in. (a)
panel (37) (three places) (12.0-14.0 N·m)
Cable bracket (39) Bridge bracket (33) Bolts (32), Nuts (41) 106-124 lb in. (a)
(12.0-14.0 N·m)
Support bracket (40) Electrical bracket (35) Bolts (32), Nuts (41) 106-124 lb in. (a)
(12.0-14.0 N·m)
NOTES:
(a) Lubricate threads and washer faces of bolts using thread lubricant.
(b) Safety-wire using R297P04 safety wire.

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Figure 6. HPT Tubing

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Table 6. HPT Tubing (Figure 6)

Cooling air tube (1), Cooling port adapter (2) Bolts (3) 106-124 lb in. (a)
Seal ring (4) (four locations) (12.0-14.0 N·m)
Check valve (5), Cooling port adapter (2) Bolts (3) 106-124 lb in. (a)
Cooling air tube (1), Check valve (1) Coupling clamp (6) 115-125 lb in.
Cooling air tube (1), Cooling air tube (8) Coupling clamp (6) 115-125 lb in.
Seal ring (7) (13.0-14.1 N·m)
Seal ring (7) (13.0-14.1 N·m)
Seal ring (7) (13.0-14.1 N·m)
Seal ring (7) (13.0-14.1 N·m)
NOTES
(a) Lubricate threads and washer faces of bolts using thread lubricant.

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Figure 7. Core Module Tubing and Clamping (Sheet 1 of 7)

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Table 7. Core Module Tubing and Clamping (Figure 7)

Air tube (2), Front frame module Bolts (51) 106-124 lb in. (a) (b)
Seal ring (52) (12.0-14.0 N·m)
Air tube (2), Air tube (1) Coupling clamp (4) 115-125 lb in.
Seal ring (3) (13.0-14.1 N·m)
Air tube (2) LPT cooling bracket Bolts (5), Nuts (6), 106-124 lb in. (a)
(6, figure 5) Retaining strap (7) (12.0-14.0 N·m)
Air tube (1), LPT supply tube (8) Coupling clamp (4) 115-125 lb in.
Seal ring (3) (13.0-14.1 N·m)
LPT supply tube (8) Support bracket Bolts (5), 106-124 lb in. (a)
LPT supply tube (8) Support bracket Bolts (5), 106-124 lb in. (a)
LPT supply tube (8), PCC manifold Coupling clamp (10) 115-125 lb in.
Seal ring (9) (13.0-14.1 N·m)
LPT supply tube (8) Bracket (93) Bolts (5), Nuts (6), 106-124 lb in. (a)
Retaining strap (7) (12.0-14.0 N·m)
Air cooling tube (11), Stage 11 bleed air Coupling clamp (13) 115-125 lb in.
Seal ring (12) manifold (13.0-14.1 N·m)
Air cooling tube (11) Support bracket Bolts (109), 106-124 lb in. (a)
Air cooling tube (16) Tube bracket Bolts (109), 60-70 lb in. (a)
Air cooling tube (11) Check valve Coupling nut 40-50 lb ft (b)
(5, figure 6) (55-67 N·m)
(5, figure 6) (55-67 N·m)

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Table 7. Core Module Tubing and Clamping (Figure 7) (Continued)

Air manifold (17), Front frame module Bolts (18) 106-124 lb in. (a)
Gasket (19) (12.0-14.0 N·m)
Air manifold (17) B-sump bracket Bolts (18), Washers (20), 106-124 lb in. (a)
(3, figure 5) Nuts (21), Retaining (12.0-14.0 N·m)
strap (22)
Air manifold (17) Vent bracket Bolts (18), Washers (20), 106-124 lb in. (a)
strap (22)
Air manifold (17) Vent brackets Bolts (18), Washers (20), 106-124 lb in. (a)
(12 and 13, figure 5) Nuts (21), Retaining (12.0-14.0 N·m)
strap (22)
Air manifold (17) B-sump air tube (58) Bolts (59), Nuts (21), 106-124 lb in. (a) (c)
Gasket (60), Preformed (12.0-14.0 N·m)
packing (61), Coupling
flange (62)
Air manifold (17) Vent bracket Bolts (18), Washers (20), 106-124 lb in. (a)
strap (22)
Air manifold (17), Front frame module Bolts (18) 106-124 lb in. (a)
Gasket (66) (12.0-14.0 N·m)
B-sump air tube (23) Air elbow (front frame Bolts (26), Nuts (27), 106-124 lb in. (a) (c)
module) Gasket (28), Preformed (12.0-14.0 N·m)
packing (29), Coupling
flange (30)
B-sump air tube (23) Tube bracket Bolts (24), 106-124 lb in. (a)
B-sump air tube (23) B-sump air tube (106) Bolts (26), Nuts (27), 106-124 lb in. (a)
Gasket (32) (12.0-14.0 N·m)
B-sump air tube (23) B/C sump bracket Bolts (24), Retaining 106-124 lb in. (a)
(21, figure 5) strap (25), Nuts (27), (12.0-14.0 N·m)
Washers (31)
B-sump air tube (106) CRF strut No. 9 Bolts (26), Nuts (27), 106-124 lb in. (a)
Gasket (32) (12.0-14.0 N·m)
LPT air tube (33), Stage 7 bleed air Coupling clamp (35) 115-125 lb in.
LPT air tube (33) Tube bracket Bolts (36), 106-124 lb in. (a)

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LPT air tube (33) LPT air tube (41) Bolts (38), Gasket (39), 106-124 lb in. (a)
Orifice plate (40) (12.0-14.0 N·m)
LPT air tube (41), LPT air manifold Coupling clamp (43) 115-125 lb in.
Seal ring (42) (13.0-14.1 N·m)
LPT air tube (41) LPT cooling bracket Bolts (36), 106-124 lb in. (a)
(107) Retaining strap (37) (12.0-14.0 N·m)
HPT air tube (44) CFF strut No. 10 Bolts (45), Nuts (46), 106-124 lb in. (a)
Gasket (47) (12.0-14.0 N·m)
HPT air tube (44) Air tube bracket Bolts (48), 106-124 lb in. (a)
HPT air tube (44) Air recoup tee (50) Coupling nut 40-50 lb ft (b)
(55-67 N·m)
LPT air tube (53), Stage 7 bleed air Coupling clamp (35) 115-125 lb in.
LPT air tube (53) LPT air tube (55) Bolts (38), Nuts (56), 106-124 lb in. (b)
Orifice plate (57) (12.0-14.0 N·m)
LPT air tube (55) Support bracket Bolts (36), 106-124 lb in. (a)
LPT air tube (55) LPT cooling bracket Bolts (36), 106-124 lb in. (a)
(108) Retaining strap (37) (12.0-14.0 N·m)
LPT air tube (55), LPT air manifold Coupling clamp (43) 115-125 lb in.
Seal ring (42) (13.0-14.1 N·m)
B-sump air tube (58) CRF strut No. 1 Bolts (63), Nuts (21), 106-124 lb in. (a)
Gasket (64) (12.0-14.0 N·m)

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(5, figure 6) (55-67 N·m)
(5, figure 6) (55-67 N·m)
HP air tube (68) Air recoup tee (69) Coupling nut 40-50 lb ft (b)
(55-67 N·m)
HP air tube (68) CDP air bracket Bolts (48), 106-124 lb in. (a)
HP air tube (68) CRF strut No. 4 Bolts (45), Nuts (46), 106-124 lb in. (a)
Gasket (47) (12.0-14.0 N·m)
B-scavenge oil tube CRF strut No. 7 Bolts (72), Nuts (73) 106-124 lb in. (a)
(70), Gasket (74) (12.0-14.0 N·m)
B-scavenge oil tube Support bracket Bolts (75), 106-124 lb in. (a)
(70) (21, figure 1) Clamps (76, 77) (12.0-14.0 N·m)
C-scavenge oil tube CRF strut No. 8 Bolts (72), Nuts (73) 106-124 lb in. (a)
(71), Gasket (74) (12.0-14.0 N·m)
C-scavenge oil tube Support bracket Bolts (75), 106-124 lb in. (a)
(71) (21, figure 1) Clamps (76, 77) (12.0-14.0 N·m)
LP recoup air tube CRF strut No. 6 Bolts (79), Nuts (80) 106-124 lb in. (a)
(78), Gasket (81) (12.0-14.0 N·m)
LP recoup air tube LP recoup air tube (82) Bolts (79), Nuts (80) 106-124 lb in. (a)
(78), Gasket (81) (12.0-14.0 N·m)
LP recoup air tube (78) Support bracket Bolts (83), 106-124 lb in. (a)
LP recoup air tube CRF strut No. 7, No. 8, Bolts (79), Nuts (80) 106-124 lb in. (a)
(82), Gasket (81) No. 9 (12.0-14.0 N·m)

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CDP air manifold (87), CRF strut No. 2, No. 3 Bolts (89), Nuts (90) 106-124 lb in. (a)
Gasket (88) (12.0-14.0 N·m)
CDP air manifold (87) CDP air bracket Bolts (91), 106-124 lb in. (a)
CDP air manifold (87) CDP air bracket Bolts (91), 106-124 lb in. (a)
Air tube (94) Cooling bracket Retaining straps (99), 106-124 lb in. (a)
(24, figure 5) Bolts (100), Nuts (101) (12.0-14.0 N·m)
(two places)
Lower HPC air tube Cooling bracket Retaining strap (99), 106-124 lb in. (a)
(96) (28, figure 5) Bolts (100) (12.0-14.0 N·m)
Lower HPC air tube Air tube (94) Coupling nut 40-50 lb ft (b)
(96) (55-67 N·m)
Lower HPC air tube Flange cooling air Coupling clamp (104), 115-125 lb in.
(96) manifold (97) Seal ring (105) (13.0-14.1 N·m)
Upper HPC air tube Cooling bracket Retaining strap (99), 106-124 lb in. (a)
(95) (20, figure 5) Bolts (100) (12.0-14.0 N·m)
Upper HPC air tube Air tube (94) Coupling nut 40-50 lb ft (b)
(95) (55-67 N·m)
Flange cooling air Cooling bracket (98) Cushion clamp (103), 106-124 lb in. (a)
manifold (97) (10 places) Bolt (100), Nut (101), (12.0-14.0 N·m)
Washer (102)
Flange cooling air Upper HPC air tube (95) Coupling clamp (104), 115-125 lb in.
manifold (97) Seal ring (105) (13.0-14.1 N·m)
NOTES:
WARNING
USE MECHANICAL EXHAUST VENTILATION - IF NOT AVAILABLE, USE AND APPROVED
RESPIRATOR.
(a) Lubricate threads and washer faces of bolts/nuts/plugs using thread lubricant.
(b) Safety-wire.
(c) Lubricate preformed packings using lubricating oil.

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Figure 8. Core Module Electrical Leads (Sheet 1 of 2)

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Figure 8. Core Module Electrical Leads (Sheet 2 of 2)

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Table 8. Core Module Electrical Lead (Figure 8)

Gasket (1), HPC discharge CRF boss between struts Bolts (4) 60-70 lb in. (a) (b)
temperature (t3) sensor (2) No. 2 and No. 3 (6.8-7.9 N·m)
HPC discharge temperature T3 cable bracket Clamp (5), Bolt (6) 60-70 lb in. (a) (c)
(T3) sensor (2) integral lead (4, figure 4) (6.8-7.9 N·m)
HPC discharge temperature T3 cable bracket Clamps (5), Bolts (6) 60-70 lb in. (a) (c)
(T3) sensor (2) integral lead (5, figure 4) (two brackets) (6.8-7.9 N·m)
HPC discharge temperature Cable bracket Clamp (5), Bolt (6) 60-70 lb in. (a) (c)
HPC discharge temperature Bridge bracket Clamps (5), Bolts (6) 60-70 lb in. (a) (c)
(three places)
HPC discharge temperature No. 3 electrical panel Jamnut Hand-tighten, then (a) (d)
(T3) sensor (2) integral lead (37, figure 5) one-quarter to one-
connector half turn
Gasket (1), HPC discharge CRF boss between struts Bolts (4) 60-70 lb in. (a) (b)
temperature (T3) sensor (3) No. 4 and No. 5 (6.8-7.9 N·m)
HPC discharge temperature Cable bracket Camp (5), Bolt (6) 60-70 lb in. (a) (c)
HPC discharge temperature Bridge bracket Camps (5), Bolts (6) 60-70 lb in. (a) (c)
(three places)
HPC discharge temperature Cable bracket Camp (5), Bolt (6) 60-70 lb in. (a) (c)
HPC discharge temperature No. 3 electrical panel Jamnut Hand-tighten, then (a) (d)
(T3) sensor (3) integral lead (37, figure 5) one-quarter to one-
connector half turn
Accelerometer (7), Accelerometer bracket Bolts (9) 106-124 lb in. (a)
PX36 bracket (8) (22, figure 1) (12.0-14.0 N·m)
Accelerometer (7) integral Accelerometer bracket Clamp (10), Bolt (11), 60-70 lb in. (a) (c)
lead (20, figure 1) Nut (12) (6.8-7.9 N·m)
Accelerometer (7) integral Cable bracket Clamp (10), Bolt (11), 60-70 lb in. (a) (c)
lead (19, figure 1) Nut (12) (6.8-7.9 N·m)

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Table 8. Core Module Electrical Lead (Figure 8) (Continued)

Accelerometer (7) integral Bridge bracket Clamp (10), Bolt (11) 60-70 lb in. (a) (c)
lead (33, figure 5) (two places) (6.8-7.9 N·m)
Accelerometer (7) integral No. 3 electrical panel Jamnut Hand-tighten, then (a) (d)
lead connector (37, figure 5) one-quarter to one-
half turn
NOTES:
(a) Coat threads and washer faces of bolts/nuts using thread lubricant.
(b) Safety-wire.
(c) Lead may be spiral wrapped using silicone tape in the area of clamps and 0.50 inch (12.7 mm) on either side of
clamp to provide positive lead clamping as required.
(d) Safety-wire to adjacent jamnut.

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LOW PRESSURE TURBINE (LPT) MODULE EXTERNAL
TUBING, HARNESSES, AND CLAMPING
())(&7,9,7</03)*$6785%,1(02'(/6

Page No. Change No.
1 - 26 ........................................................................................................................................................ 0
Alphabetical Index
Subject Page
Air Manifold Installation.......................................................................................................................... 4

Low Pressure Turbine Module Brackets and LPT Case Cooling Tubes Installation............................... 4
Low Pressure Turbine Module Electrical Leads Installation. .................................................................. 4
Low Pressure Turbine Module Tubing and Clamping Installation. ......................................................... 4
Low Pressure Turbine/Turbine Rear Frame Flange Brackets Installation. .............................................. 4
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1. Introduction.
A. This subordinate work package contains information concerning installation of the low pressure turbine
(LPT) module and turbine rear frame (TRF) external tubing, harnesses, and clamping.
disturbed:
(2) Electrical connections of leads and harnesses shall conform to the following assembly points:
the backshell assembly.
NOTE

0.75-1.00 24-26 (33-35)
1.125-1.50 20-40 (28-54)
1.625-2.00 40-50 (55-67)
2.125 and up 50-60 (68-81)
(1.52 mm) and is known to be within manufacturing tolerance, it shall be modified by bending as
required. After bending to obtain the required free-state fit, the following shall apply:
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all planes.
adjacent parts.
Title Number

Soft-faced mallet Local Purchase
(Optional)
Penetrating Oil GE Spec A50TF54 (Liquid Wrench) or Dag 2404
materials are not listed. Reference GEK 119320, Illustrated Parts Breakdown (IPB), for required parts.
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6. Low Pressure Turbine/Turbine Rear Frame Flange Brackets Installation.

7. Air Manifold Installation.

8. Low Pressure Turbine Module Brackets and LPT Case Cooling Tubes Installation.
9. Low Pressure Turbine Module Tubing and Clamping Installation.

10. Low Pressure Turbine Module Electrical Leads Installation.

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Figure 1. LPT/TRF Flange Brackets
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Table 1. LPT/TRF Flange Brackets (Figure 1)

Balance piston bracket (1) Boltholes 8, 9, 10 Bolts (2), 368-432 lb in. (a)
Self-locking nuts (3) (41.6-48.8 N·m)
Cable bracket (4) Boltholes 28, 29 Bolts (5), 368-432 lb in. (a)
Cable bracket (4), Balance Boltholes 35, 36 Bolts (2), 368-432 lb in. (a)
piston bracket (1) Self-locking nuts (6) (41.6-48.8 N·m)
Balance piston bracket (1) Bolthole 37 Bolt (2), 368-432 lb in. (a)
Self-locking nut (3) (41.6-48.8 N·m)
Accelerometer bracket (7) Boltholes 51, 52 Bolts (5), 368-432 lb in. (a)
Oil scavenge bracket (8) Boltholes 55, 56, 57 Bolts (5), 368-432 lb in. (a)
Lube supply bracket (9) Boltholes 61, 62 Bolts (5), 368-432 lb in. (a)
Electrical bracket (12) Boltholes 78 through Bolts (5), 368-432 lb in. (a)
83 Self-locking nuts (6) (41.6-48.8 N·m)
Balance piston bracket (1) Boltholes 115, 116, Bolts (2), 368-432 lb in. (a)
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Table 1. LPT/TRF Flange Brackets (Figure 1) (Continued)

Balance piston bracket (1) Boltholes 124, 125, Bolts (2), 368-432 lb in. (a)
NOTE:
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Figure 2. Air Manifold (Sheet 1 of 2)
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Figure 2. Air Manifold (Sheet 2 of 2)
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Table 2. Air Manifold (Figure 2)

Left-side air inlet LPT 2:30 o’clock Bolts (1) Finger tight (a) (b) (c)
manifold (2), Gasket cooling air port
(3)
LPT cooling air LPT 2:00 o’clock Bolts (1) Finger tight (a) (b) (c)
(3)
(3)
(3)
LPT cooling air tube LPT 11:00 o’clock Bolts (1) Finger tight (a) (b) (c)
(5), Gasket (3) cooling air port
Left-side air inlet LPT cooling air Seal ring (7), Snug (d)
manifold (2) manifold (4) Coupling clamp (8)
Left-side air inlet LPT cooling air Seal ring (7), Snug (d)
manifold (2) tube (6) Coupling clamp (8)
LPT cooling air LPT cooling air Seal ring (7), Snug (d)
manifold (4) manifold (4)(four Coupling clamp (8)
locations)
(two places)
Right-side air inlet LPT 8:30 o’clock Bolts (1) Finger tight (a) (b) (c)
(3)
(3)
(3)
(3)

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Table 2. Air Manifold (Figure 2) (Continued)

manifold (4) cooling air port
(6), Bracket (11) cooling air port
Right-side air inlet LPT cooling air Seal ring (7), Snug (d)
manifold (9) manifold (4) Coupling clamp (8)
(two places)
NOTES:
(a) Lubricate threads and faces of bolts using thread lubricant.
(b) After all coupling clamps (8) are tightened per note (d), tighten bolts (1) and (10) to 60-70 lb in.
(c) Safety-wire.
(d) After all cooling air manifolds and air tubes are installed, tighten coupling clamp (8) to 29-33 lb in.
(3.3-3.7 N·m) of torque. Tap coupling clamp lightly around circumference with a soft-faced mallet to
equally distribute load. Alternate tightening and tapping until torque stabilizes at 57-67 lb in. (6.5-7.5 N·m)
of torque. Avoid overtorquing. Inspect clamp for even seating.

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Figure 3. LPT Module Brackets and LPT Case Cooling Tubes (Sheet 1 of 4)

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Table 3. LPT Module Brackets and LPT Case Cooling Tubes (Figure 3)
CAUTION
DO NOT REMOVE NUTS (3) THAT SECURE COOLING BRACKETS (1) AND MANIFOLD
BRACKETS (4) TO LPT CASE (2). REMOVAL OF NUTS WILL RESULT IN ATTACHING
HARDWARE FALLING INTO LPT MODULE ASSEMBLY, WHICH WILL REQUIRE DEPOT
VISIT TO REPAIR LPT MODULE. ONLY CHECK NUTS (3) FOR CORRECT TORQUE.
Cooling bracket (1) LPT case (2) Nuts (3) 60-70 lb in. (6.8-7.9 N·m) (a)
(12 places)
Manifold bracket (4) LPT case (2) Nuts (3) 60-70 lb in. (6.8-7.9 N·m) (a)
(12 places)
Locator bracket (5) Manifold bracket (4) Bolts (6), Nuts (7) 60-70 lb in. (6.8-7.9 N·m) (a)
(six places)
Wear bracket (8) Cooling manifold (9) Bolts (6) 60-70 lb in. (6.8-7.9 N·m) (a)
Support bracket (10) Cooling manifold (9) Bolts (6) 60-70 lb in. (6.8-7.9 N·m) (a)
Damper Bracket (11) Cooling manifold (9) Bolts (13) 60-70 lb in. (6.8-7.9 N·m) (b)
(five places)
Damper Bracket (12) Cooling manifold (9) Bolts (16), Nuts (7) 60-70 lb in. (6.8-7.9 N·m) (a)
(five places)
Damper bracket (11) Cooling bracket (1) Bolts (13) 60-70 lb in. (6.8-7.9 N·m) (a)
(six places)
Damper bracket (12) Cooling bracket (1) Bolts (13) 60-70 lb in. (6.8-7.9 N·m) (a)
(six places)
Oil supply bracket Bracket (14) Bolts (19), Nuts (7) 60-70 lb in. (6.8-7.9 N·m) (a)
(18)
Oil supply bracket Bracket (15) Bolts (17) 60-70 lb in. (6.8-7.9 N·m) (a)
(18)
Cooling manifold (9) Manifold bracket (4) Bolts (20), Nuts (7) 60-70 lb in. (6.8-7.9 N·m) (a) (b)
(six places)
Support bracket (10) Wear bracket (8) Friction washer 60-70 lb in. (6.8-7.9 N·m) (a)
(six places) (21), Spring (22),
Bushing (23), Bolt
(24)
Flex joint (25) Cooling manifold (9) Hose clamp (26) 32-38 lb in. (3.7-4.2 N·m)
(10 places)
Flex joint (27) Cooling manifold (9) Hose clamp (26) 32-38 lb in. (3.7-4.2 N·m)
(two places)
NOTES:
(a) Lubricate threads and faces of bolts using thread lubricant.
(b) LPT outer case to PCC cooling manifold clearance shall be a minimum of 0.075 inch (1.91 mm).

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Figure 4. LPT Module Tubing and Clamping (Sheet 1 of 3)

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Table 4. LPT Module Tubing and Clamping (Figure 4)

Balance piston air TRF (3) Bolts (4), 106-124 lb in. (a) (b)
manifold (1), Self-locking nuts (5) (12.0-14.0 N·m)
Gasket (2)
Balance piston air TRF (3) Bolts (4), 106-124 lb in. (a) (b)
manifold (6), Self-locking nuts (5) (12.0-14.0 N·m)
Gasket (2) (two places)
Balance piston air Balance piston air Metal seal ring (7), 115-125 lb in. (b)
manifold (1) manifold (6) V-retainer (13.0-14.1 N·m)
coupling (8)
Balance piston air Balance piston bracket Retaining strap (10), 60-70 lb in. (a) (b)
manifold (1) (1, figure 1) Bolts (9) (6.8-7.9 N·m)
NOTES:
(b) If any tube or manifold does not fit in the free state, within 0.060 inch (1.52 mm), it may be modified by
bending, as required.

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Figure 5. LPT Module Electrical Leads (Sheet 1 of 3)

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Table 5. LPT Module Electrical Leads (Figure 5)

LPT speed electrical Cable bracket Bolts (3) 60-70 lb in. (a)
cable (1) (4, figure 1), Cushion (6.8-7.9 N·m)
clamp (2)
Cable bracket Bolts (3) 60-70 lb in. (a)
(4, figure 1), Cushion (6.8-7.9 N·m)
clamp (2)
Electrical bracket (6), Bolts (3) 60-70 lb in. (a)
Cushion clamp (2) (6.8-7.9 N·m)
Oil scavenge bracket Bolts (3) 60-70 lb in. (a)
clamp (2)
(two places)
Lube supply bracket Bolts (3) 60-70 lb in. (a)
clamp (2)
Cable bracket (10, Bolts (3) 60-70 lb in. (a)
figure 1), Cushion (6.8-7.9 N·m)
clamp (2)
clamp (2)
Electrical bracket Jamnut Hand-tighten, then (b)
(12, figure 1) one-quarter turn
LPT speed electrical Cable bracket Bolts (3) 60-70 lb in. (a)
cable (4) (4, figure 1), Cushion (6.8-7.9 N·m)
clamp (2)
(4, figure 1), (6.8-7.9 N·m)
Cushion clamp (2)
clamp (2)
Electrical bracket (11, Bolts (3) 60-70 lb in. (a)
clamp (2)
(two places)

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Table 5. LPT Module Electrical Leads (Figure 5) (Continued)

High temperature Accelerometer Bolts (3) 60-70 lb in. (a)
accelerometer (5), bracket (7, figure 1) (6.8-7.9 N·m)
Electrical bracket (6)
High temperature Oil scavenge bracket Bolts (3) 60-70 lb in. (a)
accelerometer (8, figure 1), (6.8-7.9 N·m)
cable (9) Cushion clamp (7)
(two places)
Lube supply bracket Bolts (3) 60-70 lb in. (a)
clamp (7)
clamp (7)
Cable bracket (11, Bolt (3) 60-70 lb in. (a)
clamp (7)
Electrical TMF Bolt (18), 60-70 lb in. (a)
bracket (14) Spacer (19) (6.8-7.9 N·m)
Thermocouple LPT cooling air tube Cushion clamp (12), 60-70 lb in. (a)
electrical harness (8) (6, figure 2) Bolt (18) (6.8-7.9 N·m)
LPT case Cushion clamp (12), 60-70 lb in. (a)
Bolt (18), Spacer (6.8-7.9 N·m)
(19), Bolt (11)
Cable bracket Cushion clamp (12), 60-70 lb in. (a)
(4, figure 1) Bolt (18) (6.8-7.9 N·m)
Electrical bracket Cushion clamp (12), 60-70 lb in. (a)
(12, figure 1) Bolt (18) (6.8-7.9 N·m)
Bracket (11, figure 2) Cushion clamp (16), 32-38 lb in. (a)
Bolt (10) (3.7-4.2 N·m)
LPT cooling air tube Cushion clamp (16), 32-38 lb in. (a)
(6, figure 2) Bolt (10) (3.7-4.2 N·m)
LPT cooling air Cushion clamp (17), 32-38 lb in. (a)
manifold (4, figure 2) Bolt (10) (3.7-4.2 N·m)
(four places)

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Table 5. LPT Module Electrical Leads (Figure 5) (Continued)

Thermocouple LPT cooling air Cushion clamp (16), 32-38 lb in. (a)
electrical harness (8) manifold (4, figure 2) Bolt (10) (3.7-4.2 N·m)
(continued) (two places)
Left-side air inlet Cushion clamp (17), 32-38 lb in. (a)
Thermocouple (13) Integral nut 16-18 lb in.
probe (1.9-2.0 N·m)
Thermocouple Oil scavenge bracket Cushion clamp (12), 60-70 lb in. (a)
electrical (8, figure 1) Bolt (18) (6.8-7.9 N·m)
harness (15)
Oil supply bracket Cushion clamp (12), 60-70 lb in. (a)
(18, figure 3) Bolt (18) (6.8-7.9 N·m)
LPT cooling air Cushion clamp (17), 32-38 lb in. (a)
(five places)
LPT cooling air tube Cushion clamp (18), 32-38 lb in. (a)
(6, figure 2) Bolt (12) (3.7-4.2 N·m)
Thermocouple (13) Integral nut 16-18 lb in.
probe (1.9-2.0 N·m)
NOTES:
(b) Safety-wire to adjacent jamnut.

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ENGINE ASSEMBLY EXTERNAL TUBING, HARNESSES,
AND CLAMPING
())(&7,9,7</03)*$6785%,1(02'(/6

Page No. Change No.
1 - 21 ........................................................................................................................................................ 0
22 Blank ................................................................................................................................................... 0
Alphabetical Index
Subject Page
Engine Assembly External Tubing and Hoses Installation. ..................................................................... 4

Front Frame/HPC Flange Brackets Installation. ...................................................................................... 4
LPC Module Final Assembly. .................................................................................................................. 4
VIGV/LPC Flange Brackets Installation. ................................................................................................ 4
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1. Introduction.
A. This subordinate work package contains information concerning installation of engine assembly external
tubing, harnesses, and clamping.
disturbed:
(2) Electrical connections of heads and harnesses shall conform to the following assembly points:
the back shell assembly.
NOTE

0.75-1.00 24-26 (32.6-35.2)
1.125-1.50 20-40 (27.2-54.2)
1.625-2.00 40-50 (54.3-67.7)
2.125 and up 50-60 (67.8-81.3)
(1.52 mm), and is known to be within manufacturing tolerance, it shall be modified by bending as
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all planes.
adjacent parts.
l.
Title Number
Front Frame Module External Tubing, Harnesses, and Clamping SWP 1913 01
.

(Optional)
.
materials are not listed. Refer to Illustrated Parts Breakdown, GEK 119320, for required parts.
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6. VIGV/LPC Flange Brackets Installation.

7. LPC Module Final Assembly.

8. Front Frame/HPC Flange Brackets Installation.

9. Engine Assembly External Tubing and Hoses Installation.

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Figure 1. VIGV/LPC Flange Brackets
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Table 1. VIGV/LPC Flange Brackets (Figure 1)

Electrical bracket (1) Boltholes 64, 1 Bolts (2), Washers (3), 368-432 lb in. (a)
Nuts (4) (41.6-48.8 N·m)
Nuts (4) (41.6-48.8 N·m)
Electrical bracket (6) Boltholes 19, 20 Bolts (8), Nuts (4) 368-432 lb in. (a) (b)
(41.6-48.8 N·m)
Mounting bracket (7) Boltholes 19-22 Bolts (8), Nuts (4) 368-432 lb in. (a) (b)
(41.6-48.8 N·m)
Bearing block (9) Mounting bracket (7) Bolts (20), Nuts (10) 350-410 lb in. (a)
(39.6-46.3 N·m)
Angle bracket (11) Boltholes 23, 24 Bolts (2), Washers (3), 368-432 lb in. (a)
Nuts (4) (41.6-48.8 N·m)
Panel bracket (12) Boltholes 26, 27, 28 Bolts (8), Washers (3), 368-432 lb in. (a)
Nuts (4) (41.6-48.8 N·m)
IGV bracket (13) Boltholes 29, 30 Bolts (2), Washers (3), 368-432 lb in. (a)
Nuts (4) (41.6-48.8 N·m)
Nuts (4) (41.6-48.8 N·m)
Nuts (4) (41.6-48.8 N·m)
Nuts (4) (41.6-48.8 N·m)
Nuts (4) (41.6-48.8 N·m)
Nuts (4) (41.6-48.8 N·m)
Mounting bracket (17) Boltholes 50, 51, 52, 53 Bolts (8), Nuts (4) 368-432 lb in. (a) (b)
(41.6-48.8 N·m)
Electrical bracket (16) Boltholes 52, 53 Bolts (8), Nuts (4) 368-432 lb in. (a) (b)
(41.6-48.8 N·m)
Bearing block (9) Mounting bracket (17) Bolts (8), Nuts (20) 350-410 lb in. (a)
(39.6-46.3 N·m)
Nuts (4) (41.6-48.8 N·m)
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Table 1. VIGV/LPC Flange Brackets (Figure 1) (Continued)

Nuts (4) (41.6-48.8 N·m)
Nuts (4) (41.6-48.8 N·m)
NOTES:
(b) Install mounting brackets on each side of flange.
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Figure 2. LPC Module Final Assembly (Sheet 1 of 3)
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Table 2. LPC Module Final Assembly (Figure 2)

Channel bracket (1) Panel bracket Bolts (2) 106-124 lb in. (a)
(9, figure 1, SWP 1913 01) (12.0-14.0 N·m)
Channel bracket (1) IGV bracket (13, figure 1) Bolts (2) 106-124 lb in. (a)
(12.0-14.0 N·m)
Panel bracket (3) Channel bracket (1) Bolts (2) 106-124 lb in. (a)
(2 places) (12.0-14.0 N·m)
No. 1 electrical Panel bracket Bolts (2), 106-124 lb in. (a)
interface panel (5) (8, figure 1, SWP 1913 01) Washers (6) (12.0-14.0 N·m)
No. 1 electrical Panel bracket (12, figure 1) Bolts (2) 106-124 lb in. (a)
interface panel (5) (12.0-14.0 N·m)
No. 1 electrical Panel brackets (3, 4) Bolts (2) 106-124 lb in. (a)
interface panel (5) (12.0-14.0 N·m)
Preformed packing (7), Right VIGV actuator rod-end port 133-157 lb in. (b)
Reducer (8) (15.1-17.7 N·m)
Preformed packing (9), Right VIGV actuator head-end port 133-157 lb in. (b)
Reducer (10) (15.1-17.7 N·m)
Preformed packings Oil tube/hose (14) (b)
(11, 12), Drain can (13)
Oil tube/hose (14) Reducer (8) Coupling nut 262-308 lb in.
(29.7-34.7 N·m)
Drain can (13) Right VIGV actuator rod-end port Hand-tight (c)
(11, 12), Drain can (13)
(29.7-34.7 N·m)
Drain can (13) Right VIGV actuator head-end port Hand-tight (c)
Oil tube/hose (16) Drain can (13) Coupling nuts 262-308 lb in.
(29.7-34.7 N·m)
Preformed packing (7), Left VIGV actuator rod-end port 133-157 lb in. (b)
Reducer (8) (15.1-17.7 N·m)
Preformed packing (9), Left VIGV actuator head-end port 133-157 lb in. (b)
Reducer (10) (15.1-17.7 N·m)
(11, 12), Drain can (13)
(29.7-34.7 N·m)
Drain can (13) Left VIGV actuator head-end port Hand-tight (c)

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Table 2. LPC Module Final Assembly (Figure 2) (Continued)

(11, 12), Drain can (13)
(29.7-34.7 N·m)
Drain can (13) Left VIGV actuator rod-end port Hand-tight (c)
Oil tube/hose (26) Drain cans (13) Coupling nuts 262-308 lb in.
(2 places) (29.7-34.7 N·m)
IGV oil tube (27) Oil tube/hoses (15, 24) Coupling nuts 262-308 lb in.
(29.7-34.7 N·m)
Oil manifold (28) Oil tube/hoses (16, 26) Coupling nuts 262-308 lb in.
(29.7-34.7 N·m)
Oil manifold (29) Oil tube/hoses (14, 25) Coupling nuts 262-308 lb in.
(29.7-34.7 N·m)
Oil tube/hoses (24, 25), Angle bracket (5, figure 1) Clamp (30), 57-67 lb in. (a)
Oil manifold (28) Bolts (18), (6.5-7.5 N·m)
Washers (19)
IGV oil tube (27), Oil Angle brackets (14, figure 1) Clamp (30), 57-67 lb in. (a)
manifolds (28, 29) Bolts (18), (6.5-7.5 N·m)
Washers (19)
IGV oil tube (27), Oil IGV bracket (13, figure 1) Clamp (30), 57-67 lb in. (a)
Washers (19)
IGV oil tube (27), Oil No. 1 electrical interface panel (5) Clamp (30), 57-67 lb in. (a)
Washers (19)
IGV oil tube (27), Oil Angle bracket (11, figure 1) Clamps (17), 57-67 lb in. (a)
Washers (19)
IGV oil tube (22) Oil manifold (29) Coupling nut 460-540 lb in.
(52.0-61.0 N·m)
IGV oil tube (20) IGV oil tube (27) Coupling nut 55-65 lb ft
(75-88 N·m)
Teflon hose (32) IGV oil tube (22) Coupling nut 460-540 lb in.
(52.0-61.0 N·m)
Teflon hose (32) Union (86, figure 3, SWP 1913 01) Coupling nut 460-540 lb in.
(52.0-61.0 N·m)
IGV oil hose (31) IGV oil tube (20) Coupling nut 55-65 lb ft
(75-88 N·m)
IGV oil hose (31) Union (84, figure 3, SWP 1913 01) Coupling nut 55-65 lb ft
(75-88 N·m)

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Table 2. LPC Module Final Assembly (Figure 2) (Continued)

IGV oil tube (22) No. 1 electrical interface panel (5) Clamps (23), 57-67 lb in. (a)
Bolts (2) (6.5-7.5 N·m)
IGV oil tube (20) No. 1 electrical interface panel (5) Clamps (21), 57-67 lb in. (a)
Bolts (2) (6.5-7.5 N·m)
WARNING

USE MECHANICAL EXHAUST VENTILATION - IF NOTAVAILABLE, USE AN APPROVED
RESPIRATOR.
NOTES:
(b) Lubricate preformed packing using lubricating oil.
(c) Align drain fittings before tightening.
Figure 3. Front Frame/HPC Flange Brackets

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Table 3. Front Frame/HPC Flange Brackets (Figure 3)

VSV actuator bracket (1) Boltholes 18, 19, 24, 26 Bolts (2) 368-432 lb in. (a) (b)
(41.6-48.8 N·m)
Bolthole 25 Bolt (3) 202-238 lb in. (a) (b)
(22.9-26.8 N·m)
(62.4-73.2 N·m)
Hydraulic bracket (5) Bolthole 33 Bolt (2) 368-432 lb in. (a) (b)
(41.6-48.8 N·m)
(62.4-73.2 N·m)
Bracket assembly (6) Boltholes 45, 46 Bolts (2) 368-432 lb in. (a) (b)
(41.6-48.8 N·m)
Bracket assembly (6) Front frame Bolt (7) 106-124 lb in. (a) (b)
(12.0-14.0 N·m)
Bracket assembly (8) Bolthole 54 Bolt (2) 368-432 lb in. (a) (b)
(41.6-48.8 N·m)
(62.4-73.2 N·m)
Bracket assembly (8) Front frame Bolt (7) 106-124 lb in. (a) (b)
(12.0-14.0 N·m)
VSV actuator bracket (9) Boltholes 60, 61, 66, 68 Bolts (2) 368-432 lb in. (a) (b)
(41.6-48.8 N·m)
(22.9-26.7 N·m)
(62.4-73.2 N·m)
NOTES:
(a) Lubricate threads and washer faces of bolt/nuts using thread lubricant.
(b) Safety-wire

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Figure 4. Engine Assembly External Tubing and Hoses (Sheet 1 of 5)

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Table 4. Engine Assembly External Tubing and Hoses (Figure 4)

Attach Item To Item Secure With Torque Note
Hose (1), AGB Bolts (27) 106-124 lb in. (a)
Gasket (28) (12.0-14.0 N·m)
Hose (1), B-scavenge oil tube (70, figure 7, Bolts (31), Nuts (32) 106-124 lb in. (a)
Gasket (33) SWP 1913 02) (12.0-14.0 N·m)
Hose (2) Tube (3) Coupling 55-65 lb ft
(75-88 N·m)
(75-88 N·m)
Hose (4) AGB Coupling 78-92 lb ft
(105.8-124.7 N·m)
(105.8-124.7 N·m)
Hose (5), C-scavenge oil tube (71, figure 7, Bolts (31), Nuts (32) 60-70 lb in. (a)
Gasket (33) SWP 1913 02) (6.8-7.9 N·m)
Hose (5), AGB Bolts (29) 60-70 lb in. (a)
Gasket (30) (6.8-7.9 N·m)
Nipple (6) TRF Boss 350-410 lb in.
(39.6-46.3 N·m)
Hose (7) E-scavenge nipple (6) Coupling 55-65 lb ft
(75-88 N·m)
Hose (7) Oil scavenge bracket (8, figure 1, Loop Clamp (8), 60-70 lb in. (a)
SWP 1913 03) (two places) Bolt (9) (6.8-7.9 N·m)
Hose (7) Lube supply bracket (13, figure 1, Loop Clamp (8), 60-70 lb in. (a)
SWP 1913 03) Bolt (9) (6.8-7.9 N·m)
Hose (7) Oil supply bracket (18, figure 3, Loop Clamp (20), 60-70 lb in. (a)
SWP 1913 03) Bolt (21) (6.8-7.9 N·m)
Hose (7) Oil bracket (45, Loop Clamp (22), 60-70 lb in. (a)
figure 3, SWP 1913 02) Bolt (26) (6.8-7.9 N·m)
SWP 1913 02) Bolt (26) (6.8-7.9 N·m)
(75-88 N·m)
(39.6-46.3 N·m)
Hose (11) D-scavenge nipple (10) Coupling 55-65 lb ft
(75-88 N·m)
SWP 1913 03) Bolt (19) (6.8-7.9 N·m)

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Table 4. Engine Assembly External Tubing and Hoses (Figure 4) (Continued)

Attach Item To Item Secure With Torque Note
SWP 1913 02) Bolt (26) (6.8-7.9 N·m)
(75-88 N·m)
(29.7-34.7 N·m)
Hose (13) Nipple (12) Coupling 262-308 lb in.
(29.7-34.7 N·m)
Hose (13) Electrical bracket (12, figure 1, Loop Clamp (14), 60-70 lb in. (a)
SWP 1913 03) (two places) Bolt (15) (6.8-7.9 N·m)
SWP 1913 03) Bolt (17) (6.8-7.9 N·m)
Hose (13) Tube (38) Coupling 460-540 lb in.
(52.0-61.0 N·m)
Tube (38) Oil supply bracket (3, figure 4, Loop Clamp (25), 60-70 lb in. (a)
SWP 1913 02) Bolt (26) (6.8-7.9 N·m)
Tube (38) Oil tube bracket (34) Tube clamps (36, 37), 60-70 lb in. (a)
Bolt (35) (6.8-7.9 N·m)
NOTE:
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HEAT SHIELDS REPLACEMENT
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Alphabetical Index
Subject Page
Heat Shields Installation ......................................................................................................................... 14

Heat Shields Removal. ............................................................................................................................. 3
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1. Introduction.
This work package contains instructions for removing and installing the forward, mid, and aft heat shields.
None required.
None required.
None required.
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6. Heat Shields Removal.
A. Remove four bolts (figure 1) that secure high pressure turbine (HPT) borescope cover to bottom right mid
heat shield and bottom right aft heat shield. Remove borescope cover.
B. Remove aft heat shields as follows (figure 2):
(1) Using marking pen, matchmark five aft heat shields to HPT/LPT flange.
(2) Remove 34 bolts that secure aft heat shields onto mid heat shields.
(3) Remove bolts, spacers, and washers that secure aft heat shields to connector plates (view B) (four
locations).
(4) Remove bolt, spacer, and washer that secure aft heat shield to connector plate (view C).
(5) Remove nuts and bolts that secure aft heat shields onto aft heat shield support brackets on HPT/LPT
flange (section D-D) (five locations).
(6) Remove nuts, spacers, washers, and bolts that secure aft heat shields onto aft heat shield support
brackets on HPT/LPT flange (section E-E) (26 locations). Remove aft heat shields.
WARNING
BEFORE YOU DISCONNECT THE IGNITION LEADS, MAKE SURE THE IGNITION SYSTEM
WAS OFF FOR MORE THAN 2 MINUTES. THE IGNITION SYSTEM COULD BE CHARGED
WITH HIGH VOLTAGE THAT CAN CAUSE DEATH.
CAUTION
ENSURE IGNITER PLUG ADAPTER IS RESTRAINED WHEN LOOSENING COUPLING

CAUTION
IGNITER PLUG MAY FALL OUT WHEN IGNITION LEAD IS DISCONNECTED.
C. Disconnect ignition lead from igniter plug adapter (figure 3). Momentarily ground ignition lead to remove
any residual electrical charge.
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Figure 1. Mid and Aft Heat Shield and Connector Plates
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Figure 2. Aft Heat Shields (Sheet 1of 2)
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Figure 2. Aft Heat Shields (Sheet 2 of 2)
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Figure 3. Igniter Plug and Lead
D. Remove forward heat shields and mid heat shields as follows (figure 4):
(1) Using marking pen, matchmark four forward and five mid heat shields to CRF/CRF aft case flange.
(2) Remove bolts, spacers, and washers that secure forward heat shields to connector plates (figure 4,
view C) (four locations).
(3) Remove bolts, spacers, and washers that secure mid heat shields to long connector plates and
remove four bolts, spacers, and washers that secure mid heat shields to short connector plates
(figure 4, view D) (three locations).
(4) Remove bolts, spacers, and washers that secure mid heat shields to connector plates (figure 4,
view E) (two locations).
(5) Remove bolt, spacer, and washer that secure mid heat shield and bracket to extended flange bracket
(figure 4, section F-F) at 12:00 o’clock position.
(6) Remove nut, bolt, spacer, and washer that secure mid heat shield to extended flange bracket
(figure 4, section G-G) at approximately 12:30 o’clock position.
(7) Remove nut, bolt, spacer, and washer that secure forward heat shield and mid heat shield to
extended flange bracket (figure 4, section H-H) at approximately 1:30 o’clock position.
extended flange bracket (figure 4, section J-J) at approximately 2:00 o’clock position.

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Figure 4. Forward and Mid Heat Shields - CRF/CRF Aft Case Flange (Sheet 1 of 4)
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(10) Remove top right mid heat shield.
(12) Remove nut and bolt that secure forward heat shield and mid heat shield to extended flange bracket
(figure 4, section K-K) at 3:00 o’clock position.
(14) Remove right mid heat shield.
(16) Remove nut, bolt, spacers, and washers that secure forward heat shield and mid heat shield to
(17) Remove right forward heat shield.
(18) Remove nut, bolt, spacer, and washer that secure forward heat shield and bracket to extended flange
bracket (figure 4, section L-L) at approximately 4:50 o’clock position.
(19) Remove nut and bolt that secure mid heat shield to extended flange bracket (figure 4, section M-M)
at approximately 5:00 o’clock position.
(20) Remove nut and bolt, spacer, and washer that secure forward heat shield to extended flange bracket
(figure 4, section N-N) at approximately 5:15 o’clock position.
(figure 4, section G-G) at 6:00 o’clock position.
(22) Remove nut, bolt, spacer, and washer that secure mid heat shield and forward heat shield to
extended flange bracket (figure 4, section P-P) at approximately 6:15 o’clock position.
(24) Remove bottom right mid heat shield.
(26) Remove bottom forward heat shield.
extended flange bracket (figure 4, section -H-H) at approximately 7:45 o’clock position.

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(29) Remove nut, bolt, spacer, and washer that secure mid heat shield and forward heat shield to
extended flange bracket (figure 4, section P-P) at approximately 8:30 o’clock position.
(30) Remove bottom left mid heat shield.
(33) Remove left forward heat shield.
extended flange bracket (figure 4, section H-H) at approximately 10:45 o’clock position.
(38) Remove top left mid heat shield and top forward heat shield.
NOTE
If heat shield or connector plate is not being replaced, it is not required to remove connector plate.
E. If required, remove connector plates from forward and mid heat shields as follows:
(1) Remove bolts that secure forward heat shields to connector plates (figure 4, view C) (four
locations).
(2) Remove bolts that secure mid heat shields to long connector plates and remove bolts that secure mid
heat shields to short connector plates (figure 4, view D) (three locations).
(3) Remove bolts that secure mid heat shields to connector plates (figure 4, view E) (two locations).
NOTE
If heat shield or connector plate is not being replaced, it is not required to remove connector plate.
F. If required, remove connector plates from aft heat shields (figure 2)as follows:
(1) Remove bolts that secure aft heat shields to connector plates (figure 2, view B) (four locations).
Remove connector plates.

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(2) Remove bolts that secure aft heat shield to connector plate (figure 2, view C). Remove connector
plate.
7. Heat Shields Installation
A. If required, install connector plates onto aft shields (figure 2) as follows:
(1) Lightly coat threads and contact faces of bolts with thread lubricant.
(2) Using bolts, secure aft heat shield onto connector plate (figure 2, view C). Tighten bolts hand-tight.
(3) Using bolts, secure aft heat shield onto connector plate (figure 2, view B) (four locations). Tighten
bolts hand-tight.
B. If required, install conector plates onto forward and mid heat shields (figure 4) as follows:
(1) Using two bolts for each connector plate, secure mid heat shields onto connector plates (figure 4,
view E) (two locations). Tighten bolts hand-tight.
(2) Using one bolt for each long connector plate, secure mid heat shields onto long connector plates and
using one bolt for each short connector plate, secure mid heat shields onto short connector plates
(figure 4, view D) (three locations). Tighten bolts hand-tight.
(3) Using two bolts for each connector plate, secure forward heat shields onto connector plates
(figure 4, view C) (four locations). Tighten bolts hand-tight.
C. Install forward heat shields and mid heat shields as follows (figure 4):
(1) Lightly coat threads and contact faces of bolts and nuts with thread lubricant.
(2) Place top forward heat shield onto forward side of CRF/CRF aft case flange between 10:30 and
1:30 o’clock positions and align matchmarks made per step 6.D.(1).
(3) Place top left mid heat shield onto aft side of CRF/CRF aft case flange between 8:50 and
(4) Secure forward heat shield and mid heat shield onto extended flange bracket (figure 4, section J-J) at
approximately 11:50 o’clock position with bolt (bolthead aft), spacer (under bolthead on aft side of
bracket), washer (under spacer on aft side of bracket), washer (under spacer on forward side of
bracket), spacer (under nut on forward side of bracket), and nut. Tighten nut hand-tight.

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(7) Secure forward heat shield and mid heat shield onto extended flange bracket (figure 4, section H-H)
at approximately 10:45 o’clock position with bolt (bolthead aft), spacer (under bolthead on aft side
of bracket), washer (under spacer on aft side of bracket), and nut. Tighten nut hand-tight.
(8) Place left forward heat shield onto forward side of CRF/CRF aft case flange between 7:30 and
(11) Place bottom left mid heat shield onto aft side of CRF/CRF aft case flange between 6:45 and
(12) Secure forward heat shield and mid heat shield onto extended flange bracket (figure 4, section P-P)
at approximately 8:30 o’clock position with bolt (bolthead aft), spacer (under bolthead on aft side of
bracket), washer (under spacer on aft side of bracket), and nut. Tighten nut hand-tight.
(13) Secure mid heat shield onto extended flange bracket (figure 4, section G-G) at approximately
8:00 o’clock position with bolt (bolthead aft), spacer (under bolthead on aft side of bracket), washer
(under spacer on aft side of bracket), and nut. Tighten nut hand-tight.
at approximately 7:45 o’clock position with bolt (bolthead aft), washer (under spacer on forward
side of bracket), spacer (under nut on forward side of bracket), and nut. Tighten nut hand-tight.
(15) Place bottom forward heat shield onto forward side of CRF/CRF aft case flange between 4:30 and
(17) Place bottom right mid heat shield onto aft side of CRF/CRF aft case flange between 3:45 and

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(19) Secure forward heat shield and mid heat shield onto extended flange bracket (figure 4, section P-P)
(21) Secure forward heat shield onto extended flange bracket (figure 4, section N-N) at approximately
5:15 o’clock position with bolt (bolthead aft), spacer (under nut on forward side of bracket), washer
(under spacer on forward side of bracket), and nut. Tighten nut hand-tight.
(22) Secure mid heat shield onto extended flange bracket (figure 4, section M-M) at approximately
5:00 o’clock position with bolt (bolthead aft), and nut. Tighten nut hand-tight.
(23) Secure mid heat shield and and bracket onto extended flange bracket (figure 4, section L-L) at
approximately 4:50 o’clock position with bolt (bolthead forward), spacer (under bolthead on
forward side of bracket), and washer (under spacer on forward side of bracket). Ensure bracket is on
aft side of extended flange bracket. Tighten bolt hand-tight.
(24) Place right forward heat shield onto forward side of CRF/CRF aft case flange between 1:30 and
(27) Place right mid heat shield onto aft side of CRF/CRF aft case flange between 2:30 and 3:45 o’clock
positions and align matchmarks made per step 6.D.(1).
(29) Secure forward heat shield and mid heat shield onto extended flange bracket (figure 4, section K-K)
at approximately 3:00 o’clock position with bolt (bolthead aft), and nut. Tighten nut hand-tight.
(31) Place top right mid heat shield onto aft side of CRF/CRF aft case flange between 11:50 and

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12:30 o’clock position with bolt (bolthead aft), spacer (under bolthead on aft side of bracket),
washer (under spacer on aft side of bracket), and nut. Tighten nut hand-tight.
(36) Secure mid heat shield and bracket onto extended flange bracket (figure 4, section F-F) at
12:00 o’clock position with bolt (bolthead aft), spacer (under bolthead on aft side of bracket), and
washer (under spacer on aft side of bracket). Ensure bracket is on forward side of extended flange
bracket. Tighten bolt hand-tight.
CAUTION
ENSURE IGNITER PLUG ADAPTER IS RESTRAINED WHEN TIGHTENING COUPLING

D. Install ignition lead onto igniter plug adapter (figure 3). Tighten coupling nut to 23-27 lb ft (32-36 N·m) of
torque
E. Install aft heat shields as follows (figure 2):
(1) Lightly coat threads and contact faces of bolts and nuts with thread lubricant.
(2) Place top right aft heat shield onto forward side of HPT/LPT flange between 11:50 and 2:30 o’clock
positions and align matchmarks made per step 6.B.(1).
(3) Secure top right aft heat shield onto aft heat shield support bracket (figure 2, section D-D) at
1:10 o’clock position with bolt (bolthead aft) and nut. Tighten nut hand-tight.
(4) Secure top right aft heat shield onto remaining five aft heat shield support brackets (figure 2,
section E-E) with bolts (bolthead aft), washers (under spacer on forward side of flange), spacers
(under nut on forward side of flange), and nuts. Tighten nuts hand-tight.
(5) Place right aft heat shield onto forward side of HPT/LPT flange, between 2:30 and 3:45 o’clock
(6) Secure right aft heat shield onto aft heat shield support bracket (figure 2, section D-D) at

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(7) Secure right aft heat shield onto remaining three aft heat shield support brackets (figure 2,
(8) Place bottom right aft heat shield onto forward side of HPT/LPT flange between 3:45 and
6:45 o’clock positions and align matchmarks made per step 6.B.(1).
(9) Secure bottom right aft heat shield onto aft heat shield support bracket (figure 2, section D-D) at
(10) Secure bottom right aft heat shield onto remaining six aft heat shield support brackets (figure 2,
(11) Place bottom left aft heat shield onto forward side of HPT/LPT flange between 6:45 and
8:50 o’clock positions and align matchmarks made per step 6.B.(1).
(12) Secure bottom left aft heat shield onto aft heat shield support bracket (figure 2, section D-D) at
(13) Secure bottom left aft heat shield onto remaining five aft heat shield support brackets (figure 2,
(14) Place top left aft heat shield onto forward side of HPT/LPT flange between 8:50 and 11:50 o’clock
(15) Secure top left aft heat shield onto aft heat shield support bracket (figure 2, section D-D) at
(16) Secure top left aft heat shield onto remaining seven aft heat shield support brackets (figure 2,
(17) Secure aft heat shields onto five connector plates (figure 2, view B and figure 2, view C) with bolts,
spacers (under bolthead), and washers (under spacer). Tighten bolts hand-tight.
(18) Secure aft heat shields onto mid heat shields at 34 places around engine with bolts. Tighten hand
hand-tight.
F. Install HPT borescope cover onto mid and aft heat shields as follows (figure 1):
(1) Lightly coat threads and contact faces of bolts with thread lubricant.
(2) Secure HPT borescope cover onto bottom right mid heat shield and bottom right aft heat shield at
4:45 o’clock and secure with four bolts. Tighten bolts hand-tight.
G. Tighten nuts and bolts as follows:
(1) Tighten 24 nuts that secure forward and mid heat shields onto extended flange brackets to

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(2) Tighten bolt that secures mid heat shield and bracket onto extended flange bracket at 12:00 o’clock
position to 60-70 lb in. (6.8-7.9 N·m) of torque.
(3) Tighten bolt that secures forward heat shield and bracket onto extended flange bracket at 5:00
o’clock position to 60-70 lb in. (6.8-7.9 N·m) of torque.
(4) Tighten 16 bolts that secure forward heat shields onto connector plates to 60-70 lb in. (6.8-7.9 N·m)
of torque.
(5) Tighten 20 bolts that secure mid heat shields onto connector plates to 60-70 lb in. (6.8-7.9 N·m) of
torque.
(6) Tighten 19 bolts that secure aft heat shields onto connector plates to 60-70 lb in. (6.8-7.9 N·m) of
torque (figure 2).
(7) Tighten 32 nuts that secure aft heat shields onto aft heat shield support brackets to 60-70 lb in.
(8) Tighten 34 bolts that secure aft heat shields onto mid heat shields to 60-70 lb in. (6.8-7.9 N·m) of
torque.
(9) Tighten four bolts that secure HPT borescope cover onto aft heat shield and mid heat shield to
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SPRAY INTER-COOLED TURBINE (SPRINT®) KIT
REMOVAL AND INSTALLATION
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Spray Inter-Cooled Turbine (SPRINT®) Kit Installation......................................................................... 5

Spray Inter-Cooled Turbine (SPRINT®) Kit Removal. ........................................................................... 3
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1. Introduction.
This work package contains instructions for removing and installing the spray inter-cooled turbine (SPRINT®)
kit, 738L298. The removal procedure also provides instructions to restore the gas turbine to the original
configuration. The installation procedure can only be used on a gas turbine that is SPRINT® ready.
Title Number
None required.

Cover Plate L46219P01 1
Gasket 9608M08G48 3
Machine Bolt J908P11A 11
Metal Seal Ring J1128P12 1
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6. Spray Inter-Cooled Turbine (SPRINT®) Kit Removal.
A. Remove SPRINT® kit from engine as follows:
(1) Remove coupling clamp (5, figure 1) that secures mini air tube (1) to stage 8 bleed air manifold (4).
Remove and discard metal seal ring (6).
(2) Remove self-locking nuts (8) and machine bolts (7) that secure mini air tube (1) to air tube (2).
(3) Remove mini air tube (1), orifice plate (10), and gaskets (9). Discard gaskets.
(4) Remove self-locking nuts (8) and machine bolts (7) that secure air tube (2) to SPRINT® tube (3).
(5) Remove machine bolts (11, section A-A) and retaining strap (12) that secure air tube (2) to support
bracket (16).
(6) Remove air tube (2) and gasket (9). Discard gasket.
(7) Remove machine bolts (11) and retaining strap (12) that secure SPRINT® tube (3) to SPRINT®
bracket (18) (three locations).
(8) Remove self-locking nuts (14) and machine bolts (13) that secure SPRINT® tube (3) to SPRINT®
tube support bracket (19) and packager tube.
(9) Remove SPRINT® tube (3).
(10) Remove machine bolts (15, section A-A) that secure support bracket (16) to HPC case. Remove
bracket.
(11) Remove machine bolts (15) that secure bracket (17) to HPC case. Remove bracket.
(12) Remove self-locking nuts (21, section B-B) and machine bolts (20) that secure SPRINT® bracket
(18) to air collector (22) flange (three locations). Remove brackets.
(13) Remove self-locking nuts (21) and machine bolts (20) that secure SPRINT® tube support bracket
(19) to air collector (22) flange. Remove bracket.
(14) Remove water nozzles (23) along with air and water tubing and attaching hardware on inlet volute
per packager's manual.
B. If SPRINT® kit will not be reinstalled, return gas turbine to pre-SPRINT® configuration as follows:
(1) Using coupling clamp (5) and new metal seal ring (6), secure cover plate, PN L46219P01, onto
stage 8 bleed air manifold (4). Tighten coupling clamp as follows:
(a) Tighten nut on coupling clamp to 55-65 lb in. (6.3-7.3 N·m) of torque.
(b) Using soft-face mallet, tap around outside of clamp to ensure complete seating.
(c) Final tighten nut to 115-125 lb in. (13.0-14.1 N·m) of torque.
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Figure 1. SPRINT® Kit Removal and Installation (Sheet 1 of 2)

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Figure 1. SPRINT® Kit Removal and Installation (Sheet 2 of 2)

(2) Lightly coat threads and contact faces of new (shorter) machine bolts (20), PN J908P11A, with
thread lubricant.
(3) Install new machine bolts (20) and self-locking nuts (21) into open boltholes in air collector (22)
flange. Tighten nuts to 460-540 lb in. (52.0-61.0 N·m) of torque.
(4) Plug open water nozzle (23) ports in inlet volute per packager’s manual.
7. Spray Inter-Cooled Turbine (SPRINT®) Kit Installation.
A. Install SPRINT® kit onto engine as follows:
(1) For reinstallation of SPRINT® kit, proceed to step step 7.A.(2). For initial installation of SPRINT®
kit, proceed as follows:
(a) Remove self-locking nuts (21) and machine bolts (20) from bolthole locations shown in
figure 1, section B-B. Retain nuts for reuse.
(b) Remove coupling clamp (5), metal seal ring (6) and cover plate from stage 8 bleed air manifold
(4).
(2) Install 17 water nozzles (23) onto inlet volute along with air and water tubing and attaching
hardware per packager's manual.
(3) Lightly coat threads and contact faces of machine bolts (20) with thread lubricant.
(4) Using self-locking nuts (21) and machine bolts (20) secure SPRINT® tube support bracket (19) onto
air collector (22) flange. Tighten nuts to 460-540 lb in. (52.0-61.0 N·m) of torque.
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(5) Using self-locking nuts (21) and machine bolts (20) secure SPRINT® bracket (18) onto air collector
(22) flange (three locations). Tighten nuts to 460-540 lb in. (52.0-61.0 N·m) of torque.
(7) Using machine bolts (15) secure bracket (17) onto HPC case. Tighten bolts to 60-70 lb in.
(8) Using machine bolts (15, section A-A) secure support bracket (16) onto HPC case. Tighten bolts to
60-70 lb in. (6.8-7.9 N·m) of torque.
(10) Using machine bolts (11) and retaining strap (12) secure SPRINT® tube (3) onto SPRINT® bracket
(18) (three locations). Tighten bolts hand-tight.
(11) Using machine bolts (11) and retaining strap (12) secure SPRINT® tube (3) onto bracket (17).
(13) Using self-locking nuts (14) and machine bolts (13) secure SPRINT® tube (3) onto SPRINT® tube
support bracket (19) and packager tube. Tighten nuts to 60-70 lb in. (6.8-7.9 N·m) of torque.
(15) Using machine bolts (11, section A-A) and retaining strap (12), secure air tube (2) onto support
bracket (16). Tighten bolts hand-tight.
(16) Position new gasket (9) between air tube (2) flange and SPRINT® tube (3) flange.
(18) Using self-locking nuts (8) and machine bolts (7), secure air tube (2) onto SPRINT® tube (3).
(19) Using coupling clamp (5) and new metal seal ring (6), secure mini air tube (1) onto stage 8 bleed air
manifold (4). Tighten coupling clamp hand-tight.
(20) Position orifice plate (10) and two gaskets (9) between mini air tube (1) flange and air tube (2)
flange. Ensure orifice plate is between gaskets.
(22) Using self-locking nuts (8) and machine bolts (7), secure mini air tube (1) onto air tube (2). Tighten
(23) Tighten coupling clamp (5) as follows:
(a) Tighten nut on coupling clamp to 55-65 lb in. (6.3-7.3 N·m) of torque.
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(b) Using soft-face mallet, tap around outside of clamp to ensure complete seating.
(c) Final tighten nut to 115-125 lb in. (13.0-14.1 N·m) of torque.
(24) Tighten machine bolts (11, section A-A) that secure air tube (2) onto support bracket (16) to
60-70 lb in. (6.8-7.9 N·m) of torque.
(25) Tighten machine bolts (11) that secure SPRINT® tube (3) onto bracket (17) to 60-70 lb in.
(26) Tighten machine bolts (11) that secure SPRINT® tube (3) onto SPRINT® bracket (18) (three
locations) to 60-70 lb in. (6.8-7.9 N·m) of torque.
%ODQN
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VARIABLE INLET GUIDE VANE (VIGV) ASSEMBLY
REPLACEMENT
())(&7,9,7</03)*$6785%,1(02'(/6

Page No. Change No.
1 - 10 ........................................................................................................................................................ 0
Alphabetical Index
Subject Page
Variable Inlet Guide Vane Assembly Installation. ................................................................................... 7

Variable Inlet Guide Vane Assembly Removal. ....................................................................................... 3
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1. Introduction.
A. This work package contains instructions for removing and installing the variable inlet guide vane (VIGV)
assembly.
B. Remove low pressure compressor temperature/pressure (T2/P2) sensor per WP 1111 00.
Title Number
Low Pressure Compressor Inlet Temperature/Pressure WP 1111 00
(T2/P2) Sensor Replacement

Fixture Assembly, Lift and Turn - VIGV 1C9390G01
Nitrogen (Optional) BB-N-411

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6. Variable Inlet Guide Vane Assembly Removal.
A. Using marking pen, mark position of brackets to low pressure compressor (LPC) stages 0-3 stator case
forward flange.
B. Remove VIGV actuators and mount brackets as follows:
WARNING
CAUTION
OPERATION.
(1) Tag and disconnect electrical connectors from VIGV actuators.
(2) Disconnect tubing coupling nuts from VIGV actuator fittings as follows (figure 1):
Figure 1. Variable Inlet Guide Vane (VIGV) Tubing
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WARNING

(a) Position a waste fluid container beneath VIGV actuator. Disconnect drain lines from drain
adapters.
(b) Disconnect drain adapters from VIGV actuator. Slide drain adapters away from VIGV actuator
ports to expose coupling nuts.
CAUTION
COUPLING NUT. FAILURE TO COMPLY MAY RESULT IN PART
DAMAGE.
(c) Disconnect coupling nuts from VIGV actuator fittings.
(d) Remove and discard preformed packings.
(3) Remove nuts and bolts that secure actuator-to-ring brackets to actuation ring (figure 2). Remove
actuator-to-ring brackets.
(4) Remove nuts, bolts, and bushings that secure actuator rod-ends.
(5) Remove nuts and bolts that secure VIGV actuator stationary mount brackets onto LPC stator case
front flange/VIGV stator case rear flange.
(6) Remove nuts and bolts from actuator bearing blocks.
(7) Remove actuators and stationary mount brackets as units.
C. Install lift and turn fixture, 1C9390, as follows (figure 3):
(1) Connect lift and turn fixture, 1C9390, onto 1 ton (907 kg) capacity hoist.
(2) Position lift and turn fixture, 1C9390, onto VIGV assembly forward flange.
(3) Using bolts and washers, secure lift and turn fixture, 1C9390, onto VIGV assembly forward flange.
Boltheads face aft. Tighten bolts to 46-54 lb in. (5.2-6.1 N·m) of torque.
D. Remove nuts, bolts, and washers that secure VIGV assembly aft flange onto LPC forward flange.
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Figure 2. VIGV Actuators and Mount Brackets
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Figure 3. VIGV Lift and Turn Fixture Assembly, 1C9390
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WARNING
ALWAYS USE APPROVED EQUIPMENT AND PROCEDURES TO LIFT PARTS. STAY OUT
FROM BELOW LOADS. IF THE PARTS ACCIDENTALLY MOVE OR FALL, THEY CAN
CAUSE AN INJURY OR DEATH.
E. Tap VIGV assembly forward flange using soft-face mallet. Move VIGV assembly forward until aft rabbet
clears LPC stages 0-3 stator case forward flange.
7. Variable Inlet Guide Vane Assembly Installation.
A. Install lift and turn fixture, 1C9390, as follows:
(1) Connect lift and turn fixture, 1C9390, onto 1 ton (907 kg) capacity hoist.
(2) Position lift and turn fixture, 1C9390, onto VIGV assembly forward flange.
(3) Using bolts and washers, secure lift and turn fixture, 1C9390, onto VIGV assembly forward flange.
Boltheads face aft. Tighten bolts to 46-54 lb in. (5.2-6.1 N·m) of torque.
B. Lift VIGV assembly into position on LPC stages 0-3 stator case forward rabbet.
C. Apply thread lubricant to threads and washer faces of bolts that secure VIGV assembly aft flange to LPC
forward flange.
D. Install brackets, bolts, washers, and nuts to secure VIGV assembly aft flange to LPC forward flange.
Boltheads face aft. Washer is under nut at bracket locations. At all other flange locations, washers are
under boltheads and nuts.
E. Tighten nuts to 368-432 lb in. (41.6-48.8 N·m) of torque.
F. Remove bolts and nuts that secure lift and turn fixture, 1C9390, onto VIGV assembly forward flange.
Remove lift and turn fixture.
G. Install VIGV actuators as follows (figure 2):
(1) Install bushings into actuator-to-ring brackets so bushing flanges are to outside of brackets.
(2) Apply thread lubricant onto threads of actuator rod-end retaining bolt.
(3) Using bolt (bolthead outboard) and nut, secure actuator-to-ring brackets to VIGV actuator rod-end.
Tighten nut to 193-227 lb in. (21.9-25.6 N·m) of torque.
(4) Apply thread lubricant to threads and mating surfaces of bracket retaining nuts.
(5) Align actuator-to-ring brackets with bushings installed in actuation ring. Install eight bolts
(boltheads are outside brackets) and nuts. Tighten nuts to 368-432 lb in. (41.6-48.8 N·m) of torque.
(6) Position VIGV actuator forward and aft stationary mount brackets and electrical bracket as marked
during disassembly.
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NOTE
Boltheads will face forward on VIGV actuator stationary mount flange bolts adjacent to
the left speed sensor.
(7) Using bolts and nuts, secure forward and aft stationary mounts, and electrical bracket, onto VIGV
stator case and stages 0-3 stator case. Boltheads face aft, except for two bolts adjacent to left speed
sensor.
(8) Using bolts and nuts, secure actuator bearing blocks onto forward and aft stationary mounts.
Boltheads face forward.
(9) Tighten stationary mount brackets and actuator bearing block bolts and nuts to 368-432 lb in.
(41.6-48.8 N·m) of torque.
WARNING

(10) Lubricate new packings, PN 9365M41P117 and PN 9365M41P122, with lubricating oil and install
in drain adapters (figure 1).
CAUTION
(11) Connect tubing to actuator fittings. Tighten coupling nuts to 460-540 lb in. (52.0-61.0 N·m) of
torque.
(12) Leak-check head- and rod-end fittings as follows:
CAUTION
USE HYDRAULIC ACTUATOR UNIT, 1C3569G3, WITH ENGINES
THAT USE LUBRICATING OIL, MIL-PRF-23699F (C/I). DO NOT
INTERMIX LUBRICATING OIL, MIL-PRF-7808 AND MIL-PRF-23699F
(C/I), OR DAMAGE WILL OCCUR.
(a) Install reducers from adapter set, 1C9393, on hydraulic actuator unit, 1C3569G3. Tighten
reducers to 133-157 lb in. (15.1-17.7 N·m) of torque.
(b) Disconnect head tube from hydraulic control unit (HCU). Install head tube onto -4 to -10
reducer. Tighten coupling nut to 350-410 lb in. (39.6-46.3 N·m) of torque.
(c) Disconnect rod tube from HCU. Install rod tube onto -4 to -8 reducer. Tighten coupling nut to
262-308 lb in. (29.7-34.7 N·m) of torque.
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WARNING
SERIOUS INJURY CAN OCCUR WHEN APPLYING HYDRAULIC

PRESSURE. EYE PROTECTION IS REQUIRED. RELIEVE PRESSURE
BEFORE DISCONNECTING LINES AND FITTINGS.
(d) Apply 200-250 psi (1379-1723 kPa) to head tube and hold for a minimum of 2 minutes. Check
head tube/actuator connection for leakage.
(e) Apply 200-250 psi (1379-1723 kPa) to rod tube and hold for a minimum of 2 minutes. Check
rod tube/actuator connection for leakage.
(f) Check VIGV actuation system per WP 1113 00.
(g) Disconnect hydraulic actuator unit, 1C3569. Remove reducers.
(h) Connect head tube to HCU. Tighten coupling nut to 55-65 lb ft (75-88 N·m) of torque.
(i) Connect rod tube to HCU. Tighten coupling nut to 460-540 lb in. (52.0-61.0 N·m) of torque.
(13) Slide drain adapters over coupling nuts and connect to actuator ports. Hand-tighten drain adapters.
(14) Leak-check drain adapters as follows:
WARNING
NITROGEN, BB-N-411, CAN DISPLACE OXYGEN IN ENCLOSED
AREAS. USE IN A WELL-VENTILATED AREA.
(a) Connect a source of clean, dry, regulated shop air or nitrogen to drain line fitting on drain
adapter.
WARNING
SERIOUS INJURY CAN OCCUR WHEN APPLYING PNEUMATIC
PRESSURE. EYE PROTECTION IS REQUIRED. RELIEVE PRESSURE
BEFORE DISCONNECTING LINES AND FITTINGS.
(b) Apply 50-55 psi (345-379 kPa) to drain adapter. Shut off pressure and monitor. Pressure shall
not drop off more than 10 psi (69 kPa) in 2 minutes.
(c) If pressure drop limit is exceeded, use soap solution to detect leak. Repair, as required, and
repeat leak check.
(d) Disconnect test equipment from drain adapter.
(e) Connect drain lines to drain adapters. Tighten coupling nuts to 262-308 lb in. (29.7-34.7 N·m)
of torque.
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(15) Connect electrical connector to VIGV actuator as follows:
(a) Engage connector with mating interface and turn knurled coupling ring while wiggling back
shell assembly.
NOTE
(d) Repeat step 7.G.(15)(b) and step 7.G.(15)(c), as required. It may be necessary to loosen lead

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LOW PRESSURE COMPRESSOR (LPC) MODULE
REPLACEMENT
())(&7,9,7</03)*$6785%,1(02'(/6

Page No. Change No.
1 - 13 ........................................................................................................................................................ 0
14 Blank ................................................................................................................................................... 0
Alphabetical Index
Subject Page
Low Pressure Compressor Module Installation. ..................................................................................... 10

Low Pressure Compressor Module Removal........................................................................................... 3
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1. Introduction.
A. This work package contains instructions for removing and installing the low pressure compressor (LPC)
module.
B. Disconnect and connect electrical leads and connecting tubes between LPC module and gas turbine per
SWP 1913 04.
C. Remove and install the variable inlet guide vane (VIGV) per WP 2110 00.
Title Number
Variable Inlet Guide Vane (VIGV) Assembly Replacement WP 2110 00

Fixture, Lift and Turn - LPC Rotor and Stator 1C9053G01
Fixture, Lift - LPC Rotor and Stator, Horizontal 1C9054G02
Fixture, Lift - LPC Rotor and Stator, Forward 1C9116G01
Tool Set, Jackscrew 1C9150G02
Adapter, Support/Lift - LPC 1C9317G01
Fixture, Support - LPC Rotor/Stator 1C9385G01
Dolly, LPC Rotor and Stator - Vertical 1C9440G01
Guide Pin - Fan Rotor Installation 2C6348P02
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6. Low Pressure Compressor Module Removal.
A. Remove forward manifold as follows (figure 1):
(1) Using marking pen, matchmark forward manifold and forward drive adapter.
(2) Remove bolts that secure forward manifold onto forward drive adapter.
(3) Using four jackscrews from jackscrew tool set, 1C9150, remove forward manifold.
B. Install LPC support/lift adapter, 1C9317, and LPC horizontal lift fixture, 1C9054, as follows:
(1) Install LPC forward lift fixture, 1C9116, onto LPC horizontal lift fixture, 1C9054, at position
marked 1C9054. Secure with quick-release pin (figure 2).
WARNING
(2) Connect 4 ton (3629 kg) capacity hoist onto LPC forward lift fixture, 1C9116. Lift LPC horizontal
lift fixture, 1C9054, into position on LPC support/lift adapter, 1C9317. Secure with two
quick-release pins.
(3) Reposition hoist onto LPC horizontal lift fixture, 1C9054.
(4) Position LPC support/lift adapter, 1C9317, so that inner ring boltholes align with forward drive
adapter boltholes.
(5) Using 16 bolts and nuts, secure LPC support/lift adapter, 1C9317, inner ring onto forward drive
adapter. Tighten nuts to 170-200 lb in. (19.3-22.5 N·m) of torque.
(6) Using 56 equally spaced screws and nuts, secure outer ring of LPC support/lift adapter, 1C9317,
onto stator case forward flange. Tighten nuts to 170-200 lb in. (19.3-22.5 N·m) of torque.
C. Separate LPC module from fan shaft assembly as follows:
(1) If necessary to gain access, move actuation ring to aftmost position by actuating variable bypass
valve (VBV) doors to fully closed. Refer to WP 1312 00.
(2) Remove bolts that secure LPC aft fan case aft flange onto front frame forward face.
(3) Remove bolts, washers, and nuts that secure rotor shaft onto fan shaft assembly.
*(. /03)
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Figure 1. Low Pressure Compressor (LPC) Module
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Figure 2. LPC Support/Lift Adapter, 1C9317, and LPC Horizontal Lift Fixture, 1C9054
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NOTE
Perform step 6.C.(4) only if same LPC module will be reinstalled.
(4) Using marking pen, matchmark rotor shaft to forward fan shaft assembly.
WARNING
CAUTION
USE CARE TO KEEP LPC ROTOR HORIZONTAL DURING DISENGAGEMENT
FROM FAN SHAFT ASSEMBLY TO PREVENT ROTOR DAMAGE.
(5) Pull rotor forward from fan shaft. Simultaneously support LPC rotor using overhead hoist. Closely
monitor disengagement to prevent damage.
(6) Move LPC module forward, beyond No. 1 bearing seal.
(7) Remove and discard preformed packing from rotor shaft (figure 3).
Figure 3. Packing Installation
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NOTE
If LPC module is to be placed forward end down for stage 3 stator vane or stage 4 rotor
blade replacement, proceed to step 6.E.
D. Install LPC module onto LPC support fixture, 1C9385, as follows (figure 4):
(1) Move LPC module clear of gas turbine.
(2) Install LPC forward lift fixture, 1C9116, onto LPC horizontal lift fixture, 1C9054, at location
marked 1C9050, LPCR. Secure with quick-release pin.
(3) Connect second 4 ton (3629 kg) capacity hoist onto LPC forward lift fixture, 1C9116.
WARNING

(4) Rotate LPC module so that forward end is up.
(5) Remove hoist from LPC horizontal lift fixture, 1C9054.
(6) Position LPC support fixture, 1C9385, beneath suspended LPC module.
(7) Lower LPC module onto LPC support fixture, 1C9385, and secure with washers and nuts.
(8) Remove nuts and bolts that secure LPC support/lift adapter, 1C9317, onto LPC module.
marked 1C9054. Secure with quick-release pin.
(10) Connect hoist onto LPC forward lift fixture, 1C9116. Lift assembled LPC horizontal lift fixture,
1C9054, and LPC support/lift adapter, 1C9317, from LPC assembly.
NOTE
If LPC module has been installed in LPC support fixture, 1C9385, per step 6.D., disregard step 6.E.
E. Install LPC module into LPC vertical dolly, 1C9440, as follows:
(1) Move LPC module clear of gas turbine.
(2) Install LPC lift and turn fixture, 1C9053, into bore of LPC rotor shaft (figure 5).
(3) Attach forward end of LPC lift and turn fixture, 1C9053, onto LPC horizontal lift fixture, 1C9054.
Secure with quick-release pin.
(4) Attach second 4 ton (3629 kg) capacity hoist onto eye of LPC lift and turn fixture, 1C9053.
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Figure 4. LPC Support Fixture, 1C9385
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Figure 5. LPC Lift and Turn Fixture, 1C9053
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WARNING

(5) Rotate LPC module so that forward end is down.
(6) Remove hoist from LPC horizontal lift fixture, 1C9054.
(7) Position LPC vertical dolly, 1C9440, beneath suspended LPC module.
(8) Lower LPC module onto LPC vertical dolly, 1C9440, so that LPC horizontal lift fixture, 1C9054, is
between dolly supports. Remove quick-release pin and remove LPC lift and turn fixture, 1C9053.
(figure 6).
marked 1C9054, 1C9050. Secure using quick-release pin.
(10) Connect hoist to forward lift fixture, then lift assembled LPC horizontal lift fixture, 1C9054, and
LPC support/lift adapter, 1C9317, from LPC assembly.
7. Low Pressure Compressor Module Installation.
NOTE
If LPC module is in a forward end down position, proceed to step 7.B.
A. Install LPC support/lift adapter, 1C9317, and LPC horizontal lift fixture, 1C9054, as follows:
(1) Install LPC forward lift fixture, 1C9116, onto LPC horizontal lift fixture, 1C9054, at position
marked 1C9054. Secure with quick-release pin (figure 2).
(2) Connect 4 ton (3269 kg) capacity hoist onto LPC forward lift fixture, 1C9116. Lift LPC horizontal
lift fixture, 1C9054, into position on LPC support/lift adapter, 1C9317. Secure with two quick-
release pins.
(3) Move LPC forward lift fixture, 1C9116, into position marked 1C9054, 1C9050. Secure with quick-
release pin.
(4) Position LPC support/lift adapter, 1C9317, so that inner ring boltholes align with forward drive
adapter boltholes.
(5) Using 16 bolts and nuts, secure LPC support/lift adapter, 1C9317, inner ring onto forward drive
adapter outer flange. Tighten nuts to 170-200 lb in. (19.3-22.5 N·m) of torque.
(6) Using 56 equally spaced screws and nuts, secure outer ring of LPC support/lift adapter, 1C9317,
onto LPC stages 0-3 stator case forward flange. Tighten nuts to 170-200 lb in. (19.3-22.5 N·m) of
torque.
(7) Move LPC forward lift fixture, 1C9116, to position marked 1C9054, 1C9050, LPCR. Secure with
quick-release pin.

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Figure 6. LPC Vertical Dolly, 1C9440

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(8) Connect second 4 ton (3269 kg) capacity hoist onto LPC horizontal lift fixture, 1C9054.
WARNING

(9) Lift and rotate LPC module into horizontal position. Remove LPC forward lift fixture, 1C9116.
NOTE
If LPC module has been rotated to the horizontal position per step 7.A., proceed to step 7.C.
B. Install LPC lift and turn fixture, 1C9053, as follows:
(1) Connect 4 ton (3269 kg) capacity hoist onto LPC lift and turn fixture, 1C9053.
(2) Install LPC lift and turn fixture, 1C9053, into bore of LPC rotor shaft (figure 5).
(3) Attach forward end of LPC lift and turn fixture, 1C9053, onto LPC horizontal lift fixture, 1C9054.
Secure with quick-release pin (part of 1C9054).
(4) Attach second 4 ton (3629 kg) capacity hoist onto LPC horizontal lift fixture, 1C9054.
(5) Lift and rotate LPC module into horizontal position.
(6) Remove hoist from LPC lift and turn fixture, 1C9053.
(7) Remove LPC lift and turn fixture, 1C9053.
(8) Adjust center of gravity of LPC horizontal lift fixture, 1C9054, until LPC module is horizontal.
C. Lubricate new preformed packing, PN 9607M05P21, with petrolatum, and install into rotor shaft
preformed packing groove (figure 3).
D. Install guide pins, 2C6348P02, at three equally spaced locations on fan shaft flange.
CAUTION
IF SAME LPC ROTOR IS BEING INSTALLED, ENSURE THAT ALIGNMENT MARKS ARE
ALIGNED PROPERLY. FAILURE TO COMPLY WILL REQUIRE THAT LP SECTION BE
BALANCED.
E. If same LPC module is being installed, align matchmark on rotor shaft with that on fan shaft assembly.
F. Position LPC module so that offset boltholes at top vertical centerline align.
G. Push LPC module aft so that aft fan case aft flange mates with forward face of front frame and aft rabbet of
rotor shaft mates with fan shaft assembly. Ensure flanges and shafts are fully seated.
H. Remove three guide pins, 2C6348P02.

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I. Apply thread lubricant onto threads of bolts and onto threads and washer faces of nuts which secure rotor
shaft onto fan shaft assembly.
J. Using bolts, washers, and nuts, secure rotor shaft onto fan shaft assembly. Boltheads face aft, washers
under nuts.
K. Using crisscross pattern, tighten nuts to 258-302 lb ft (350-409 N·m) of torque. Bolts shall not rotate
during torquing. Wipe excess lubricant from nuts.
L. Loosen bolts that secure LPC support/lift adapter, 1C9317, onto LPC stages 0-3 stator case (figure 4).
M. Apply thread lubricant to threads of bolts which secure aft fan case aft flange onto front frame forward
face.
N. Using bolts, secure aft fan case aft flange onto front frame forward face.
O. Tighten bolts to 106-124 lb in. (12.0-14.0 N·m) of torque.
P. Remove LPC horizontal lift fixture, 1C9054, and LPC support/lift adapter, 1C9317 (figure 2).
Q. Install forward manifold as follows:
(1) Apply thread lubricant to threads of bolts that secure forward manifold to forward drive adapter.
(figure 1).
(2) Install forward manifold onto forward drive adapter, aligning matchmarks. Secure with bolts.
(3) Using crisscross pattern, tighten bolts to 106-124 lb in. (12.0-14.0 N·m) of torque.
%ODQN
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LOW PRESSURE COMPRESSOR (LPC) STAGE 0 ROTOR
BLADES REPLACEMENT
())(&7,9,7</03)*$6785%,1(02'(/6

Page No. Change No.
1 - 9 .......................................................................................................................................................... 0
10 Blank ................................................................................................................................................... 0
Alphabetical Index
Subject Page
LPC Stage 0 Rotor Blades Installation..................................................................................................... 5

LPC Stage 0 Rotor Blades Removal. ....................................................................................................... 3
Part Rework - Tip Grinding to Obtain Blade Tip to Stator Case Clearance. ........................................... 8
Replacement Blades Selection. ................................................................................................................ 5
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1. Introduction.
A. This work package contains instructions for removing and installing low pressure compressor (LPC)
stage 0 rotor blades.
B. Remove variable inlet guide vane (VIGV) assembly per WP 2110 00 to gain access.
Title Number

Program, Balance - Blade Replacement 9446M61G02
(or latest CD-Rom version)
Sharpening Stone Fed Spec SS-S-736
None required.
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6. LPC Stage 0 Rotor Blades Removal.
A. Remove blade retainer as follows (figure 1):
CAUTION
ENSURE MATCHMARKS ARE NOT ERASED DURING MAINTENANCE.

IMPROPER INSTALLATION OF COMPONENTS WILL CAUSE ROTOR
IMBALANCE.
NOTE
The following procedure is for replacement of any number of LPC stage 0 rotor blades.
Instructions for grinding blade tips to meet clearance requirements are included. If an
entire stage of blades requires replacement, contact General Electric Customer Service
Representative to obtain a set of preground blades.
(1) Using marking pen, matchmark blade retainer to stage 0 disk.
(2) Using marking pen, mark location of balance bolts.
Figure 1. LPC Stage 0 Rotor Blade Replacement
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(3) Remove balance bolts, washers, and nuts. Maintain each balance bolt and related washer and nut
together as a set.
(4) Weigh each balance bolt set and record on position map (figure 2).
(5) Remove bolts, washers, and nuts that secure blade retainer. Maintain each bolt and related washer
and nut together as a set. Remove blade retainer.
B. Using marking pen, position mark stage 0 blades to be removed and corresponding dovetail slot on stage 0
disk. If all stage 0 rotor blades are being replaced, position mark No. 1 and No. 5 dovetail slots on stage 0
disk.
C. Measure blade tip to stator case clearance of blades being replaced as follows:
(1) Pull blade radially outward. Shake blade to ensure it is at its most outward position.
(2) Measure clearance between blade tip and edge of stator case. Measurement may be taken from any
area on blade tip, provided each blade is measured from the same area. Record clearance.
(3) Repeat step 6.C.(1) and step 6.C.(2) for each blade requiring replacement.
D. Slide stage 0 blade forward to remove.
Figure 2. LPC Stage 0 Blade/Balance Bolt Position Map
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7. Replacement Blades Selection.
A. Weigh removed blades and record on position map (figure 2).
NOTE
Replacement blades shall be weighed after tip grinding to meet clearance requirement.
B. Weigh replacement blades. Mark weight on blade using marking pen.
NOTE
If individual stage 0 rotor blades are being replaced, select blades per step 7.C. If all stage 0 rotor
blades are being replaced, calculate blade position per step 7.D.
C. Select replacement blade within 0.5 gram of original blade. Blades replacing those with portions missing
shall weigh within 0.5 gram of the average of eight serviceable blades. If replacement blade within
0.5 gram of original blade is not available, use blade replacement guide (figure 3).
NOTE
For a copy of GE computerized balance program and instructions for use, contact GE customer
service.
D. Calculate blade position using GE computerized balance program, 9446M61. Mark position on
replacement blade using marking pen.
8. LPC Stage 0 Rotor Blades Installation.
WARNING
A. Apply molybdenum disulfide lubricant to pressure surfaces of stage 0 blade dovetails (figure 4).
B. Slide stage 0 blade into corresponding dovetail slot in stage 0 disk (figure 1).
NOTE
If preground blades are installed, proceed to step 8.D.
C. Measure blade tip to stator case clearance as follows:
(2) Measure clearance between blade tip and edge of stator case. Take measurement from same area on
replacement blade tip as that used to measure replaced blade clearance.
(3) Repeat step 8.C.(1) and step 8.C.(2) for each blade requiring replacement.
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Figure 3. Blade Replacement Guide
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Figure 4. Blade Dovetail Pressure Surface
D. Apply thread lubricant to threads of all nuts and bolts.
CAUTION
ENSURE RUN-ON TORQUE FOR ALL NUTS IS A MINIMUM OF 5 LB IN. (0.6 N·M) TO
ENSURE INTEGRITY OF LOCKING FEATURE.
E. Align matchmark on blade retainer with matchmark on stage 0 disk and install blade retainer. Secure blade
retainer with 12 equally spaced nuts, washers, and bolts, boltheads aft, washer under nut.
F. Tighten nuts to 190-220 lb in. (21.5-24.8 N·m) of torque. Back off nuts one-half turn, then tighten to
190-220 lb in. (21.5-24.8 N·m) of torque.
G. Install remaining bolts, washers, and nuts that secure blade retainer, boltheads aft, washer under nut.
H. Tighten nuts to 190-220 lb in. (21.5-24.8 N·m) of torque. Back off nuts one-half turn, then tighten to
190-220 lb in. (21.5-24.8 N·m) of torque.
I. Install balance bolts, washers, and nuts into previously marked positions, boltheads aft, washer under nut.
Tighten nuts to 106-124 lb in. (12.0-14.0 N·m) of torque. A minimum of 0.060 inch (1.52 mm) of threads
shall protrude beyond nut after torquing.
*(. /03)
:3
9. Part Rework - Tip Grinding to Obtain Blade Tip to Stator Case Clearance.
WARNING
TITANIUM DUST IS FLAMMABLE. DO NOT ALLOW THE DUST TO COLLECT. DO NOT

USE WATER TO EXTINGUISH A TITANIUM FIRE. EXTINGUISH WITH AN APPROVED
CHEMICAL FOR METAL FIRES.
CAUTION
DO NOT USE HARD ABRASIVE GRINDING WHEELS TO TIP GRIND BLADES. DAMAGE
TO BLADES MAY OCCUR.
CAUTION
TO AVOID CONTAMINATION OF TITANIUM BLADES, DO NOT USE SHARPENING

STONES THAT HAVE BEEN USED ON OTHER METALS.
A. Hand-blend replacement blade tip using sharpening stone and observe the following:
(1) Minimum and maximum blade clearance for stage 0 is shown on figure 5. Replacement blade shall
not exceed length of longest blade in stage 0, or be shorter than shortest blade in stage 0.
(2) Do not remove more than 0.007 inch (0.18 mm) of material from blade tip.
(3) Maintain original contour of blade.
B. Break all edges 0.005-0.015 inch (0.13-0.38 mm).
/03) *(.
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Figure 5. LPC Stage 0 Rotor Blade to Stator Case Clearance
%ODQN
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LOW PRESSURE COMPRESSOR (LPC) STAGES 0-3
UPPER AND LOWER STATOR CASE REPLACEMENT
())(&7,9,7</03)*$6785%,1(02'(/6

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Alphabetical Index
Subject Page
LPC Stages 0-3 Lower Stator Case Installation. ...................................................................................... 7

LPC Stages 0-3 Lower Stator Case Removal........................................................................................... 6
LPC Stages 0-3 Upper and Lower Stator Cases Removal. ...................................................................... 3
LPC Stages 0-3 Upper Stator Case Installation........................................................................................ 8
LPC Stages 0-3 Upper Stator Case Removal. .......................................................................................... 5
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1. Introduction.
stages 0-3 upper and lower stator cases, with engine installed in maintenance dolly.
B. If upper and lower LPC stator cases are being removed, remove the VIGV assembly WP 2110 00.
Title Number

Fixture, Lift - LPC Case, Stages 0-3 1C9602G01
None required.
/03) *(.
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6. LPC Stages 0-3 Upper and Lower Stator Cases Removal.
NOTE
If only the upper stator case requires removal, proceed to paragraph 7.
A. Remove variable inlet guide vane (VIGV) assembly per WP 2110 00.
WARNING
CAUTION

NOTE
If VIGV kit is installed, perform step 6.B and step 6.C.
B. Position waste fluid container beneath hydraulic control unit (HCU). Disconnect variable inlet guide vane
(VIGV) tubing coupling nuts from HCU fittings. Install protective caps/plugs (figure 1).
C. Disconnect VIGV actuator drain line flexible hose from drain line manifold.
WARNING

CAUTION
OPERATION.
D. Tag and disconnect electrical connectors at No. 1 electrical interface panel.
E. Remove nuts and bolts that secure No. 1 electrical interface panel aft support bracket onto air collector.
*(. /03)
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Figure 1. No. 1 Electrical Interface Panel, VIGV Tubing, Channel Bracket, and Electrical Cables
/03) *(.
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F. Remove nuts and bolts that secure channel bracket tray onto rear electrical panel support bracket.
G. Using marking pen, mark location of brackets.
H. Remove No. 1 electrical interface panel, VIGV tubing and brackets (if installed), channel bracket, and
electrical cables and brackets as a unit.
I. Remove LPC stages 0-3 upper stator case per paragraph 7.
J. Remove LPC stages 0-3 lower stator case per paragraph 8.
7. LPC Stages 0-3 Upper Stator Case Removal.
NOTE
If both upper and lower stator cases require removal, proceed to step 7.B.
A. If only upper stator case requires removal, remove and disconnect the following:
(1) Disconnect T2 electrical lead from bracket clips on upper case forward flange.
NOTE
If VIGV kit is installed, perform step 7.A.(2) and step 7.A.(3).
(2) Disconnect left VIGV hydraulic actuator from upper (stationary) bracket.
(3) Disconnect right VIGV hydraulic actuator from actuation ring bracket.
B. Remove bolts, nuts, and washers from forward and aft flanges of stages 0-3 upper case. Remove and retain
doublers.
C. Remove bolts, nuts, and washers that secure horizontal flanges of stages 0-3 case. If necessary, gently tap
five body-bound bolts on each horizontal flange using hammer and nylon drift to release bolts.
D. Attach lift fixture, 1C9602, onto forward and aft flanges of stages 0-3 upper case (figure 2).
WARNING
E. Attach 1 ton (907 kg) capacity overhead hoist to lift fixture. Lift stages 0-3 upper case free of gas turbine
and place on suitable pallet using care not to damage horizontal flange surfaces or internal hardware. If
new case will be installed, transcribe bracket matchmarks to new case using marking pen.
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Figure 2. LPC Stages 0-3 Case Lift Fixture, 1C9602
8. LPC Stages 0-3 Lower Stator Case Removal.
A. Remove bolts, nuts, and washers that secure aft flange of stages 0-3 lower case to aft fan case. Remove and
retain doublers.
WARNING
NOTE
Nylon straps may be used to lower or elevate the lower stator case. Attach hoist to nylon straps.
B. Place nylon straps under stages 0-3 lower case. Raise straps to support stages 0-3 lower case (figure 3).
C. Remove bolts, nuts, and washers that secure horizontal flanges of stages 0-3 case. If necessary, gently tap
five body-bound bolts on either horizontal flange using hammer and nylon drift to release bolts.
D. Slowly lower stages 0-3 lower case. If new case is to be installed, transcribe bracket matchmarks to new
case using marking pen.
/03) *(.
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Figure 3. LPC Stator Lower Case Support
9. LPC Stages 0-3 Lower Stator Case Installation.
WARNING
A. Position stages 0-3 lower case under LPC rotor using nylon straps and hoist.
B. Slowly raise stages 0-3 lower case until LPC stator case aft flange and aft fan case forward flange boltholes
align.
WARNING
ZINC CHROMATE PRIMER, TT-P-1757, IS HIGHLY TOXIC TO SKIN, EYES, AND
RESPIRATORY TRACT. SKIN AND EYE PROTECTION, AND VAPOR CONTROL ARE
C. Apply zinc chromate primer onto shank and bearing surface of bolts which secure aft circumferential
flange of stages 0-3 case onto aft fan case. Allow primer to air dry.
D. Apply thread lubricant onto threads and bearing surface of aft circumferential flange bolts.
E. Install bolts and nuts into aft circumferential flange, boltheads aft, doublers on forward side of aft
circumferential flange. Tighten nuts finger-tight.
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10. LPC Stages 0-3 Upper Stator Case Installation.
WARNING
A. Position stages 0-3 upper case over LPC rotor using lift fixture, 1C9602, and a 1 ton (907 kg) capacity
overhead hoist. Inspect flanges for cleanliness.
B. Install washers on five body-bound bolts.
C. Install body-bound bolts, boltheads down, through lower stator case. Install bolts into horizontal flange
bolthole numbers 1, 4, 9, 13, and 17 (boltholes are counted from forward flange) on both sides of stator
case (figure 4).
CAUTION
BE CAREFUL WHEN MATING UPPER AND LOWER STAGES 0-3 CASE HALVES. THE
INNER SHROUDS HAVE INTERLOCKING FEATURES AT THE HORIZONTAL
SPLITLINES. THE UPPER AND LOWER STATOR SHROUDS SHALL BE PROPERLY
ENGAGED AS THE CASE HALVES ARE MATED. DO NOT FORCE CASE HALVES
TOGETHER. FAILURE TO COMPLY WILL RESULT IN LPC STATOR DAMAGE.
D. Slowly lower stages 0-3 upper case until horizontal flanges are mated. Use flashlight to ensure that shrouds
interlock properly.
E. Remove lift fixture, 1C9602.
F. Install washers and nuts onto body-bound bolts. Tighten nuts finger-tight.
WARNING

G. Apply zinc chromate primer onto shanks and bearing surfaces of remaining bolts and washers which
secure horizontal flanges together. Also apply zinc chromate primer onto inside diameter of boltholes these
bolts go through.
NOTE
Casing assembly procedure: L refers to 9:00 o’clock position flange and R refers to 3:00 o’clock
position flange.
H. Install remaining horizontal flange bolts, washers, and nuts, boltheads up, with washer under each nut and
each bolthead. Tighten nuts on non-body-bound bolts, left to right, in ascending order 2L, 2R, 3L, 3R, 5L,
5R, etc., to 193-227 lb in. (21.9-25.6 N·m) of torque.
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Figure 4. LPC Stages 0-3 Stator Case Horizontal Flanges
*(. /03)
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I. Tighten horizontal flange nuts on body-bound bolts in ascending order 1L, 1R, 4L, 4R, 9L, 9R, etc., to
193-227 lb in. (21.9-25.6 N·m) of torque.
WARNING
J. Apply zinc chromate primer onto shank and bearing surface of bolts which secure aft circumferential
flange. Allow primer to dry.
K. Apply thread lubricant onto threads and bearing surfaces of aft circumferential flange bolts.
L. Install bolts, doublers, and nuts in aft circumferential flange, boltheads aft, doublers on forward side of aft
circumferential flange.
M. Tighten all aft circumferential flange nuts to 129-151 lb in. (14.6-17.0 N·m) of torque.
N. Remove nylon straps.
NOTE
If the VIGV assembly is not installed, proceed to step 10.P.
O. If VIGV assembly or inlet frame assembly is installed, complete the following steps.
(1) Install brackets, bolts, washers, and nuts into forward circumferential flange per WP 2110 00.
(2) Connect VIGV hydraulic actuators per WP 2110 00.
(3) Install T2 electrical lead into bracket clips on upper case forward flange.
NOTE
If the VIGV assembly is installed, disregard the remaining steps.
P. Install assembled No. 1 electrical interface panel, VIGV tubing and brackets, channel bracket, and
electrical cables and brackets as a unit. Align brackets at locations marked at removal (figure 1).
Q. Using bolts and nuts, secure No. 1 electrical interface panel aft mount brackets onto air collector flange.
R. Using bolts and nuts, secure channel bracket to rear electrical panel support bracket. Tighten nuts to
57-67 lb in. (6.5-7.5 N·m) of torque.
S. Connect electrical connectors at No. 1 electrical interface panel locations tagged at removal as follows.
Remove tags.

/03) *(.
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WARNING

assembly.
mating connector.
NOTE
(4) Repeat step 10.S.(2) and step 10.S.(3), as required. It may be necessary to loosen lead clamps that
restrict mating.
CAUTION
T. Connect VIGV actuator drain line flexible hose onto drain line manifold. Tighten coupling nut to
133-157 lb in. (15.1-17.7 N·m) of torque.
U. Connect tubes to HCU. Tighten head tube coupling nut to 350-410 lb in. (39.6-46.3 N·m) of torque.
Tighten rod tube coupling nut to 262-308 lb in. (29.7-34.7 N·m) of torque.
V. Install VIGV assembly per WP 2110 00.
%ODQN
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STATOR VANES REPLACEMENT
())(&7,9,7</03)*$6785%,1(02'(/6

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Alphabetical Index
Subject Page
LPC Stages 0-3 Stator Vanes Installation................................................................................................. 3

LPC Stages 0-3 Stator Vanes Removal. ................................................................................................... 3
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1. Introduction.
stages 0-3 stator vanes.
B. To gain access, remove stages 0-3 LPC upper and lower stator cases per WP 2212 00.
Title Number
Low Pressure Compressor (LPC) Stages 0-3 Upper and WP 2212 00
Lower Stator Case Replacement
None required.
None required.
/03) *(.
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6. LPC Stages 0-3 Stator Vanes Removal.
A. Place upper and lower stator cases on a skid or table, aft end up.
B. Remove nuts, bolts, and washers from stage 3 inner shrouds (figure 1).
CAUTION
USE CARE WHEN SEPARATING FORWARD AND AFT SHROUD SECTIONS TO

PREVENT DAMAGE FROM PRYING TOOL.
C. Separate forward shroud section from aft shroud section. If necessary, pry between forward and aft shroud
sections to separate them. Remove shroud.
D. Remove vane bushings from vane inner diameter.
E. Remove two screws and locking strip from each stator case half horizontal flange.
F. Slide vanes circumferentially until they can be removed from slot in stator case.
G. Remove dovetail liners (figure 2).
H. Repeat step 6.B through step 6.G. for stages 2, 1, and 0.
7. LPC Stages 0-3 Stator Vanes Installation.
A. Install dovetail liners in vane slots (figure 2). If necessary, grind ends to allow assembly. The gap between
any two adjacent liner segments shall not exceed 0.030 inch (0.76 mm).
B. Slide stage 3 vanes circumferentially into lined slots (figure 3). Adjust quantity of A and D vanes to obtain
required clearance (dimension K) on each half of case. Dimension K shall be met prior to installing
shrouds. During stage 1, 2, and 3 vane installation, install borescope vane so that a 0.405 inch (10.29 mm)
diameter rod will pass freely through case and platform of vane.
CAUTION
FUMES FROM ADHESIVE MAY DAMAGE NATURAL GAS SENSORS. ENSURE

NATURAL GAS SENSORS ARE PROTECTED FROM FUMES.
C. If natural gas sensors are installed in area, encase sensor heads in plastic bags and seal with tie wraps to
protect sensors.
*(. /03)
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Figure 1. LPC Stator Assembly
/03) *(.
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Figure 2. LPC Dovetail Liners Installation
WARNING
VENTILATED AREA.
CAUTION
NO ADHESIVE IS ALLOWED ON ANY MATING SHROUD SURFACE OR OUTER

FLOWPATH SURFACE, OR SHROUD MISASSEMBLY MAY OCCUR.
NOTE
• Silicone rubber adhesive is applied during stage 3 inner shroud bushing assembly. Silicone rubber
adhesive should be allowed to cure for minimum of 8 hours before engine operation.
• Ensure shim is installed and securely adhered to bottom of stage 3 bushing.
D. Apply thin layer of silicone rubber adhesive to outer surface of new stage 3 fan booster bushing assemblies
except flowpath surfaces, as well as vane-to-bushing interface, inside bushing vane tang slot (figure 4).
E. While adhesive is still wet, install 3 vane bushing assemblies onto vane tangs.
F. While adhesive is still wet, install stage 3 shroud.
G. Apply thread lubricant to threads and friction surface of shroud nuts.
*(. /03)
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Figure 3. LPC Stator Vane Location
/03) *(.
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NOTE
Section of shroud with seal is aft on stages 0, 1, and 3. Section of shroud with seal is forward on stage
2.
H. Install aft section of shroud so that vane bushings fit into each semicircle cup.
I. On stages 0, 1, and 2, install vane bushings onto vane tangs.
J. Install forward section of shroud so bushings fit in semicircular cups. Hold both shroud sections together
and install bolts, washers, and nuts in each end and center of shroud. Install one washer under bolthead
(boltheads aft), and one washer under nut. Tighten nuts finger-tight.
K. Install remaining bolts, washers, and nuts in same orientation as step 7.J.
CAUTION
ENSURE RUN-ON TORQUE FOR ALL NUTS IS A MINIMUM OF 5 LB IN. (0.6 N·M) TO
ENSURE INTEGRITY OF LOCKING FEATURE.
L. Tighten nuts to appropriate torque values as follows:
(1) Tighten fifty 0.250-28 stage 0 nuts to 60-70 lb in. (6.8-7.9 N·m) of torque.
(2) Tighten forty-four 0.250-28 stage 1 nuts to 60-70 lb in. (6.8-7.9 N·m) of torque.
(3) Tighten fifty-six 0.250-28 stage 2 nuts to 60-70 lb in. (6.8-7.9 N·m) of torque.
(4) Tighten six 0.190-32 stage 3 nuts to 32-38 lb in. (3.7-4.2 N·m) of torque.
(5) Tighten thirty 0.250-28 stage 3 nuts to 60-70 lb in. (6.8-7.9 N·m) of torque.
M. Apply silicone rubber adhesive over ends of nuts to cover exposed bolt threads.
WARNING

N. Using isopropyl alcohol, remove excess silicone rubber adhesive.
O. Repeat step 7.A through step 7.D, and step 7.H through step 7.O for stages 1, 2, and 3.
*(. /03)
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WARNING

P. Install locking strip on each stator case half. Secure with screws coated with wet zinc chromate primer.
Tighten screws to 106-124 lb in. (12.0-14.0 N·m) of torque.
Q. Allow silicone rubber adhesive to cure for minimum of 8 hours before operating engine.
R. If applicable, remove protective plastic bags from natural gas sensors prior to engine operation
/03) *(.
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Figure 4. Application of Silicone Adhesive Sealant to Tabbed Bushing
%ODQN
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ROTOR BLADES REPLACEMENT
())(&7,9,7</03)*$6785%,1(02'(/6

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Alphabetical Index
Subject Page
LPC Stages 1-3 Rotor Blades Installation................................................................................................ 6

LPC Stages 1-3 Rotor Blades Removal. .................................................................................................. 3
Part Rework - Tip Grinding to Obtain Blade Tip to Stator Case Clearance. ........................................... 9
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1. Introduction.
stages 1-3 rotor blades.
B. Remove LPC stages 0-3 upper stator case to gain access per WP 2212 00.
Title Number
Low Pressure Compressor (LPC) Stages 0-3 Upper and WP 2212 00
Lower Stator Case Replacement

Sharpening Stone Fed Spec SS-S-736
None required.
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6. LPC Stages 1-3 Rotor Blades Removal.
CAUTION
ENSURE MATCHMARKS ARE NOT ERASED DURING MAINTENANCE. IMPROPER

INSTALLATION OF COMPONENTS WILL CAUSE ROTOR IMBALANCE.
NOTE
This procedure is for removal of any number of LPC stages 1-3 rotor blades. Instructions for grinding
blade tips to meet clearance requirements are included in paragraph 7. If an entire stage of blades
requires replacement, contact a General Electric Customer Service Representative to obtain a set of
preground blades.
A. Position mark blades using marking pen (figure 1). Blade 1 is first blade to right of right locking lug (aft
looking forward).
B. Measure blade tip to lower stator case clearance of blades being replaced as follows:
(2) Measure clearance between blade tip and edge of lower stator case. Measurement may be taken
from any area on blade tip, provided each blade is measured from the same area. Record clearance.
(3) Repeat step 6.B.(1) and step 6.B.(2) for each blade requiring replacement.
C. Mark centerline of locking lugs on outside diameter of disk or spool using marking pen.
D. Apply penetrating oil to setscrews and allow to soak for 15 minutes.
E. Loosen setscrews of two locking lugs until lugs will slip below surface of retaining slot sufficiently to
permit circumferential movement of blades.
F. Rotate entire stage of blades circumferentially (in either direction) approximately one-half the width of
blade platform, until one blade can be removed from loading slot. If necessary, tap blades as close to
platform as possible using hammer and nylon drift.
G. Slide locking lug to loading slot and remove. Record on position map (figure 2).
H. Remove remaining blades, other locking lug, and all balance weights from stage being removed. Mark and
record position of balance weights on position map as removed. Weigh each balance weight and record on
position map.
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Figure 1. Typical LPC Stages 1-3 Rotor Blade Replacement
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Figure 2. Stages 1-3 Blade/Balance Weight Position Map
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A. Weigh removed blades and record on position map.
NOTE
Replacement blades shall be weighed after tip grinding to meet clearance requirement.
B. Weigh replacement blades. Mark weight on blade using marking pen.
NOTE
If individual rotor blades are being replaced, select blades per step 7.C. If all rotor blades in a stage are
being replaced, calculate blade position per step 7.D.
0.5 gram is not available, use blade replacement guide (figure 3).
NOTE
For a copy of GE computerized blade replacement balance program and instructions for use, contact
GE customer service.
D. Calculate blade position using GE computerized blade replacement balance program, 9446M61. Mark
position on replacement blade using marking pen.
8. LPC Stages 1-3 Rotor Blades Installation.
A. Ensure locking lug centerline locating marks are still visible. Mark again, if necessary.
WARNING
SOLID FILM LUBRICANT IS TOXIC TO SKIN, EYES, AND RESPIRATORY TRACT. SKIN,
EYE, AND RESPIRATORY PROTECTION IS REQUIRED.
B. Apply molybdenum disulfide lubricant to pressure surfaces of blade dovetails (figure 4).
CAUTION
• ENSURE BALANCE WEIGHTS, LOCKING LUGS, AND REINSTALLED BLADES ARE

REPLACED IN EXACT POSITIONS FROM WHICH THEY WERE REMOVED.
• ENSURE REPLACEMENT BLADES ARE INSTALLED IN POSITIONS CALCULATED

IN paragraph 7. FAILURE TO COMPLY CAN RESULT IN ENGINE DAMAGE.
C. Install blades and balance weights (figure 1).
D. Install two locking blades, one on each side of loading slot, so cutout on blade platform faces loading slot.
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E. Install locking lugs as follows:
(1) Install setscrews in each of two locking lugs. Run setscrews in and out twice, full length of threads.
NOTE
Run-on torque is the torque value observed while the setscrew is in motion during one full
revolution in the lug. Breakaway torque is the torque required to start an installed screw
rotating in the lug, with no axial load on the lug (screw is not seated and is stationary at
initiation of torque). Threads of setscrew and lug must be clean and free of lubricant.
(2) After completion of second cycle, record run-on torque of each screw. Also, check breakaway
torque of each screw. Replace setscrew or locking lug if breakaway torque is less than 8 lb in.
(0.9 N·m).
(3) Install two locking lugs, one on each side of loading slot. Ensure slope of locking lug follows slope
of blade platform.
F. Install one locking blade so cutout on blade platform faces locking lug.
G. Rotate entire stage of blades approximately one-half the width of blade platform, or until last blade can be
installed. Install last locking blade so cutout on blade platform faces locking lug.
H. Rotate entire stage of blades in the opposite direction until locking lugs align with position marks on disk
or spool.
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I. Slide blades circumferentially away from an outside locking blade. Measure clearance between blade
platforms. Total accumulated clearance shall be within 0.010-0.020 inch (0.26-0.50 mm). If this
requirement is not met, replace blade or blades adjacent to locking blades with narrow or wide platform
blades of equal weight.
J. Check each blade for shingling of platforms. If blade tends to shingle, replace with blade of equal weight.
NOTE
If preground blades are installed, proceed to step 8.L.
K. Measure blade tip to lower stator case clearance as follows:
(2) Measure clearance between blade tip and edge of lower stator case. Take measurement from same
area on replacement blade tip as that used to measure replaced blade clearance.
(3) Repeat step 8.K.(1) and step 8.K.(2) for each blade requiring replacement.
L. Tighten setscrews in locking lugs to 19-21 lb in. (2.2-2.3 N·m) of torque above the run-on torque recorded
in step 8.E.(2). Top of the locking lug must be even with, or a maximum of 0.025 inch (0.64 mm) below,
top of blade platform when blade is fully extended radially.
9. Part Rework - Tip Grinding to Obtain Blade Tip to Stator Case Clearance.
CAUTION
DO NOT USE HARD ABRASIVE GRINDING WHEELS TO TIP GRIND BLADES. DAMAGE
TO BLADES MAY OCCUR.
A. Hand-blend replacement blade tip using sharpening stone. Observing the following:
(1) Minimum and maximum blade clearance for each stage is shown in figure 5. Replacement blade
shall not exceed length of longest blade in stage, or be shorter than shortest blade in stage.
(2) Do not remove more than 0.007 inch (0.18 mm) of material from blade tip.
(3) Maintain original contour of blade.
B. Break all edges 0.005-0.015 inch (0.13-0.38 mm).
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Figure 5. LPC Stages 0-3 Rotor Blade to Stator Case Clearance

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LOW PRESSURE COMPRESSOR (LPC) AFT FAN
CASE REPLACEMENT
())(&7,9,7</03)*$6785%,1(02'(/6

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Alphabetical Index
Subject Page
Aft Fan Case Installation.......................................................................................................................... 3

Aft Fan Case Removal. ............................................................................................................................ 3
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1. Introduction.
A. This work package contains instructions for removing and installing low pressure compressor (LPC) aft
fan case.
B. Remove LPC module and install in LPC rotor and stator vertical dolly, 1C9440 (figure 1) per WP 2210 00.
Title Number
Low Pressure Compressor (LPC) Module Replacement WP 2210 00
None required.
None required.
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6. Aft Fan Case Removal.
A. Remove nuts, bolts, and doublers that secure forward flange of aft fan case to aft flange of low pressure
compressor (LPC) stages 0-3 stator case (figure 1).
B. Tap gently around circumference of aft fan case aft flange using plastic face hammer.
WARNING
CAUTION
USE CARE WHEN REMOVING LPC AFT FAN CASE TO AVOID DAMAGING LPC STAGE
4 ROTOR BLADES.
C. Lift aft fan case from LPC module.
7. Aft Fan Case Installation.
A. Install aft fan case over LPC stage 4 rotor blades.
B. Ensure aft fan case forward flange is fully seated against LPC stages 0-3 stator case aft flange.
WARNING

C. Apply zinc chromate primer onto shank and bearing surface of bolts. Allow primer to air dry.
D. Lubricate threads of bolts and threads and bearing surfaces of nuts using thread lubricant. Install bolts,
doublers, and nuts to secure aft fan case forward flange. Doublers are on forward side of LPC stages 0-3
stator case aft flange. Boltheads face aft.
E. Using crisscross pattern, tighten all nuts at forward flange to 129-151 lb in. (14.6-17.0 N·m) of torque.
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Figure 1. LPC Module Installed in LPC Rotor and Stator Vertical Dolly, 1C9052
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LOW PRESSURE COMPRESSOR (LPC) STAGE 4 STATOR
VANES REPLACEMENT
())(&7,9,7</03)*$6785%,1(02'(/6

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Alphabetical Index
Subject Page
Stage 4 Stator Vanes Installation. ............................................................................................................. 3

Stage 4 Stator Vanes Removal.................................................................................................................. 3
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1. Introduction.
A. This work package contains instructions for removing and installing the stage 4 stator vanes.
B. Remove low pressure compressor (LPC) module to gain access per WP 2210 00.
Title Number
Low Pressure Compressor (LPC) Module Replacement WP 2210 00
None required.
None required.
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6. Stage 4 Stator Vanes Removal.
A. Remove stage 4 stator vane retaining bolts, as required (figure 1).
CAUTION
ENSURE BUMPERS ARE REMOVED WITH VANES, OR DAMAGE TO PART MAY

OCCUR.
B. Remove stage 4 stator vanes and bumpers.
7. Stage 4 Stator Vanes Installation.
WARNING

A. Clean front frame bumper slots and outer surface of bumpers using isopropyl alcohol.
B. Apply a thin layer of silicone rubber adhesive onto bumper slots in front frame.
C. Install stage 4 stator vane bumpers onto stator vane, rounded portion aft.
NOTE
Ensure stator vane bumpers remain in position during stator vane installation.
D. Install stage 4 stator vanes while silicone rubber adhesive is still wet.
E. Wipe off excess silicone rubber adhesive.
F. Install retaining bolts. Tighten bolts to 57-67 lb in. (6.5-7.5 N·m) of torque.
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Figure 1. Stage 4 Stator Vane
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LOW PRESSURE COMPRESSOR (LPC) STAGE 4 ROTOR
BLADES REPLACEMENT
())(&7,9,7</03)*$6785%,1(02'(/6

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Alphabetical Index
Subject Page
LPC Stage 4 Rotor Blades Installation..................................................................................................... 7

LPC Stage 4 Rotor Blades Removal. ....................................................................................................... 3
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1. Introduction.
stage 4 rotor blades.
B. Remove aft fan case to gain access per WP 2215 00.
Title Number
Low Pressure Compressor (LPC) Aft Fan Case Replacement WP 2215 00

None required.
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6. LPC Stage 4 Rotor Blades Removal.
CAUTION
ENSURE MATCHMARKS ARE NOT ERASED DURING MAINTENANCE. IMPROPER

INSTALLATION OF COMPONENTS WILL CAUSE ROTOR IMBALANCE.
A. Using marking pen, position mark blades per 1 and 2, figure 1. Blade 1 is first blade to right of right
locking lug (3) (aft looking forward).
B. Using marking pen, mark centerline of locking lugs (3) on outside diameter of spool.
C. Apply penetrating oil onto setscrews (4) and allow to soak for 15 minutes.
D. Loosen setscrews (4) of two locking lugs (3) until lugs slip below surface of retaining slot sufficiently to
permit circumferential movement of blades (1 and 2).
E. Rotate entire stage of blades circumferentially (in either direction) approximately one-half the width of
blade base, until one blade can be removed from loading slot. If necessary, tap blades as close to platform
as possible, using hammer and nylon drift.
F. Slide locking lug to loading slot and remove. Record on position map (figure 2).
G. Remove remaining blades (1 and 2, figure 1), other locking lug (3), and all balance weights (5) from stage
being removed. Mark and record position of balance weights on position map (figure 2) as removed.
Weigh each balance weight and record on position map.
A. Weigh removed blades and record on position map.
B. Weigh replacement blades. Using marking pen, mark weight on blade.
NOTE
If individual rotor blades are being replaced, select blades per step 7.C. If all rotor blades in a stage are
being replaced, calculate blade position per step 7.D.
0.5 gram is not available, use blade replacement guide (figure 3).
NOTE
For a copy of GE computerized blade replacement balance program and instructions for use, contact
GE customer service.
D. Calculate blade position using GE computerized blade replacement balance program, 9446M61. Using
marking pen, mark position on replacement blade.
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Figure 1. Typical LPC Stage 4 Rotor Blade Replacement
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Figure 2. Stage 4 Blade/Balance Weight Position Map
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8. LPC Stage 4 Rotor Blades Installation.
A. Ensure locking lug centerline locating marks are still visible. Mark again, if necessary.
WARNING
B. Apply molybdenum disulfide lubricant to pressure surfaces of blade dovetails (figure 4).
CAUTION
• ENSURE BALANCE WEIGHTS, LOCKING LUGS, AND REINSTALLED BLADES ARE

REPLACED IN EXACT POSITIONS FROM WHICH THEY WERE REMOVED.
• ENSURE REPLACEMENT BLADES ARE INSTALLED IN POSITIONS CALCULATED

IN paragraph 7.
C. Install blades and balance weights (figure 1).
D. Install two locking blades (2), one on each side of loading slot, so cutout on blade platform faces loading
slot.
E. Install locking lugs as follows:
(1) Install setscrews (4) into each of two locking lugs (3). Run setscrews in and out twice, full length of
threads.
NOTE
Run-on torque is the torque value observed while the setscrew is in motion during one full
revolution in the lug. Breakaway torque is the torque required to just start an installed
setscrew rotating in the lug, with no axial load on the lug (setscrew is not seated and is
stationary at initiation of torque). Threads of setscrew and lug must be clean and free of
lubricant.
(2) After completion of second cycle, record run-on torque of each setscrew. Also, check breakaway
torque of each setscrew. Replace setscrew (4) or locking lug (3) if breakaway torque is less than
8 lb in. (0.9 N·m).
(3) Install two locking lugs (3), one on each side of loading slot. Ensure slope of locking lug follows
slope of blade platform.
F. Install one locking blade (2) so cutout on blade platform faces locking lug.
G. Rotate entire stage of blades approximately half the width of a blade platform, or until last blade can be
installed. Install last locking blade so cutout on blade platform faces locking lug.
H. Rotate entire stage of blades in the opposite direction until locking lugs align with position marks on disk
or spool.
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I. Move all blades in a fan out direction, away from an outside locking blade (2). Measure clearance between
blade platforms. Total accumulated clearance shall be within 0.001-0.010 inch (0.03-0.25 mm) at
narrowest point along axial length of platform. Clearance at other axial positions shall not exceed
0.030 inch (0.76 mm). If this requirement is not met, replace blade or blades adjacent to locking blades
with narrow or wide platform blades of equal weight.
J. Check each blade (1 and 2) for shingling of platforms. Replace any blade that tends to shingle with a blade
of equal weight.
K. Tighten setscrews (4) into locking lugs (3) to 19-21 lb in. (2.2-2.3 N·m) of torque above the run-on torque
recorded in step 8.E.(2). The top of the locking lug must be even with, or a maximum of 0.025 inch
(0.64 mm) below, the top of the blade platform when blade is fully extended radially.
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FRONT FRAME AIR COLLECTOR REPLACEMENT
())(&7,9,7</03)*$6785%,1(02'(/6

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Alphabetical Index
Subject Page
Lower Left Air Collector Section Installation. ....................................................................................... 13

Lower Left Air Collector Section Removal. ........................................................................................... 11
Lower Right Air Collector Section Installation. ...................................................................................... 9
Lower Right Air Collector Section Removal........................................................................................... 7
Transfer Gearbox Mount Plate Installation. ............................................................................................ 15
Transfer Gearbox Mount Plate Removal................................................................................................. 15
Upper Air Collector Section Installation.................................................................................................. 3
Upper Air Collector Section Removal. .................................................................................................... 3

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1. Introduction.
This work package contains instructions for removing and installing the front frame air collector.
Title Number

Jack, Lowering - Engine Components 1C5654G03
Fixture, Lift - Air Collector 1C9300G01
Bottle Jack Local Purchase
Lift Sling Local Purchase

Shim L63925P03 AR
Shim L63925P04 AR
Shim L63925P05 AR
Shim L63925P06 AR

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6. Upper Air Collector Section Removal.
NOTE
• Engine must be removed from the enclosure prior to removal of the upper air collector section. Do
not support the gas turbine by the air collector in the maintenance stand or support pedestals.
• The upper air collector section weighs 375 lb (170 kg).
A. Ensure variable bypass valve (VBV) doors are in closed position so hardware or tools will not fall into
compressor front frame (CFF).
B. Using four bolts, washers, and nuts, install air collector lift fixture, 1C9300, onto upper air collector
section (figure 1). Boltheads face up, washers under nuts. Tighten nuts to 428-502 lb in. (48.4-56.7 N·m)
of torque.
C. Connect 1-ton (907 kg) capacity overhead hoist to air collector lift fixture, 1C9300.
D. Remove bolts that secure actuator seal to upper air collector section (figure 2). Remove actuator seal.
E. Remove bolts, washers, and four access panels from upper air collector section.
F. Remove screws that secure frame seals to upper air collector section at 3:00 and 9:00 o’clock positions.
G. Remove nuts and bolts that secure upper air collector section to CFF forward flange.
H. Using marking pen, mark location of CFF aft flange brackets and bolts. Cut safety wire and remove bolts
and brackets from CFF aft flange.
I. Remove bolts and spacers securing upper air collector section and brackets to CFF aft flange.
J. Remove nuts and bolts that secure upper air collector section horizontal flanges to lower air collector
sections.
WARNING
K. Lift upper air collector section clear of engine.
7. Upper Air Collector Section Installation.
A. Using four bolts, washers, and nuts, install air collector lift fixture, 1C9300, onto upper air collector
section (figure 1). Boltheads face up, washers under nuts. Tighten nuts to 428-502 lb in. (48.4-56.7 N·m)
of torque.
B. Connect 1-ton (907 kg) capacity overhead hoist to air collector lift fixture, 1C9300.

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Figure 1. Air Collector Lift Fixture, 1C9300

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Figure 2. Upper Air Collector Section

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WARNING
CAUTION
USE CARE WHEN INSTALLING UPPER AIR COLLECTOR SECTION TO AVOID

DAMAGING FRAME SEALS.
C. Lift upper air collector section onto CFF and align boltholes.
WARNING
D. Apply molybdenum disulfide lubricant to threads and washer faces of all bolts and nuts, except apply
thread lubricant to bolts used to secure upper air collector section onto CFF aft flange.
E. Using bolts and nuts (boltheads face up), secure air collector horizontal flanges. Tighten nuts finger-tight.
F. Using bolts and nuts (boltheads face aft), secure upper air collector section onto CFF forward flange
(figure 2). Tighten nuts to 58-66 lb in. (6.6-7.4 N·m) of torque.
G. Install aft flange brackets at positions marked at disassembly. Using bolt only (no spacer) at 12:00 o’clock
position and using bolts with spacers at remaining positions, secure upper air collector section and brackets
onto CFF aft flange. Tighten bolts to 58-66 lb in. (6.6-7.4 N·m) of torque. Safety-wire bolts.
H. Tighten nuts on air collector horizontal flanges to 483-567 lb in. (54.6-64.0 N·m) of torque.
I. Using screws, secure frame seals onto upper air collector section at 3:00 and 9:00 o’clock positions.
Tighten screws to 58-66 lb in. (6.6-7.4 N·m) of torque.
J. Using bolts, secure actuator seal onto upper air collector section. Tighten bolts to 58-66 lb in.
CAUTION
ALL TOOLS OR MAINTENANCE ITEMS SHALL BE ACCOUNTED FOR UPON JOB

COMPLETION, OR DAMAGE TO ENGINE COULD RESULT.
K. Before installing access panels, perform thorough, final inspection for tools or foreign objects left in air
collector.
L. Using washers and bolts, secure four access panels onto upper air collector section. Tighten bolts to
58-66 lb in. (6.6-7.4 N·m) of torque.
M. Remove air collector lift fixture.

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8. Lower Right Air Collector Section Removal.
NOTE
The lower right air collector section weighs 170 lb (77 kg).
A. Position bottle jack, with protective block, to support transfer gearbox assembly.
B. If the upper air collector section is installed, remove it per paragraph 6.
C. Install air collector lift fixture, 1C9300, onto lower right air collector section with two bolts, washers, and
nuts (figure 1). Boltheads face up, washers are under nuts. Tighten nuts to 428-502 lb in. (48.4-56.7 N·m)
of torque.
D. Connect 1-ton (907 kg) capacity overhead hoist to lift fixture or sling. Take up slack on hoist.
E. Remove bolts and washers that secure two access panels from lower right air collector section (figure 3).
F. Using marking pen, mark location of lower right air collector flange brackets. Remove nuts and bolts that
secure lower right air collector section onto transfer gearbox mount plate.
G. Remove nuts and bolts that secure lower right air collector section onto CFF forward flange.
H. Cut safety wire and remove bolts and spacers that secure lower right air collector section onto CFF aft
flange.
I. If shims are installed between the air collector and front frame, remove them.
J. Loosen bolts that secure support bracket to No. 1 electrical interface panel. Position support bracket clear
of air collector.
WARNING
K. Slowly raise hoist while pulling lower right air collector section clear of engine.

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Figure 3. Lower Right Air Collector Section

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9. Lower Right Air Collector Section Installation.
A. Install air collector lift fixture, 1C9300, onto lower right air collector section using two bolts, washers, and
nuts (figure 1). Boltheads face up, washers under nuts. Tighten nuts to 428-502 lb in. (48.4-56.7 N·m) of
torque.
B. Connect 1-ton (907 kg) capacity overhead hoist to lift fixture or sling.
WARNING
CAUTION
USE CARE WHEN INSTALLING LOWER AIR COLLECTOR SECTION TO AVOID

C. Carefully position lower right air collector section onto transfer gearbox mount plate flange. See figure 3.
WARNING
D. Apply molybdenum disulfide lubricant to threads and washer faces of all bolts and nuts, except apply
thread lubricant to bolts used to secure lower right air collector section onto CFF aft flange.
E. Install brackets at positions marked at disassembly. Using bolts and nuts, secure lower right air collector
section and brackets onto transfer gearbox mount plate. Boltheads face outboard. Tighten nuts finger-tight.
F. Using bolts and nuts, secure lower right air collector section onto CFF forward flange. Boltheads face aft.
G. Install shims as follows between the air collector and CFF aft flange at the locations shown in figure 4:
(1) Measure and record the gap between the air collector and front frame within 0.5 inch (13 mm) of
each bolthole at each location.
(2) If the gap is greater than 0.006 inch (0.15 mm), install shims as necessary until the gap is not more
than 0.006 inch (0.15 mm) at any hole location.
• Shims are 0.010 inch (0.25 mm) thick, composed of five layers of material, each layer being
0.002 inch (0.05 mm) thick.
• Multiple shims are permitted as required.
• Peel layers from shim as necessary to obtain desired thickness.
• The shorter shim with four holes is installed at Location 5.

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Figure 4. Shim Locations

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H. Using bolts and spacers, secure lower right air collector section onto CFF aft flange. Tighten bolts to 58-66
lb in. (6.6-7.4 N·m) of torque. Safety-wire bolts.
I. Tighten nuts at lower right air collector and transfer box mount plate to 483-567 lb in. (54.6-64.0 N·m) of
torque.
J. Tighten bolts securing support bracket to No. 1 electrical interface panel to 58-66 lb in. (6.6-7.4 N·m) of
torque.
CAUTION

K. Before installing access panels, perform thorough, final inspection for tools or foreign objects left in air
collector.
L. Using washers and bolts, secure access panels onto lower right air collector section. Tighten bolts to
58-66 lb in. (6.6-7.4 N·m) of torque.
M. Remove air collector lift fixture or lift sling.
N. Remove bottle jack from under transfer gearbox assembly.
10. Lower Left Air Collector Section Removal.
NOTE
The lower left air collector section weighs 170 lb (77 kg).
A. Position bottle jack, with protective block, to support transfer gearbox assembly.
B. If the upper air collector section is installed, remove it per paragraph 6.
C. Install air collector lift fixture, 1C9300, onto lower left air collector section using two bolts, washers, and
nuts (figure 1). Boltheads face up, washers under nuts. Tighten nuts to 428-502 lb in. (48.4-56.7 N·m) of
torque.
D. Connect 1-ton (907 kg) capacity overhead hoist to lift fixture or sling. Take up slack on hoist.
E. Remove bolts and washers that secure two access panels from lower left air collector section (figure 5).
F. Mark location of lower left air collector flange brackets using marking pen. Remove nuts and bolts that
secure lower left air collector section onto transfer gearbox mount plate.
G. Remove nuts and bolts that secure lower left air collector section onto CFF forward flange.
H. Cut safety wire and remove bolts and spacers that secure lower left air collector section onto CFF aft
flange.
I. If shims are installed between the air collector and front frame, remove them.

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Figure 5. Lower Left Air Collector Section

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J. Loosen bolts that secure support bracket to No. 1 electrical interface panel. Position support bracket clear
of air collector.
WARNING
K. Slowly raise hoist while pulling lower left air collector section clear of engine.
L. Remove four bolts and air collector baffle from lower left air collector section.
11. Lower Left Air Collector Section Installation.
A. Install air collector baffle onto lower left air collector section and secure with four bolts. Tighten bolts to
33-37 lb in. (3.8-4.1 N·m) of torque.
B. Install air collector lift fixture, 1C9300, onto lower left air collector section (figure 1) using two bolts,
washers, and nuts. Boltheads face up, washers under nuts. Tighten nuts to 428-502 lb in. (48.4-56.7 N·m)
of torque.
C. Connect 1-ton (907 kg) capacity overhead hoist to lift fixture or sling.
CAUTION
USE CARE WHEN INSTALLING LOWER AIR COLLECTOR SECTION TO AVOID

D. Carefully position lower left air collector section onto transfer gearbox mount plate flange (figure 5).
WARNING
EYE, AND RESPIRATORY PROTECTION ISREQUIRED.
E. Apply molybdenum disulfide lubricant to threads and washer faces of all bolts and nuts, except apply
thread lubricant to bolts used to secure lower left air collector section onto CFF aft flange.
F. Install brackets at positions marked at disassembly. Using bolts and nuts, secure lower left air collector
section and brackets onto transfer gearbox mount plate. Boltheads face outboard. Tighten nuts finger-tight.
G. Using bolts and nuts, secure lower left air collector section onto CFF forward flange. Boltheads face aft.

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H. Install shims as follows between the air collector and CFF aft flange at the locations shown in figure 4:
(1) Measure and record the gap between the air collector and front frame within 0.5 inch (13 mm) of
each bolthole at each location.
• The shorter shim with four holes is installed at Location 1.
I. Using bolts and spacers, secure lower left air collector section onto CFF aft flange. Tighten bolts to 58-66
lb in. (6.6-7.4 N·m) of torque. Safety-wire bolts.
J. Tighten nuts at lower left air collector and transfer gearbox mount plate to 483-567 lb in. (54.6-64.0 N·m)
of torque.
K. Tighten bolts securing support bracket to No. 1 electrical interface panel to 58-66 lb in. (6.6-7.4 N·m) of
torque.
CAUTION

L. Before installing access panels, perform thorough, final inspection for tools or foreign objects left in air
collector.
M. Using washers and bolts, secure access panels onto lower left air collector section. Tighten nuts to
58-66 lb in. (6.6-7.4 N·m) of torque.
N. Remove air collector lift fixture or lift sling.
O. Remove bottle jack from under transfer gearbox assembly.

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12. Transfer Gearbox Mount Plate Removal.
NOTE
• The transfer gearbox mount plate weighs 400 lb (181 kg).
• The transfer gearbox assembly has been removed from the gearbox mount plate.
A. Remove bolts, washers, and lockwashers that secure access panel to transfer gearbox mount plate
(figure 6).
B. Support transfer gearbox mount plate using lowering jack, 1C5654.
C. Remove bolts that secure actuator seal.
D. Mark location of CFF forward flange bracket using marking pen. Remove nuts and bolts that secure
transfer gearbox mount plate onto CFF forward flange.
E. Cut safety wire and remove bolts and spacers that secure transfer gearbox mount plate onto CFF aft flange.
F. If lower air collector sections are installed, mark location of flange brackets. Remove nuts and bolts that
secure transfer gearbox mount plate onto lower air collector sections.
G. Carefully lower jack to remove transfer gearbox mount plate.
13. Transfer Gearbox Mount Plate Installation.
WARNING
A. Using jack, 1C5654, lift transfer gearbox mount plate into position.
WARNING
B. Apply molybdenum disulfide lubricant onto threads and washer faces of all bolts and nuts, except apply
thread lubricant to bolts used to secure transfer gearbox mount plate onto CFF aft flange.
C. If lower air collector sections are installed, install flange brackets at positions marked at disassembly.
Using bolts and nuts, secure transfer gearbox mount plate and brackets onto lower air collector sections.
Boltheads face outboard. Tighten nuts finger-tight. See figure 6.
D. Install CFF forward flange bracket at position marked at disassembly. Using bolts and nuts, secure transfer
gearbox mount plate and bracket onto CFF forward flange. Boltheads face aft. Tighten nuts to 58-66 lb in.

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Figure 6. Transfer Gearbox Mount Plate

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E. Install shims as follows between the gearbox mount plate and CFF aft flange at the locations shown in
figure 4:
(1) Measure and record the gap between the gearbox mount plate and front frame within 0.5 inch
(13 mm) of each bolthole at each location.
• The long shim with two holes at each end is installed at Location 2.
• The slightly shorter shim with its two holes close together is installed at Location 3.
• The slightly longer shim with its two holes further apart is installed at Location 4.
F. Using bolts and spacers, secure transfer gearbox mount plate onto CFF aft flange. Tighten bolts to
58-66 lb in. (6.6-7.4 N·m) of torque. Safety-wire bolts.
G. Tighten nuts at lower air collector sections and transfer gearbox mount plate to 483-567 lb in.
(54.6-64.0 N·m) of torque.
CAUTION

H. Before installing access panel, perform thorough, final inspection for tools or foreign objects left in air
collector.
I. Using washers, lockwashers, and bolts, secure access panel onto transfer gearbox mount plate. Tighten
%ODQN
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HIGH PRESSURE COMPRESSOR (HPC) UPPER AND
LOWER STATOR CASE REPLACEMENT
())(&7,9,7</03)*$6785%,1(02'(/6

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16 Blank ................................................................................................................................................... 0
Alphabetical Index
Subject Page
HPC Lower Stator Case Installation. ...................................................................................................... 13

HPC Lower Stator Case Removal........................................................................................................... 10
HPC Upper Stator Case Installation......................................................................................................... 8
HPC Upper Stator Case Removal. ........................................................................................................... 3
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1. Introduction.
A. This work package contains instructions for removing and installing the high pressure compressor (HPC)
upper and lower stator cases.
B. Disconnect and connect electrical leads and connecting tubes between low pressure compressor (LPC)
module and gas turbine per SWP 1913 03.
Title Number
Variable Stator Vane (VSV) Actuator Components Replacement WP 1410 00

Fixture, HPC Dummy Stator Case 1C9413G01
Retainer, HPC Lower Stator Case, 6-12 Vanes 1C9414G01
Jack Assembly, CRF Support 1C9447G01
Fixture, Lift - Compressor Stator Case, Upper 2C14699G02
Tool Set, Alignment - Compressor Horizontal Flange 2C14779G02
Fixture, Holding - Variable Stator Arms 2C6259G05
CAUTION
IF THREAD PENETRATING OIL IS USED, USE LIQUID WRENCH. USE OF OTHER PRODUCTS
COULD REDUCE HARDWARE LIFE.
Penetrating Oil GE Spec A50TF54 (Liquid Wrench)
Thread Lubricant GE Spec A50TF201, CL-A
None required.
/03) *(.
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6. HPC Upper Stator Case Removal.
A. Disconnect variable stator vane (VSV) actuating mechanism as follows:
(1) Remove VSV hydraulic actuators, actuator brackets, and actuation levers per WP 1410 00.
(2) Position VSV to full open position (hydraulic actuators extended).
(3) Remove VSV connecting links as follows (figure 1):
(a) Using marking pen, mark stage number on connecting links to be removed.
(b) Remove bolts, washers, and lineup pins from inlet guide vane (IGV) and stages 1-4 connecting
links and remove links from actuation rings. Retain sleeves, if not damaged, for reinstallation.
CAUTION
DO NOT OVERTIGHTEN BOLTS SECURING VANE HOLDING

FIXTURE, 2C6259, OR TOOL DAMAGE WILL RESULT.
(d) Install vane holding fixture, 2C6259, onto VSV stages 3-5 (figure 2). Secure with washers and
bolts removed in step 6.A.(3). Tighten bolts only enough to secure vane holding fixture in
place.
B. Remove HPC upper stator case as follows:
WARNING
PENETRATING OIL 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.
(1) Apply penetrating oil to forward and aft circumferential flange and horizontal flange nuts and bolts.
(2) Using marking pen, matchmark brackets to front frame and compressor rear frame (CRF) flanges.
(3) Position jack, 1C9447, at 6:00 o’clock position on CRF forward flange. Raise jack enough to
support CRF flange, but not enough to exert any upward force.
(4) Remove nuts, bolts, spacers, and brackets that secure HPC upper stator case forward and aft
circumferential flanges.
(5) Install upper compressor stator case lift fixture, 2C14699, as follows (figure 3):
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Figure 1. VSV Connecting Links
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Figure 2. Vane Holding Fixture, 2C6259
Figure 3. Upper Compressor Stator Case Lift Fixture, 2C14699
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WARNING
ALWAYS USE APPROVED EQUIPMENT AND PROCEDURES TO

LIFT PARTS. STAY OUT FROM BELOW LOADS. IF THE PARTS
ACCIDENTALLY MOVE OR FALL, THEY CAN CAUSE AN INJURY
OR DEATH.
CAUTION
ENSURE COMPRESSOR VANE LEVERS ARE POSITIONED FULLY
OPEN TO PREVENT DAMAGE TO ROTOR SPOOL.
(a) Using overhead hoist, position upper compressor stator case lift fixture, 2C14699, over upper
stator case top vertical centerline.
(b) Turn knurled nut to expand upper compressor stator case lift fixture, 2C14699, until pins
engage boltholes in circumferential flanges.
(6) Remove hardware from horizontal flanges, observing the following:
CAUTION
BODY-BOUND BOLTS SHALL NOT BE TURNED, OR DAMAGE TO
PARTS CAN RESULT. DO NOT ALLOW BODY-BOUND BOLTS TO
TURN DURING REMOVAL.
(a) Remove nuts, spacers, and bolts from horizontal flanges (figure 4). Use drift pin and mallet to
drive out body-bound bolts.
(b) If horizontal flange bolt or nut is loose, broken, or missing, replace that bolt and nut, plus bolt
and nut on each side.
(c) If more than five horizontal flange bolts or nuts are loose, broken, or missing, replace all bolts
and nuts in both horizontal flanges.
(7) Using overhead hoist, lift upper stator case from engine.
(8) Place stator case on clean work surface and remove upper compressor stator case lift fixture,
2C14699, and vane holding fixture, 2C6259.
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Figure 4. HPC High-Boss Case Horizontal Flange Hardware

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7. HPC Upper Stator Case Installation.
WARNING

A. Using a clean cloth moistened with isopropyl alcohol, clean horizontal flange contact faces of upper and
lower stator cases.
CAUTION
DO NOT OVERTIGHTEN BOLTS SECURING VANE HOLDING FIXTURE, 2C6259, OR
TOOL DAMAGE WILL RESULT.
B. Install vane holding fixture, 2C6259, onto VSV stages 3-5 (figure 2). Secure with washers and bolts.
Tighten bolts only enough to secure vane holding fixture in place.
C. Install upper compressor stator case lift fixture, 2C14699, as follows (figure 3):
WARNING

(1) Using overhead hoist, position upper compressor stator case lift fixture, 2C14699, over upper stator
case top vertical centerline.
(2) Turn knurled nut to expand upper compressor stator case lift fixture, 2C14699, until pins engage
boltholes in circumferential flanges.
(3) Inspect HPC rotor for FOD.
D. Use overhead hoist to position upper stator case over compressor rotor.
CAUTION
ENSURE COMPRESSOR VANE LEVERS ARE POSITIONED FULLY OPEN TO PREVENT

DAMAGE TO ROTOR SPOOL.
E. Carefully lower stator case into position. Remove upper compressor stator case lift fixture, 2C14699, and
vane holding fixture, 2C6259.
F. Install brackets, bolts, and nuts at aft circumferential flange. Install hardware at locations marked during
disassembly. Do not tighten nuts at this time.
G. Apply thread lubricant to threads of forward circumferential flange.
H. Install hardware at locations marked during disassembly. Do not tighten bolts at this time.
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I. Install horizontal flange retaining hardware as follows:
(1) Apply thread lubricant to threads and washer faces of horizontal flange attaching bolts.
(2) Inspect to ensure flanges are in contact on both sides over full length of case. If required, install
clamps or bolts at forward and aft ends and tighten slightly to pull flanges together. Do not
overtighten clamps on bolts so that alignment pins cannot function. Do not remove clamps or bolts
until assembly bolts are installed and tightened to final torque.
NOTE
Bolt positions on the horizontal flanges are counted from the aft flange forward.
(3) Counting from aft end on both sides, install body-bound bolts or alignment pins from alignment tool
set, 2C14779, in horizontal flange bolthole locations 2, 5, 9, 15, 21, 25, 31, and 35 (figure 4).
(4) Ensure body-bound bolts or alignment pins are fully seated. While restraining pins with Allen
wrench, tighten nuts on small diameter pins to 40 lb in. (4.5 N·m) of torque. Use socket from
alignment tool set, 2C14779, to enable access in tight clearance areas. Avoid side loads.
(5) While restraining pins with Allen wrench, tighten nuts on large diameter pins to 240 lb in.
(27.1 N·m) of torque.
(6) Install bolts, spacers, and nuts into remaining horizontal flange boltholes per figure 4.
NOTE
For ease of assembly, it is permitted to advance up to four bolts farther along one
horizontal flange than the other.
(7) Tighten nuts, in sequence, starting from the aft end and alternating from flange to flange. Torque
nuts per figure 4.
(8) Remove alignment pins and replace with body-bound bolts, spacers, and nuts per figure 4.
(9) Tighten nuts, in sequence, starting from aft end and alternating from flange to flange. Torque nuts
per figure 4.
(10) Retighten horizontal flange bolts with spacers, starting from aft end and alternating from flange to
flange. Do not unseat nuts during retightening.
J. Tighten aft circumferential flange nuts to 380-420 lb in. (43.0-47.4 N·m) of torque. Tightening sequence is
as follows:
(1) Tighten two aft circumferential flange nuts directly above horizontal-split flange and tighten two aft
circumferential flange nuts directly below horizontal-split flange (both left and right horizontal-split
flanges).
(2) Tighten four aft circumferential flange nuts at top vertical centerline.
(3) Continue tightening aft circumferential flange nuts, alternating from side to side, until all nuts are
tightened.
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K. Tighten forward circumferential flange bolts per figure 5. Safety-wire bolts in groups of two or three.
L. Remove jack, 1C9447.
M. Connect VSV actuating mechanism as follows:
(1) Remove vane holding fixture, 2C6259, from VSV stages 3-5.
(2) Install connecting links as follows:
(a) Loosen self-locking nuts that secure first five vane arms at each end of upper and lower stage 5
actuator rings. Loosen self-locking nut until flush with end of vane stem.
CAUTION
CONNECTING LINKS SHALL BE INSTALLED ON CORRECT STAGE
AND WITH LEVER ARM PINS ENGAGING SLEEVES, OR VSV OFF-
SCHEDULE OPERATION AND ENGINE DAMAGE MAY RESULT.
(b) Install sleeves into connecting link ID. Ensure connecting link is correct for stage being
installed.
(c) Position connecting link onto actuation rings, ensuring FWD marking faces forward. Install
IGV and stages 1-4 lineup pins, ensuring lever arm pins engage sleeves.
(d) Install bolts and washers on IGV and stages 1-4. Install bolts on stage 5. Tighten bolts to
(e) Ensure all lever arm pins are engaged in sleeves and are not engaged with connecting link
lightening holes.
CAUTION
STAGE 5 VANE STEM SELF-LOCKING NUTS PREVIOUSLY
LOOSENED SHALL BE TORQUED, OR DAMAGE TO ENGINE WILL
OCCUR.
(f) Tighten self-locking nuts loosened in step 7.M.(2)(a) to 60-70 lb in. (6.8-7.9 N·m) of torque.
(3) Install VSV hydraulic actuators, actuator brackets, and actuation levers per WP 1410 00.
8. HPC Lower Stator Case Removal.
CAUTION
DO NOT REMOVE HPC LOWER STATOR CASE UNLESS THE UPPER STATOR CASE OR
DUMMY CASE IS INSTALLED IN THE LOWER POSITION.
A. Remove HPC upper stator case per paragraph 6.

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Figure 5. Forward Circumferential Flange Bolt Installation

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B. Install stator case retainer, 1C9414, to HPC lower stator case as follows:
NOTE
The HPC stator case retainer retains the stator vanes in the lower case half as the case is
rotated to the 12:00 o’clock position.
(1) Install retainer with bend outboard and down, with aft edge against CRF.
CAUTION
DO NOT OVERTIGHTEN KNOBS SECURING RETAINER, OR TOOL DAMAGE

WILL RESULT.
(2) Align retainer studs through their respective boltholes along horizontal flange. Secure with knurled
knobs from bottom side of flange. Tighten knobs only enough to secure retainer in place.
(3) Repeat step 8.B.(1) and step 8.B.(2) for the other retainer and flange.
C. Install upper stator case or dummy stator case, 1C9413, and secure with nuts and bolts in boltholes 4, 8, 12,
and 16. Install nut and bolt in bolthole 34 of case. Tighten nuts to 202-238 lb in. (22.9-26.8 N·m) of torque.
D. Rotate HPC lower stator case to top position as follows:
WARNING

(2) Using marking pen, matchmark brackets to front frame and CRF flanges.
(3) Remove nuts, bolts, spacers, and brackets that secure stator case forward and aft circumferential
flanges.
(4) Rotate stator cases so lower case is on top.
(5) Install bolts and nuts to secure upper stator case or dummy stator case, 1C9413, to lower portion of
forward and aft circumferential flanges. Tighten bolts and nuts to 202-238 lb in. (22.9-26.8 N·m) of
torque.
E. Remove HPC lower stator case as follows:
(1) Install upper compressor stator case lift fixture, 2C14699, as follows (figure 3):

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WARNING

OR DEATH.
CAUTION
(a) Use overhead hoist to position upper compressor stator case lift fixture, 2C14699, over lower
stator case top vertical centerline.
(b) Turn knurled nut to expand upper compressor stator case lift fixture, 2C14699, until pins
engage boltholes in circumferential flanges.
(2) Lift lower stator case from engine using overhead hoist.
(3) Place stator case on clean work surface and remove tooling.
9. HPC Lower Stator Case Installation.
WARNING
A. Using a clean cloth moistened with isopropyl alcohol, clean horizontal flange contact faces of upper and
lower stator cases.
CAUTION
DO NOT OVERTIGHTEN BOLTS SECURING VANE HOLDING FIXTURE, 2C6259, OR

B. Install vane holding fixture, 2C6259, on VSV stages 3-5 (figure 2). Secure using washers and bolts.
C. Install stator case retainer, 1C9414, to HPC lower stator case as follows:
NOTE
The HPC stator case retainer retains the stator vanes in the lower case half as the case is
rotated to the 12:00 o’clock position.
(1) Install retainer with bend outboard and down, with aft edge against CRF.

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CAUTION
DO NOT OVERTIGHTEN KNOBS SECURING RETAINER, OR TOOL DAMAGE

WILL RESULT.
(2) Align retainer studs through their respective boltholes along horizontal flange. Secure with knurled
knobs from bottom side of flange. Tighten knobs only enough to secure retainer in place.
(3) Repeat step 9.C.(1) and step 9.C.(2) for the other retainer and flange.
(4) Inspect HPC rotor for FOD.
D. Install upper compressor stator case lift fixture, 2C14699, as follows (figure 3):
(1) Use overhead hoist to position lower stator case over compressor rotor.
(2) Turn knurled nut to expand upper compressor stator case lift fixture, 2C14699, until pins engage
boltholes in circumferential flanges.
WARNING
E. Use overhead hoist to position lower stator case over compressor rotor.
CAUTION

F. Carefully lower the stator case into position. Remove upper compressor stator case lift fixture, 2C14699.
G. Install nuts and bolts in horizontal flange boltholes 4, 8, 12, and 16. Install nut and bolt into bolthole 34 of
case. Tighten nuts to 202-238 lb in. (22.9-26.8 N·m).
H. Rotate stator cases as follows:
(1) Remove nuts and bolts that secure the upper stator case or dummy case onto lower portion of
forward and aft circumferential flanges.
(2) Rotate stator cases so that lower case is at bottom position.
I. Apply thread lubricant to threads of forward circumferential flange attaching bolts.
J. Install brackets, bolts, and nuts to lower case forward and aft circumferential flanges. Install hardware at
locations marked during disassembly. Do not tighten bolts or nuts at this time.
K. Remove nuts and bolts from horizontal flanges.

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L. Remove screws that secure stator case retainer, 1C9414, onto lower stator case horizontal flange. Remove
stator case retainer, 1C9414, from between stator case horizontal flanges.
WARNING
M. If dummy stator case, 1C9413, is installed, remove using overhead hoist.
N. Install upper stator case per paragraph 7.
%ODQN
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HIGH PRESSURE COMPRESSOR UPPER/LOWER
STATOR CASE OPENING/CLOSING
())(&7,9,7</03)*$6785%,1(02'(/6

Page No. Change No.
1 - 26 ........................................................................................................................................................ 0
Alphabetical Index
Subject Page
High Pressure Compressor Lower Stator Case Closing.......................................................................... 23

High Pressure Compressor Lower Stator Case Opening. ....................................................................... 18
High Pressure Compressor Upper Stator Case Closing. ......................................................................... 14
High Pressure Compressor Upper Stator Case Opening.......................................................................... 3
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1. Introduction.
A. This subordinate work package (SWP) contains instructions for installation and removal of the fixture set
to raise and hinge the high pressure compressor (HPC) upper stator case.
B. Disconnect electrical leads and connecting tubes between low pressure compressor (LPC) module and gas
turbine per SWP 1913 02.
C. A shim set is provided which allows the lower case to be rotated 180 degrees about horizontal axis to
position the lower case at the top.
Title Number
Variable Stator Vane (VSV) Actuator Components Replacement WP 1410 00

Jack Assembly, CRF Support 1C9448G01/G02
Fixture Set, Raise and Hinge - Upper Compressor Case 1C9400G01
Fixture, Holding - Variable Stator Arms 2C6259G05
Tool Set, Alignment - Compressor Horizontal Flange 2C14779G02
CAUTION
IF THREAD PENETRATING OIL IS USED, USE LIQUID WRENCH. USE OF OTHER PRODUCTS
COULD REDUCE HARDWARE LIFE.
Penetrating Oil GE Spec A50TF54 (Liquid Wrench)
None required.
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6. High Pressure Compressor Upper Stator Case Opening.
A. Disconnect variable stator vane (VSV) actuating mechanism as follows:
(1) Position VSVs to full open position (hydraulic actuators extended).
(2) Remove piping, as required, per SWP 1913 02.
(a) Mark stage number on connecting links to be removed with marking pen.
(b) Remove bolts, washers, and lineup pins from stages IGV and 1-4 connecting links and remove
links from actuation rings. Retain sleeves, if not damaged, for reinstallation.
CAUTION
DO NOT OVERTIGHTEN BOLTS SECURING VANE HOLDING FIXTURE OR
(5) Install vane holding fixture, 2C6259, onto VSV stages 3-5 (figure 2). Using bolts removed in
step 6.A.(4), secure fixture to stages. Tighten bolts only enough to secure fixture in place.
B. Open HPC upper stator case as follows:
WARNING
(2) Using marking pen, matchmark brackets to front frame (figure 3) and compressor rear frame (CRF)
(figure 4) flanges.
(3) Position jack assembly, 1C9448, at 6:00 o'clock position on CRF forward flange. Raise jack just
enough to support CRF flange, but not enough to exert any upward force (figure 5).
circumferential flanges (figures 3 and 4).
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Figure 1. VSV Connecting Links
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Figure 2. Holding Fixture, 2C6259
Figure 3. Forward Circumferential Flange Bolt Locations
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Figure 4. Aft Circumferential Flange Bolts (Sheet 1 of 2)
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Figure 4. Aft Circumferential Flange Bolts (Sheet 2 of 2)
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Figure 5. Compressor Case Orientation
CAUTION
• ENSURE COMPRESSOR VANE LEVERS ARE POSITIONED FULLY OPEN

TO PREVENT DAMAGE TO ROTOR SPOOL.
• BODY-BOUND BOLTS SHALL NOT BE TURNED, OR DAMAGE TO PARTS

CAN RESULT. DO NOT ALLOW BODY-BOUND BOLTS TO TURN
DURING REMOVAL.
(a) Remove nuts, spacers, and bolts from horizontal flanges (figure 6). Use a drift pin and mallet to
(b) If horizontal flange bolt or nut is loose, broken, or missing, record location and replace bolt and
nut plus bolt and nut on each side.
(c) If more than five horizontal bolts or nuts are loose, broken, or missing, replace all bolts and
nuts in both horizontal flanges.
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Figure 6. HPC High-Boss Case Horizontal Flange Hardware
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(6) Install aft jack, 1C9400P17, and forward jacks, 1C9400P18 and 1C9400P19, as follows:
(a) For forward jacks, 1C9400P18 and 1C9400P19, remove second and fourth bolts from forward
HPC stator case to fan frame flange, counting down from horizontal splitline (figure 3).
(b) Align lower tabs on forward jacks, 1C9400P18 and 1C9400P19, with flange connecting
forward HPC stator case to fan frame flange (figure 7).
(c) For aft jack, 1C9400P17, remove second bolt and nut from flange connecting HPC stator case
to CRF (figure 4).
(d) Align lower tabs on aft jack, 1C9400P17, to straddle HPC stator case/CRF flange (figure 7).
(e) Extend threaded rod on each jack so that arm aligns with second hole in flange. Insert pin until
upper arm is flush against engine flange.
(f) For aft jack, 1C9400P17, fit lower tabs over aft flange and bolt into place.
(g) For forward jacks, 1C9400P18 and 1C9400P19, fit lower tabs against HPC stator case forward
flange and bolt into place on fan frame. Secure with two bolts on each side.
(7) Extend each jack until resistance is felt. Using four operators, turn each nut, in unison,
approximately 1/4 turn each time until HPC stator case is raised approximately 1 inch (25 mm) for
installing hinges.
(8) Install hinges and lift bar as follows:
(a) Align forward, upper and lower hinges, 1C9400P05 and 1C9400P06, onto horizontal flange of
HPC stator case, right side, aft looking forward (ALF). Position hinges so forward hole in hinge
aligns with second hole from forward end of upper HPC stator case.
(b) Using three 1/4-inch fasteners, secure forward hinges to HPC stator case.
(c) Align aft, upper and lower hinges, 1C9400P07 and 1C9400P08, from fixture set, 1C9400, onto
horizontal flange of HPC stator case, right side, ALF. Position hinges so aft hole in hinge aligns
with sixth hole from aft end of HPC stator case.
(d) Using two 3/8-inch and two 7/16-inch fasteners, secure aft hinges onto HPC stator case.
(e) Using three 1/4-inch fasteners, secure forward handle, 1C9400P03, onto underside of left side
of horizontal flange of HPC stator case, ALF.
(f) Using two 3/8-inch and two 7/16-inch fasteners, secure aft handle, 1C9400P04, onto underside
of left side of horizontal flange of HPC stator case, ALF.
(9) Ensure upper HPC stator case is supported by hinges and lift bar assembly. Remove jacks.

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Figure 7. Use of Jacks, Hinges, and Lift Bar from Fixture Set, 1C9400 (Sheet 1 of 3)

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(10) Install strut into position as follows:
(a) Raise upper HPC stator case by lifting up on lift bar (two man operation). Open to height
desired.
(b) Install top end of strut over aft flange of HPC stator case. Align strut holes over fourth hole CW
from the horizontal flanges holes, ALF.
(c) Insert ball-lock pin through holes in strut and flange.
(d) Install bottom end of strut over forward flange of CRF. Align strut over third hole CCW from
top vertical centerline, ALF. Insert ball-lock pin.
7. High Pressure Compressor Upper Stator Case Closing.
A. Inspect HPC rotor for FOD.
B. Close HPC upper stator case as follows:
(1) Install jacks, 1C9400P17, 1C9400P18, and 1C9400P19, as follows:
(a) For forward jacks, 1C9400P18 and 1C9400P19, remove second and fourth bolts from flange
connecting forward HPC stator case to fan frame, counting from splitline (figure 3).
forward HPC stator case to fan frame (figure 7).
to CRF (figure 4).
(f) For aft jack, 1C9400P17, fit the lower tabs over aft flange and bolt into place.
(g) For forward jacks, 1C9400P18 and 1C9400P19, fit the lower tabs against HPC stator case
forward flange and bolt into place on fan frame. Secure with two bolts on each side.
(h) Extend each jack approximately 1 inch (25 mm).
(2) Remove struts as follows:
(a) While two people hold HPC stator case to keep it from falling, remove ball-lock pins that
secure struts to upper HPC stator case.
(b) Disconnect struts from the lower HPC stator case.
(c) Lower upper HPC stator case until it rests on jacks, 1C9400P17, 1C9400P18, and 1C9400P19.

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(3) Remove lift bar and hinges as follows:
(a) Remove two 3/8-inch and two 7/16-inch fasteners that secure aft handle, 1C9400P04, onto
horizontal flange of HPC stator case. Remove handle.
(b) Remove three 1/4-inch fasteners that secure forward handle, 1C9400P03, onto horizontal
flange of HPC stator case. Remove handle.
(c) Remove two 3/8-inch and two 7/16-inch fasteners that secure aft hinge onto horizontal flange
of HPC stator case. Remove hinge.
(d) Remove three 1/4-inch fasteners that secure forward hinge onto horizontal flange of HPC stator
case. Remove hinge.
(4) Turn jacks, 1C9400P17, 1C9400P18, and 1C9400P19, in unison and lower upper HPC stator case
down to fit onto lower HPC stator case.
(5) Remove jacks, 1C9400P17, 1C9400P18, and 1C9400P19.
(6) Clean and store all tools from fixture set, 1C9400, in container, 1C9400P02.
WARNING
C. Using clean cloth moistened with Isopropyl alcohol, clean horizontal flange contact faces of upper and
lower stator cases.
CAUTION
DO NOT OVERTIGHTEN BOLTS SECURING VANE HOLDING FIXTURE OR TOOL

DAMAGE WILL RESULT.
D. Install holding fixture, 2C6259, onto VSV stages 3-5 (figure 2). Secure with washers and bolts. Tighten
bolts only enough to secure vane holding fixture in place.
CAUTION

E. Install brackets, bolts, and nuts at aft circumferential flange (figure 4). Install hardware at locations marked
during disassembly. Do not tighten nuts at this time.
F. Apply thread lubricant to threads of forward circumferential flange attaching bolts.
G. Install brackets and bolts at forward circumferential flange (figure 8). Install hardware at locations marked
during disassembly. Do not tighten bolts at this time.

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H. Install horizontal flange retaining hardware as follows:
(1) Apply thread lubricant to threads and washer faces of horizontal flange attaching bolts (figure 6).
(2) Ensure flanges are in contact on both sides over their full length. If required, install clamps or bolts
at forward and aft ends and tighten slightly to pull flanges together. Do not overtighten clamps or
bolts so that alignment pins cannot function. Do not remove these clamps or bolts until assembly
bolts are installed and tightened to final torque.
NOTE
(3) Install body-bound bolts or alignment pins from tool set, 2C14779, in horizontal flange bolthole
locations 2, 5, 9, 15, 21, 25, 31, and 35, counting from aft end on both sides.
(4) Ensure that body-bound bolts or alignment pins are fully seated. Restrain pins using Allen wrench
and tighten nuts on small diameter pins to 40 lb in. (4.5 N·m) of torque. Use socket from tool set,
2C14779, to enable access in tight clearance areas. Avoid side loads.
(5) Using Allen wrench, restrain pins, and tighten nuts on large diameter pins to 240 lb in. (27.1 N·m)
of torque.
(6) Install bolts, spacers, and nuts in remaining horizontal flange boltholes per figure 6.
(7) Tighten nuts, in sequence, starting from aft end and alternating from flange to flange. For ease of
assembly, it is permitted to advance up to four bolts farther along one horizontal flange than the
other. Tighten nuts to torque values listed in figure 6.
(9) Tighten nuts, in sequence, starting from aft end and alternating from flange to flange. Tighten nuts to
torque values listed in figure 6.
(10) Tighten horizontal flange bolts with spacers, starting from aft end and alternating from flange to
I. Tighten aft circumferential flange nuts to 368-432 lb in. (41.6-48.8 N·m) of torque. Tightening sequence is
as follows:
flanges).
tightened (figure 4).
J. Tighten forward circumferential flange bolts to torque values listed in figure 8. Safety-wire bolts in groups
of two or three.

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Figure 8. Forward Circumferential Flange Bolt Installation

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K. Remove jack assembly, 1C9448.
L. Connect VSV actuating mechanism as follows:
(2) Install connecting links as follows (figure 1):
CAUTION
installed.
(d) Install bolts and washers onto IGV and stages 1-4. Install bolts onto stage 5. Tighten bolts to
lightening holes.
CAUTION
OCCUR.
(f) Tighten self-locking nuts loosened in step 7.L.(2)(a) to 60-70 lb in. (6.8-7.9 N·m) of torque.
(4) Install piping per SWP 1913 02.
8. High Pressure Compressor Lower Stator Case Opening.
A. Disconnect VSV actuating mechanism as follows:
(1) Position VSVs to full open position (hydraulic actuators extended).
(2) Remove piping, as needed, per SWP 1913 02.

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(a) Mark stage number on connecting links to be removed with marking pen.
(b) Remove bolts, washers, and lineup pins from stages IGV and 1-4 connecting links and remove
links from actuation rings. Retain sleeves, if not damaged, for reinstallation.
CAUTION
DO NOT OVERTIGHTEN BOLTS SECURING VANE HOLDING FIXTURE OR

(5) Install vane holding fixture, 2C6259, onto VSV stages 3-5 (figure 2). Using bolts removed in
substep (4), secure fixtures to stages. Tighten bolts only enough to secure fixtures in place.
B. Open HPC lower stator case as follows:
WARNING
(2) Using marking pen, matchmark brackets to front frame (figure 3) and CRF (figure 4) flanges.
(3) Position jack assembly, 1C9376, at 6:00 o’clock position on CRF forward flange. Raise jack just
enough to support CRF flange, but not enough to exert any upward force (figure 5).
circumferential flanges (figures 3 and 4).
CAUTION
• ENSURE COMPRESSOR VANE LEVERS ARE POSITIONED FULLY OPEN

TO PREVENT DAMAGE TO ROTOR SPOOL.
• BODY-BOUND BOLTS SHALL NOT BE TURNED, OR DAMAGE TO PARTS

CAN RESULT. DO NOT ALLOW BODY-BOUND BOLTS TO TURN
DURING REMOVAL.
(a) Remove nuts, spacers, and bolts from horizontal flanges (figure 6). Use drift pin and mallet to
(b) If horizontal flange bolt or nut is loose, broken, or missing, record location and replace bolt and
nut plus bolt and nut on each side.

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(c) If more than five horizontal bolts or nuts are loose, broken, or missing, replace all bolts and
nuts in both horizontal flanges.
(6) Install aft jack, 1C9400P17, and forward jacks, 1C9400P18 and 1C9400P19, as follows:
(c) For aft jacks, 1C9400P17, remove second bolt and nut from flange connecting HPC stator case
to CRF (figure 4).
(d) Align lower tabs on aft jacks, 1C9400P17, to straddle HPC stator case/CRF flange (figure 7).
(f) For aft jacks, 1C9400P17, fit lower tabs over aft flange and bolt into place.
(g) For forward jacks, 1C9400P18 and 1C9400P19, fit lower tabs against HPC stator case forward
flange and bolt into place on fan frame. Secure with two bolts on each side.
installing hinges.
(8) Install aft shims, 1C9400P11 and 1C9400P23, as follows:
(a) Align aft shim, 1C9400P11, onto right side horizontal flange. Insert studs into the second and
thirteenth holes from aft end of HPC stator case. Install stud through horizontal flange of lower
case and secure finger-tight at under side of flange.
(b) Align aft shim, 1C9400P23, onto left side horizontal flange. Insert studs into the second and
thirteenth holes from aft end of HPC stator case. Install stud through horizontal flange of lower
case and secure finger-tight at under side of flange.
(9) Install forward shims, 1C9400P10 and 1C9400P22, as follows:
(a) Align forward shim, 1C9400P10, onto right side horizontal flange. Position shim so forward
most hole in shim aligns with third flange hole from forward end of HPC stator case.
(b) Align forward shim, 1C9400P22, onto left side horizontal flange. Position shim so forward
most hole in shim aligns with third flange hole from forward end of HPC stator case.
(10) Using jacks, 1C9400P17, 1C9400P18, and 1C9400P19, lower upper HPC stator case down onto
lower compressor case.

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(12) Bolt HPC stator case halves together as follows:
CAUTION

(a) Install bolts and nuts at aft circumferential flange. Do not tighten nuts at this time.
(b) Install bolts at forward circumferential flange. Do not tighten bolts at this time.
(c) Install horizontal flange retaining hardware as follows:
(d) Ensure flanges are in contact on both sides over their full length. If required, install clamps or
bolts at forward and aft ends and tighten slightly to pull flanges together. Do not overtighten
clamps or bolts so that alignment pins cannot function. Do not remove these clamps or bolts
until assembly bolts are installed and tightened to final torque (figure 6).
NOTE
Bolt positions on the horizontal flanges are counted from the aft flange
forward.
(e) Install body-bound bolts or alignment pins from tool set, 2C14779, in horizontal flange
bolthole locations 2, 5, 9, 15, 21, 25, 31, and 35, counting from aft end on both sides.
(f) Ensure that body-bound bolts or alignment pins are fully seated. Using Allen wrench, restrain
pins, and tighten nuts on small diameter pins to 40 lb in. (4.5 N·m) of torque. Use socket from
tool set, 2C14779, to enable access in tight clearance areas. Avoid side loads.
(g) Using Allen wrench, restrain pins, and tighten nuts on large diameter pins to 240 lb in.
(h) Install bolts, spacers, and nuts in remaining horizontal flange boltholes per figure 6.
(i) Tighten nuts, in sequence, starting from aft end and alternating from flange to flange. For ease
of assembly, it is permitted to advance up to four bolts farther along one horizontal flange than
the other. Tighten nuts to torque values listed in figure 6.
(j) Remove alignment pins and replace with body-bound bolts, spacers, and nuts per figure 6.
(k) Tighten nuts, in sequence, starting from aft end and alternating from flange to flange. Tighten
nuts to torque values listed in figure 6.
(l) Tighten horizontal flange bolts with spacers, starting from aft end and alternating from flange
to flange. Do not unseat nuts during retightening.
(m) Tighten aft circumferential flange nuts to 368-432 lb in. (41.6-48.8 N·m) of torque. Tightening
sequence is as follows (figure 4):

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1 Tighten two aft circumferential flange nuts directly above horizontal-split flange and
tighten two aft circumferential flange nuts directly below horizontal-split flange (both left
and right horizontal-split flanges).
2 Tighten four aft circumferential flange nuts at top vertical centerline.
3 Continue tightening aft circumferential flange nuts, alternating from side to side, until all
nuts are tightened.
(n) Tighten forward circumferential flange bolts to torque values listed in figure 8.
(13) Rotate HPC stator casing so lower half is on top.
(14) Install jacks, 1C9400P17, 1C9400P18, and 1C9400P19, per step 8.B.(6).
installing hinges.
(16) Install hinges and lift bar as follows (figure 7):
(a) Align forward, upper and lower hinges, 1C9400P05 and 1C9400P06, onto horizontal flange of
HPC stator case, right side, aft looking forward. Position hinges so forward hole in hinge aligns
with the second hole from forward end of upper HPC stator case.
(b) Using three 1/4-inch fasteners, secure forward hinges to case.
(c) Align aft, upper and lower hinges, 1C9400P07 and 1C9400P08, onto horizontal flange of HPC
stator case, right side, aft looking forward. Position hinges so aft hole in hinge aligns with sixth
hole from aft end of the case.
(d) Using two 3/8-inch and two 7/16-inch fasteners, secure aft hinges to HPC stator case.
(e) Using three 1/4-inch fasteners, secure forward handle, 1C9400P03, onto underside of left side
of horizontal flange of HPC stator case, ALF.
(f) Using two 3/8-inch and two 7/16-inch fasteners, secure aft handle, 1C9400P04, onto underside
of left side of horizontal flange of HPC stator case, ALF.
(17) Ensure case is supported by hinges and lift bar assembly. Remove jacks, 1C9400P17, 1C9400P18,
and 1C9400P19.
(18) Install strut into position as follows (figure 7):
(a) Raise upper HPC stator case by lifting up on lift bar (two man operation). Open to height
desired.
(b) Install top end of strut over aft flange of HPC stator case. Align strut holes over fourth hole CW
from the horizontal flanges holes, ALF.
(c) Insert ball-lock pin through holes in strut and flange.

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(d) Install bottom end of strut over forward flange of CRF. Align strut over third hole CCW from
top vertical centerline, ALF. Insert ball-lock pin.
9. High Pressure Compressor Lower Stator Case Closing.
A. Inspect HPC rotor for FOD.
B. Close HPC stator case as follows:
(1) Install jacks, 1C9400P17, 1C9400P18, and 1C9400P19, as follows:
to CRF (figure 4).
(f) For aft jack, 1C9400P17, fit the lower tabs over aft flange and bolt into place.
(g) For forward jacks, 1C9400P18 and 1C9400P19, fit the lower tabs against HPC stator case
forward flange and bolt into place on fan frame. Secure with two bolts on each side.
(h) Extend each jack approximately 1 inch (25 mm).
(2) Remove struts as follows (figure 7):
(a) While two people hold HPC stator case to keep it from falling, remove ball-lock pins that
secure struts to upper HPC stator case.
(b) Disconnect struts from lower HPC stator case.
(c) Lower upper HPC stator case until it rests on jacks, 1C9400P17, 1C9400P18, and 1C9400P19.
(3) Remove lift bar and hinges as follows:
(a) Remove two 3/8-inch and two 7/16-inch fasteners that secure aft handle, 1C9400P04, onto
horizontal flange of HPC stator case. Remove handle.
(b) Remove three 1/4-inch fasteners that secure forward handle, 1C9400P03, onto horizontal
flange of HPC stator case. Remove handle.
(c) Remove two 3/8-inch and two 7/16-inch fasteners that secure aft hinge onto horizontal flange
of HPC stator case. Remove hinge.

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(d) Remove three 1/4-inch fasteners that secure forward hinge onto horizontal flange of HPC stator
case. Remove hinge.
(4) Remove shims as follows:
(a) Remove studs and remove aft shims, 1C9400P11 and 1C9400P23, from aft end of HPC stator
case.
(b) Remove studs and remove forward shims, 1C9400P10 and 1C9400P22, from forward end of
HPC stator case.
(5) Turn jacks, 1C9400P17, 1C9400P18, and 1C9400P19, in unison, and lower upper HPC stator case
down to fit onto lower HPC stator case.
(7) Clean and store all tools from fixture set, 1C9400, in container, 1C9400P02.
WARNING

C. Using clean cloth moistened with isopropyl alcohol, clean horizontal flange contact faces of upper and
lower HPC stator cases.
CAUTION
DO NOT OVERTIGHTEN BOLTS SECURING VANE HOLDING FIXTURE OR TOOL
DAMAGE WILL RESULT.
NOTE
The shims contain through-holes in line with the case flange holes to permit bolting of the halves
together and to later install the hinges without having to remove the shims.
D. Install vane holding fixture, 2C6259, onto VSV stages 3-5 (figure 2). Secure using washers and bolts.
CAUTION

E. Install brackets, bolts, and nuts at aft circumferential flange. Install hardware at locations marked during
disassembly. Do not tighten nuts at this time.
F. Apply thread lubricant to threads of forward circumferential flange attaching bolts.
G. Install brackets and bolts at forward circumferential flange. Install hardware at locations marked during
disassembly. Do not tighten bolts at this time.

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H. Install horizontal flange retaining hardware as follows:
(1) Apply thread lubricant to threads and washer faces of horizontal flange attaching bolts (figure 6).
(2) Ensure flanges are in contact on both sides over their full length. If required, install clamps or bolts
at forward and aft ends and tighten slightly to pull flanges together. Do not overtighten clamps or
bolts so that alignment pins cannot function. Do not remove these clamps or bolts until assembly
bolts are installed and tightened to final torque.
NOTE
(3) Install body-bound bolts or alignment pins from tool set, 2C14779, in horizontal flange bolthole
locations 2, 5, 9, 15, 21, 25, 31, and 35, counting from aft end on both sides.
(4) Ensure that body-bound bolts or alignment pins are fully seated. Restrain pins using Allen wrench
and tighten nuts on small diameter pins to 40 lb in. (4.5 N·m) of torque. Use socket from tool set,
2C14779, to enable access in tight clearance areas. Avoid side loads.
(5) Restrain pins using Allen wrench and tighten nuts on large diameter pins to 240 lb in. (27.1 N·m) of
torque.
(6) Install bolts, spacers, and nuts in remaining horizontal flange boltholes per figure 6.
(7) Tighten nuts, in sequence, starting from aft end and alternating from flange to flange. For ease of
assembly, it is permitted to advance up to four bolts farther along one horizontal flange than the
other. Tighten nuts to torque values listed in figure 6.
(9) Tighten nuts, in sequence, starting from aft end and alternating from flange to flange. Tighten nuts to
torque values listed in figure 6.
(10) Tighten horizontal flange bolts with spacers, starting from aft end and alternating from flange to
I. Tighten aft circumferential flange nuts to 368-432 lb in. (41.6-48.8 N·m) of torque. Tightening sequence is
flanges).
tightened.
J. Tighten forward circumferential flange bolts to torque values listed in figure 8. Safety-wire bolts in groups
of two or three.

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K. Remove jack assembly, 1C9376.
L. Connect VSV actuating mechanism as follows:
(2) Install connecting links as follows (figure 1):
CAUTION
installed.
(d) Install bolts and washers onto IGV and stages 1-4. Install bolts onto stage 5. Tighten bolts to
lightening holes.
CAUTION

OCCUR.
(f) Tighten self-locking nuts loosened in step 9.L.(2)(a) to 60-70 lb in. (6.8-7.9 N·m) of torque.
(4) Install piping per SWP 1913 02.

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HIGH PRESSURE COMPRESSOR (HPC) STATOR VANES
REPLACEMENT
())(&7,9,7</03)*$6785%,1(02'(/6

Page No. Change No.
1 - 72 ........................................................................................................................................................ 0
Alphabetical Index
Subject Page
HPC IGV and Stage 1-5 Variable Stator Vanes Dimensional Inspection................................................ 20
HPC IGV and Stage 1-5 Variable Stator Vanes Visual Inspection.......................................................... 15
HPC Stage 6-13 Stator Vanes Dimensional Inspection........................................................................... 22
HPC Stage 6-13 Stator Vanes Visual Inspection. .................................................................................... 21
HPC Stator Case Inspection. ................................................................................................................... 28
HPC Stator Case - Repair of VSV Bushing Mounting Hole Threads..................................................... 28
HPC Stator Vanes Installation. ................................................................................................................ 48
HPC Stator Vanes Removal...................................................................................................................... 4
Parts Repair - Vanes - General. ............................................................................................................... 26
Parts Repair - Vanes - Leading and Trailing Edge Blending. ................................................................. 26
Parts Repair - Vanes - Tip Blending........................................................................................................ 26
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1. Introduction.
NOTE
The LM6000 HPC high-boss case stages 3-5 bushings are replaceable externally without top case removal.
Refer to WP 1412 00 for replacement instructions.
This work package contains instructions for removing and installing the high pressure compressor (HPC) stator
case.
Title Number
Maintenance Considerations Chapter 11
Variable Stator Vane (VSV) stages 3 to 5 Bushing Replacement WP 1412 00
(High-Boss HPC Stator Case)
High Pressure Compressor (HPC) Upper and Lower Stator Case Replacement WP 2411 00

Fixture Set, VSV Torque Measuring 1C9408G02
Wrench, VSV Locknut Torque Break 1C9428G01
Removal Tool, Vane Spring Retainers 2C14684G02
Tool Set, Holding VSV 2C6018G01
Driver Set, Compressor Stator Vane 2C6019G03
Holder Set, VSV 2C6171G02
Wrench, Torque - Nut Retaining Actuation Arms 2C6965P03
Adjustable Drill Stop (7/32 Inch Diameter) Local Purchase
Bushing Rework Tool Local Manufacture
Depth Gage Local Manufacture
Drilling Jig Local Manufacture
HSS 0.250-28 UNJF-3B Tap Set (Taper, Plug and Bottoming Taps) Local Purchase
Pull Scale, Calibrated 0-50 lb Local Purchase
7 mm or 9/32 inch Diameter Drill (bushing rework) Local Purchase
7/32 inch Diameter Drill (case rework) Local Purchase
3374A21 Transfer Punch (Ref. McMaster) Local Purchase
8492A102 Drill Guide (Ref. McMaster) Local Purchase
8492A176 Drill Guide (Ref. McMaster) Local Purchase
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Sharpening Stone Fed Spec SS-S-736C
Tapping Fluid Trim Tap NC (Masters Chemical Co.)

Bushing - Spare Part 2083M62P01 through P08 AR
Spring Retainer, Stages 6 and 8 9382M94P02 127
Spring Retainer, Stages 9, 10, 12, and 13 9382M95P05 300
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6. HPC Stator Vanes Removal.
A. Before disassembly, inspect inlet guide vane (IGV) and stages 0-5 stator vanes for off-schedule condition
per WP 4028 00.
B. Remove HPC stator cases per WP 2411 00.
C. Remove stages IGV-2 stator vanes as follows:
(1) Remove stages IGV-2 vane shrouds as follows (figure 1):
(a) Using marking pen, position mark shroud sections.
NOTE
The forward and aft parts of each shroud half section are a matched set. If
either part requires replacement, the entire half section shall be replaced.
NOTE
Shroud retaining bolts are body-bound. Do not allow bolts to turn during
removal.
(b) Remove nuts from shroud retaining bolts. Support vanes and tap bolts out using a plastic
mallet. Separate and remove forward and aft shroud segments.
(c) Remove flanged bushings from vane inner trunnions.
(2) Using marking pen, position mark vanes to stator case.
(3) Using holding tool from holding VSV tool set, 2C6018, support individual vanes. Support entire
stage of vanes using holder from VSV holder set, 2C6171 (figure 2).
(4) Loosen locknut using locknut torque break wrench, 1C9428, and channel-lock pliers (figures 3).
Remove locknut (1, figure 4), alignment sleeve (2), and lever arm (3).
(5) If a large number of vanes are being removed, remove all lever arms (3) and remove actuation
ring (11).
CAUTION
BUSHING MAY STICK IN STATOR CASE COUNTERBORE. ENSURE ALL

PIECES ARE REMOVED BEFORE INSTALLING NEW PARTS.
(6) Remove spacer (5) and bushing (6) from outside of stator case (12).
(7) Remove vane (8) by pulling from inside of stator case (12).
(8) Remove washer (7) from inside of stator case (12).
(9) If HPC stator cases are to be replaced, remove stages IGV-2 borescope plugs from stator case.
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Figure 1. Stages IGV-2 Vane Shrouds Removal
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Figure 2. Variable Stator Vane Holding Tools
Figure 3. Stages IGV-4 Locknut Removal
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Figure 4. Stages IGV-2 Stator Vanes
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D. Remove stages 3-5 stator vanes as follows:
(1) Using marking pen, position mark vanes to stator case.
(2) Using holding tool from holding VSV tool set, 2C6018, support individual vanes. Support entire
stage of vanes using holding tool from VSV holder set, 2C6171 (figure 2).
(3) Remove high-boss case vanes as follows (figure 5):
(a) Remove locknut (1) and lever arm (2).
(b) Remove jamnut (3), alignment sleeve (4), and spacer (5).
(c) Remove vane (9) by pulling from inside of high-boss case (12).
(d) If large number of vanes are being removed, remove all lever arms (2) and remove actuation
ring (11) and actuation ring sleeves (10).
(e) Remove housing (6), washer (8), and bushing (13) as follows:
1 Remove bolts (7) that secure housing to high-boss case (12).
2 Remove washer (8), housing (6), and bushing (13).
(f) If upper and lower HPC stator cases are to be replaced, remove stages 3-5 borescope plugs
from stator case.
E. Remove stages 6-12 stator vanes as follows:
(1) Remove borescope plugs from HPC stator case on effected stages.
(2) Using marking pen, position mark vanes to HPC stator case.
(3) Remove vane retaining keys from horizontal flanges of upper HPC stator case (figure 6). Lower
HPC stator case has no retaining keys.
NOTE
Stages 7 and 11 do not have spring retainers.
(4) On stages 7 and 11, remove vanes by sliding circumferentially from retaining slots. Use driver from
compressor stator vane driver set, 2C6019, to drive against vane base, not airfoil.
CAUTION
DO NOT SLIDE VANES WITH SPRING RETAINERS INSTALLED. SPRING

RETAINERS WILL SCAR CASE.
(5) On stages 6, 8, 9, 10, and 12, remove vanes to expose first spring retainer by sliding
circumferentially from retaining slots.
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Figure 5. High-Boss Stages 3-5 Vane Removal
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Figure 6. Stages 6-12 Stator Vane Removal (Sheet 1 of 2)

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Figure 6. Stages 6-12 Stator Vane Removal (Sheet 2 of 2)

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(6) Using vane spring retainer removal tool, 2C14684, remove spring retainers (figure 7). Discard
spring retainers.
(7) Remove remaining vanes and retainers per step 6.E.(5) and step 6.E.(6) .
F. Remove stage 13 stator vanes as follows (figure 8):
(1) Remove borescope plug from lower HPC stator case.
(2) Using marking pen, position mark liner segments to HPC stator case.
(3) Remove bolts that secure liner segments to HPC stator case.
CAUTION
USE CARE SO END-STOP DOES NOT FALL OUT OF THE LINER SEGMENTS
AND LEAF SEALS DO NOT BECOME DISENGAGED.
(4) Remove liner segments by sliding circumferentially from retaining slots.
(5) Remove stationary seal segments.
(6) Remove vanes as follows:
(a) Remove end-stop and leaf seals from liner.
(b) Remove vane to expose first spring retainer by sliding circumferentially from liner retaining
slots, sliding it over liner end-stop pin.
(c) Using vane spring retainer removal tool, 2C14684, remove exposed spring retainer (figure 7).
Discard spring retainer.
(d) Slide second vane toward liner end-stop pin to expose next spring retainer (figure 8).
(e) Repeat step 6.F.(6)(c) and step 6.F.(6)(d) until all spring retainers are removed from liner.
(f) Remove vanes from end of liner opposite end-stop pin.
(g) Install end-stop and leaf seals to liner. Retain end-stop in place with two rubber bands, one
around each end of end-stop.
G. If HPC stator cases are to be replaced, remove variable stator vane (VSV) lever bracket from stator case.

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Figure 7. Stages 6-12 Vane Removal Tools

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Figure 8. Stage 13 Vane Removal

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7. HPC IGV and Stage 1-5 Variable Stator Vanes Visual Inspection.
A. Visually inspect IGV and stage 1-5 vanes per table 1 and figure 9.
Table 1. HPC IGV and Stage 1-5 Vanes Visual Inspection

NOTE
Airfoil defects within defined limits resulting in protrusion on the opposing surface are acceptable. Defects
superimposed at same airfoil location but on opposing sides are not acceptable if sum of two defects
exceeds defined limits.
1. All Areas for:
a. Cracks Not serviceable Not repairable Replace vane
2. Area A for:
a. Nicks, pits, and 0.003 inch (0.08 mm) 0.010 inch (0.25 mm) Blend per
scratches deep deep paragraph 11
b. Dents 0.010 inch (0.25 mm) Not repairable Replace vane
deep. None allowed in
fillets
3. Area B (Leading and Trailing Edges) for:
a. Nicks, pits, and 0.005 inch (0.13 mm) Any amount if repair Blend per
scratches deep does not exceed paragraph 11 and
minimum Chord V paragraph 12
(table 2)
b. Dents 0.020 inch (0.51 mm) Any amount if repair Blend per
deep does not exceed paragraph 11 and
minimum Chord V paragraph 12
(table 2)
c. Erosion Minimum root Chord V Any amount if repair Blend per
and minimum thicknesses, does not exceed paragraph 11 and
measured 0.03 inch minimum Chord V paragraph 12
(0.8 mm) from leading/ (table 2)
trailing edge are
0.012 inch (0.30 mm) in
area from root to midspan
and 0.010 inch (0.25 mm)
in area from midspan to
tip
4. Area C for:
a. Nicks, pits, and 0.003 inch (0.08 mm) 0.010 inch (0.25 mm) Blend per
scratches deep deep paragraph 11

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Table 1. HPC IGV and Stage 1-5 Vanes Visual Inspection (Continued)
b. Dents 0.010 inch (0.25 mm) Not repairable Replace vane*
deep. None permitted in
fillets
5. Area G (Stage 3-5 Squealer Tips) for:
a. Cracks, nicks, and Not serviceable 0.030 inch (0.76 mm) Blend per
dents deep paragraph 11 and
paragraph 13
b. Burrs and high Not serviceable Any amount Remove high metal
metal
c. Top tip corner Not serviceable Maximum blend radius Blend per
damage must remove all paragraph 11 and
defective material. paragraph 13
Rework may extend
into areas B and C
d. Airfoil bending 0.020 inch (0.51 mm) for Not repairable Replace vane*
each 1.0 inch (25 mm) of
airfoil length
6. Area E (IGV, Stage 1-2 Trunnions, Platforms, and Tangs) for:
a. Nicks and 0.005 inch (0.13 mm) 0.015 inch (0.38 mm) Blend high metal
scratches deep if 80 percent of area deep if 30 percent of per paragraph 11
is clear of defects. None area is clear of defects
allowed in fillets and no
raised metal
b. Scoring or wear 0.010 inch (0.25 mm) 0.020 inch (0.51 mm) Replace vane*
on outer trunnion deep, 0.100 inch deep
diameter (2.54 mm) wide
c. Scoring or wear 0.020 inch (0.51 mm) Not repairable Replace vane*
on inner trunnion deep for 50 percent of
diameter circumference
d. Wear on outer 0.010 inch (0.25 mm) Not repairable Replace vane*
platform surface deep
e. Wear on inner 0.010 inch (0.25 mm) Not repairable Replace vane*
platform face deep
f. Runout of inner 0.020 inch (0.51 mm) FIR Not repairable Replace vane*
trunnion diameter
with respect to
outer trunnion
diameter (IGV-2
only)

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Table 1. HPC IGV and Stage 1-5 Vanes Visual Inspection (Continued)
g. Scoring or wear 0.010 inch (0.25 mm) Not repairable Replace vane*
on tang deep
h. Wear on inner 0.030 inch (0.76 mm) Not repairable Replace vane*
platform outer deep
edge
7. Area F (Threaded Stem) for:
a. Thread damage Not serviceable Entrance thread may be Remove entrance
removed if remaining thread or replace
threads are not damaged vane
b. High metal Not serviceable Any amount Remove high metal
per paragraph 11
* May be repairable; consult GE for disposition of replaced parts.

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Figure 9. IGV and Stages 1 Through 5 Vanes Inspection Areas

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m
Table 2. HPC IGV and Stage 1-5 Vanes Minimum Chord Values
Dim D Minimum Chord V
IGV Stage 1 Stage 2
inches mm inches mm inches mm inches mm
Root Root 2.26 57.4 2.02 51.3 1.74 44.2
0.50 12.7 2.24 56.9 2.00 50.8 1.73 43.9
1.00 25.4 2.19 55.6 1.96 49.8 1.69 42.9
1.50 38.1 2.14 54.4 1.92 48.8 1.66 42.2
2.00 50.8 2.08 52.8 1.88 47.8 1.63 41.4
2.50 63.5 2.03 51.6 1.83 46.5 1.60 40.6
3.00 76.2 1.98 50.3 1.80 45.7 1.57 39.9
3.50 88.9 1.92 48.8 1.75 44.5 1.53 38.9
4.00 101.6 1.87 47.5 1.70 43.2 1.50 38.1
4.50 114.3 1.81 46.0 1.64 41.7 1.46 37.1
5.00 127.0 1.76 44.7 1.59 40.4 1.43 36.3
5.50 139.7 1.71 43.4 1.52 38.6 1.40 35.6
6.00 152.4 1.65 41.9 1.46 37.1
6.50 165.1 1.60 40.6 1.40 35.6
7.00 177.8 1.55 39.4
7.50 190.5 1.49 37.8
Stage 3 Stage 4 Stage 5
Root Root 1.64 41.7 1.50 38.1 1.26 32.0
0.50 12.7 1.60 40.6 1.48 37.6 1.25 31.8
1.00 25.4 1.54 39.1 1.42 36.1 1.21 30.7
1.50 38.1 1.48 37.6 1.37 34.8 1.17 29.7
2.00 50.8 1.44 36.6 1.34 34.0 1.15 29.2
2.50 63.5 1.42 36.1 1.31 33.3 1.12 28.4
3.00 76.2 1.39 35.3 1.29 32.8 1.09 27.7
3.50 88.9 1.36 34.5 1.27 32.3 1.06 26.9
4.00 101.6 1.32 33.5 1.24 31.5
4.50 114.3 1.29 32.8

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8. HPC IGV and Stage 1-5 Variable Stator Vanes Dimensional Inspection.
NOTE
Dimensional inspections should follow all required repairs.
A. Dimensionally inspect IGV and stage 1-5 vane chord (dimension V) as follows (figure 9):
(1) Measure vane Chord V at dimension D listed in table 2.
(2) Check measured Chord V with table 2 limits. Replace vanes as required.
B. Dimensionally inspect vane length (dimension L) of stage 3-5 vanes per table 3 and figure 10.
Table 3. Stage 3-5 Vane Length Dimension L Inspection
Stage Minimum Vane Length Corrective Action
3 5.027 in. (127.69 mm) Replace vane
NOTE
The lengths tabulated represent the shortest vanes which should occur as a result of assembly processing
(minimum radius case and maximum grind).
Figure 10. Stages 3–5 Vanes Length Dimension L Inspection

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9. HPC Stage 6-13 Stator Vanes Visual Inspection.
A. Visually inspect stage 6-13 vanes per table 4 and figure 11.
Table 4. HPC Stages 6-13 Vanes Visual Inspection

NOTE
Airfoil defects within defined limits resulting in protrusion on the opposing surface are acceptable.
Defects superimposed at same airfoil location but on opposing sides are not acceptable if sum of two
defects exceeds defined limits.
1. All Areas for:

a. Cracks Not serviceable Not repairable Replace vane*
2. Area A for:
a. Nicks, pits, 0.005 inch (0.13 mm) 0.010 inch (0.25 mm) Blend per
and scratches deep deep paragraph 11
b. Dents 0.010 inch (0.25 mm) Not repairable Replace vane*
deep. None allowed in
fillets
3. Area B (Leading and Trailing Edges) for:
a. Nicks, pits, 0.005 inch (0.13 mm) Any amount if repair does Blend per
and scratches deep not exceed minimum paragraph 11 and
Chord V (table 5) paragraph 12
b. Dents 0.020 inch (0.51 mm) Any amount if repair does Blend per
deep not exceed minimum paragraph 11 and
Chord V (table 5) paragraph 12
c. Erosion Minimum root Chord V Any amount if repair does Blend per
and minimum thicknesses, not exceed minimum paragraph 11 and
measured 0.030 inch Chord V (table 5) paragraph 12
(0.76 mm) from leading/
trailing edge are
0.012 inch (0.030 mm) in
area from root to midspan
and 0.010 inch (0.25 mm)
in area from midspan to
tip
4. Area G (Squealer Tips) for:
a. Cracks, nicks, Not serviceable 0.030 inch (0.76 mm) Blend per
and dents deep paragraph 11 and
paragraph 13
b. Burrs and high Not serviceable Any amount Remove high metal
metal

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Table 4. HPC Stages 6-13 Vanes Visual Inspection (Continued)

c. Tip corner Not serviceable Maximum blend radius Blend per
damage must remove all defective paragraph 11 and
material. Rework may paragraph 13
extend into areas B and G
5. Areas E, H, and J (Vane Base) for:
a. Dovetail 10 percent of parent metal - Replace vane
coating exposed
missing
b. Dovetail Not to parent metal - Replace vane
coating wear
c. Dovetail Not serviceable - Replace vane
parent metal
wear
d. Nicks and 0.020 inch (0.51 mm) 0.030 inch (0.76 mm) Blend per
scratches deep. None allowed in deep paragraph 11
other than fillets. Remove high metal
dovetail
surfaces
e. Wear from 0.005 inch (0.13 mm) 0.050 inch (1.27 mm) Remove high metal
retaining key deep deep per paragraph 11
f. Platform end Any amount, not into Not repairable Replace vane
fretting airfoil root radius fillet
10. HPC Stage 6-13 Stator Vanes Dimensional Inspection.
NOTE
Dimensional inspections should follow all required repairs.
A. Dimensionally inspect stage 6-13 vane chord (dimension V) as follows (figure 11):
(1) Measure vane Chord V at dimension D listed in table 5.
(2) Check measured Chord V with table 5 limits. Replace vanes as required.
B. Inspect stage 6-13 vane length (dimension L) per table 6 and figure 12.

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Figure 11. Stages 6 Through 13 Vanes Inspection Areas

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Table 5. HPC IGV and Stage 1-5 Vanes Minimum Chord Values
Root Root 1.34 34.0 1.23 31.2 1.26 32.0
0.50 12.7 1.32 33.5 1.22 31.0 1.24 31.5
1.00 25.4 1.28 32.5 1.16 29.5 1.22 31.0
1.50 38.1 1.24 31.5 1.11 28.2 1.20 30.5
2.00 50.8 1.20 30.5 1.06 26.9 1.17 29.7
2.50 63.5 1.16 29.5 1.01 25.7 1.14 29.0
3.00 76.2 1.11 28.2
Root Root 1.21 30.7 1.11 28.2 1.12 28.4
0.50 12.7 1.20 30.5 1.10 27.9 1.12 28.4
1.00 25.4 1.16 29.5 1.08 27.4 1.08 27.4
1.50 38.1 1.13 28.7 1.04 26.4 1.02 25.9
2.00 50.8 1.10 27.9 0.98 24.9
2.50 63.5
3.00 76.2
Stage 12 Stage 13
inches mm inches mm inches mm
Root Root 1.14 29.0 0.86 21.8
0.50 12.7 1.13 28.7 0.86 21.8
1.00 25.4 1.07 27.2 0.86 21.8
1.50 38.1 0.99 25.1 0.86 21.8
2.00 50.8
2.50 63.5
3.00 76.2

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Table 6. Stage 3-5 Vane Length Dimension L Inspection

Stage Minimum Vane Length Corrective Action
NOTE
The lengths tabulated represent the shortest vanes which should occur as a result of assembly processing
(minimum radius case and maximum grind).
Figure 12. Stages 6–13 Vanes Length Dimension L

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11. Parts Repair - Vanes - General.
A. Use smooth file when repair blending compressor vanes not over 8.0 inches (200 mm) long, or emery cloth
to remove nicks and dents when removal of considerable material is necessary. File or blend in
longitudinal direction (parallel with airfoil length). Power tools may be used for initial heavy removal of
material such as excessive tip curl. Final blend and polish 0.020–0.030 inch (0.51–0.76 mm) must be
accomplished by hand.
CAUTION
ALL BLEND REPAIR AND POLISHING SHALL BE DONE IN DIRECTION PARALLEL
WITH THE VANE LEADING OR TRAILING EDGES. DO NOT USE POWER TOOLS FOR
FINAL POLISH OR FINISH BLENDING.
B. Use medium stone on any areas which have been blended with file or emery cloth, and on areas containing
small nicks and dents.
C. Use fine emery cloth and/or fine abrasive stone to polish blended area until finish looks and feels like
original.
D. Blend leading edges to as near original configuration as possible. Blend trailing edges to remove all sharp
edges (figure 13).
12. Parts Repair - Vanes - Leading and Trailing Edge Blending.
A. Blend leading and trailing edges to within maximum repairable limits of figure 9. Contour blend edges per
figure 13.
B. When blending out cracks, blend away enough material to remove defect and continue to blend an
additional 0.015 inch (0.38 mm).
CAUTION
WHEN POWER BLENDING OUT CRACKS, BLEND AWAY ENOUGH MATERIAL TO

REMOVE DEFECT AND CONTINUE TO BLEND AN ADDITIONAL 0.015 INCH (0.38 MM).
C. Power tools may be used to shorten time required to remove metal but hand bench last 0.005 inch
(0.13 mm).
D. After blending, spot-fluorescent-penetrant-inspect per Chapter 11. No cracks allowed.
13. Parts Repair - Vanes - Tip Blending.
A. Blend to within limits of figure 9.
B. Blends may be 0.100 inch (2.54 mm) maximum depth on 20 percent of vanes per stage.

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Figure 13. Compressor Vane Blending

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14. HPC Stator Case Inspection.
A. Inspect HPC stator case per table 7.
Table 7. HPC Stator Case Inspection

Maximum Serviceable Maximum
Inspect Limit Repairable Limit Repair Method
1. High Boss Field Repair Stages 3-5 VSV Bushing Mounting Holes for:
a. Damage to threads Loss of first full thread Any amount Repair per paragraph 15
15. HPC Stator Case - Repair of VSV Bushing Mounting Hole Threads.
A. This procedure provides instructions to field repair stages 3-5 VSV bushing mounting hole threads in the
HPC stator case by drilling two new holes 90º from the original holes and tapping new threads (figure 14).
Dimensional information for this repair is given in figure 15.
B. Locally manufacture drilling jig for stages that have damaged VSV bushing mounting holes (figure 16).
C. Locally manufacture drilling jig depth gage (figure 17).
D. Locally manufacture bushing rework tool (figure 18).
E. Install locally manufactured drilling jig onto damaged VSV bushing mounting holes as follows (figure 19):
(1) If case is off engine, place drilling jig in VSV hole. Tighten bolt to secure tool to VSV hole. Tighten
(2) If case is assembled, install drilling jig using vane stem and a nut.
(3) Ensure drilling jig is correctly attached and seated against case wall and guiding holes are in correct
position.
(4) Using drilling jig base and locally manufactured depth gage, adjust drill depth to ensure depth of
drilled hole in HPC case does not exceed limit of 0.370 inch (9.39 mm) (figure 17).
CAUTION
ASSURE DRILL STOP IS SECURE AND DEPTH IS SET ON THE DRILL OR DAMAGE TO
CASE MAY OCCUR.
F. Drill two new holes located on the opposite position to old damaged holes (figure 15). Ensure you use the
transfer punch to facilitate drilling.
G. Deburr machined holes. Refer to Chapter 11.
H. Tap threads inside new drilled holes. Refer to requirements in figure 15. Use thread tapping fluid.

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Figure 14. Stages 3-5 VSV Bushing Mounting Holes

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Figure 15. Case Rework Dimensional Information

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Figure 16. Locally Manufactured Drilling Jig (Sheet 1 of 6)

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Figure 17. Drilling Jig Depth Gage (Sheet 1 of 3)

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Figure 18. Bushing Rework Tool (Sheet 1 of 6)

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Figure 18. Rework Tool (Sheet 4 of 6)

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Figure 18. Rework Tool (Sheet 5 of 6)

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Figure 19. Drilling Jig Installation (Sheet 1 of 2)

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Figure 19. Drilling Jig Installation (Sheet 2 of 2)

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I. Deburr machined threads. Refer to Chapter 11.
J. Do a swab etch of all repaired areas. Refer to Chapter 11.
K. Do a spot fluorescent penetrant inspection of compressor stator case. Refer to Chapter 11.
(1) All indications less than 0.03 inch (0.8 mm) are permitted.
(2) Indications less than 0.06 inch (1.5 mm), not interpreted as linear indications, are permitted.
(3) The above defects are permitted if they are not closer than 0.5 inch (12.7 mm).
L. Select correct bushing. Rework bushing by drilling two holes 90° from existing two mounting holes. Use
bushing rework tool (figure 18).
M. Deburr machined holes. Refer to Chapter 11.
N. Reidentify reworked bushing to 2083M62. Refer to Chapter 11.
O. Install new bushing on repaired VSV holes. Use standard compressor case bolts to attach replacement
bushings to VSV mounting holes (figure 20).
16. HPC Stator Vanes Installation.
A. Install stages IGV-2 stator vanes as follows:
(1) Install bushing (6, figure 4) into vane (8) counterbore on stator case (12) outer diameter. Press
bushing evenly to avoid snagging or cracking. Locally fabricate bushing installation tool per
figure 21 and use to install bushings, if required.
CAUTION
ENSURE ALL STAGES IGV-2 STATOR VANES HAVE THE LETTER H

MARKED AT TOP OF VANE STEM. FAILURE TO COMPLY MAY RESULT IN
PART DAMAGE.
(2) Install washer (7, figure 4) onto vane (8). Install vane into stator case (12). Washer shall protrude
into case bore when vane is installed.
(3) Install spacer (5) and lever arm (3) onto vane (8). Ensure spacer and lever arm slide over vane tangs.
(4) Install alignment sleeve (2) and locknut (1) onto vane (8). Ensure alignment sleeve seats between
vane tangs.
CAUTION
DO NOT USE LEVER ARM TO HOLD VANE WHEN TORQUING LOCKNUT, OR

LEVER WILL BE DAMAGED.
(5) Using vane holding tool from holding VSV tool set, 2C6018, and torque wrench, tighten locknut (1)
to 69-81 lb in. (7.8-9.1 N·m). A minimum of two threads shall show beyond nut if parts are seated
properly.

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Figure 20. SPAD Bushing Installation

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Figure 21. VSV Bushing Installation Tool
(6) Measure stages IGV-2 vane rotational torque as follows:
(a) Manually rotate vane (8) several times to ensure assembly is seated.
CAUTION
FAILURE TO MEET PROPER VANE ROTATIONAL TORQUE MAY

CAUSE BINDING AND RESULT IN BENT LEVER ARM.
(b) Check that vane (8) rotational torque is between 2-10 lb in. (0.3-1.1 N·m). Replace spacer (5),
as required, to obtain proper rotational torque (figure 22).
NOTE
A thinner spacer will reduce rotational torque. A thicker spacer will increase
rotational torque.
(c) Small changes to vane (8, figure 4) rotational torque may be accomplished by lapping spacer
face, using circular motion to remove material. Final surface finish shall match original finish.
(d) Record final rotational torque of each vane (8). Torque value will be required for checking total
actuation load for half-ring segments.

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Figure 22. Variable Vane Travel Limits

(7) Ensure actuation travel limits of replacement vanes as follows:
(a) Check each replacement vane for freedom of travel through limits shown in figure 23. If vane
binds, check for interference adjacent to casing bore.
(b) Vane areas adjacent to casing bore may be blended to obtain clearance at travel limits
(figure 24). Remove only enough material to eliminate interference. Do not use power tools.
Gap in reworked area shall not exceed 0.005 inch (0.13 mm). Original finish required. No
undercutting allowed.
(8) Ensure stages IGV-2 vanes are correctly seated using 0.004-inch (0.10 mm) feeler stock between
bushing and spacer (figure 25). Parts are not seated correctly if feeler stock can be inserted between
bushing and spacer.
B. Install stages IGV-2 vane shrouds as follows:
WARNING
ALCOHOL IS FLAMMABLE AND TOXIC TO SKIN, EYES, AND RESPIRATORY
TRACT. SKIN AND EYE PROTECTION IS REQUIRED. AVOID REPEATED OR
(1) Using isopropyl alcohol, clean old silicone rubber adhesive from shroud retaining bolts and nuts.
(2) Install bushings onto vane inner trunnions (figure 26).
(3) Position forward and aft shroud segments onto bushings.

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Figure 23. Variable Vane Travel Limits
Figure 24. Variable Vane Rework Areas

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Figure 25. Variable Stator Vane Seating Check
NOTE
Shroud retaining bolts are body-bound. Do not allow bolts to turn during installation.
(4) Install shroud retaining bolts. On stage IGV, boltheads face aft. On stages 1 and 2, boltheads face
forward.
(5) Tighten nuts to 57-67 lb in. (6.5-7.5 N·m) of torque.
(6) Ensure actuation travel limits of replacement vanes as follows:
binds, check for interference adjacent to shroud.
(b) Vane areas adjacent to shroud may be blended to obtain clearance at travel limits (figure 24).
Remove only enough material to eliminate interference. Do not use power tools. Gap in
reworked area shall not exceed 0.005 inch (0.13 mm). Original finish required. No
undercutting allowed.
(7) Check that torque required to rotate vanes assembled into shrouds does not exceed 15 lb in.
(1.7 N·m).

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Figure 26. Stages IGV-2 Vane Shrouds Installation

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WARNING
VAPOR FROM UNCURED SEALANT IS FLAMMABLE AND TOXIC TO SKIN,

EYES, AND RESPIRATORY TRACT. AVOID CONTACT WITH SKIN AND EYES.
USE IN A WELL-VENTILATED AREA.
(8) Remove nuts one at a time, and fill nut threads with silicone rubber adhesive. Install nuts before
adhesive dries. Tighten nuts to 60-70 lb in. (6.8-7.9 N·m) of torque.
(9) Use 0.001-inch (0.03 mm) feeler stock to check that shrouds are mated.
(10) Apply silicone rubber adhesive over nuts and exposed bolt threads, to a minimum thickness of
0.032 inch (0.81 mm).
(11) Allow silicone rubber adhesive to cure for a minimum of 8 hours before engine operation.
C. Select and grind replacement stages 3-5 stator vanes as follows:
(1) Select replacement vane of equal length to, or slightly longer than, vane being replaced. If replaced
vane length cannot be determined, use length of shorter of two adjacent vanes.
NOTE
Power blending shall be accomplished so no excessive heat and thermal stresses are
generated. Failure to comply may result in part damage.
(2) Hand-grind replacement vane to length of original vane +0.000 to -0.005 inch (+0.00 to -0.13 mm).
Maintain proper length and angle across vane tip. Stages 3-5 vanes have double angles on tip. Power
tools may be used to shorten grinding time but last 0.005 inch (0.13 mm) must be hand ground.
D. Install stages 3-5 stator vanes as follows:
(1) Install high-boss case stages 3-5 stator vanes (figure 27) as follows:
(a) Visually check for evidence of locking feature on bolts (7). Lightly coat threads and seating
surfaces of bolts with thread lubricant.
1 Install self-locking bolts by hand into case. If bolts can be run into case without stopping,
self-locking feature is not adequate. Replace bolt with new bolt.
2 If bolthole condition does not allow any self-locking fastener to engage locking feature,
remove adjacent self-locking bolt and install two non-self-locking bolts so they may be
safety-wired or safety-cabled together.

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Figure 27. High-Boss Case Stages 3-5 Vane Installation

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(b) Pre-assemble multiple-piece bushing assemblies as follows:
CAUTION
PART NUMBERS ARE NOT MARKED ON NEW BUSHINGS AND

ARE DIFFICULT TO DIFFERENTIATE BY SIZE AND SHAPE.
STAGE 5 BUSHINGS HAVE A PAINT MARKING ON BUSHING
BARREL AND STAGE 3 AND 4 BUSHINGS HAVE NO PAINT
MARKINGS. FAILURE TO ASSEMBLE CORRECTLY MAY CAUSE
VSV OFF-SCHEDULE OPERATION.
CAUTION
PART NUMBERS ARE NOT MARKED ON NEW WASHERS AND

ARE DIFFICULT TO DIFFERENTIATE BY SIZE AND SHAPE.
STAGE 5 WASHERS HAVE A PAINT MARKING ON WASHER
FACE AND STAGES 3 AND 4 WASHERS HAVE NO PAINT
MARKINGS. FAILURE TO ASSEMBLE CORRECTLY MAY CAUSE
VSV OFF-SCHEDULE OPERATION.
1 Pre-assemble multiple-piece bushing assemblies for stages 3 and 4 as follows:
a Insert barrel end of unpainted stages 3 and 4 flanged bushing (13) inside barrel
end of stages 3 and 4 compressor stator vane actuation housing (6).
b Insert unpainted stages 3 and 4 flat washer (8) in recessed area on housings
assembled in previous step.
2 Pre-assemble multiple-piece bushing assemblies for stage 5 as follows:
a Insert barrel end of painted stage 5 flanged bushing (13) inside barrel end of
stage 5 compressor stator vane actuation housing (6).
b Insert painted stage 5 flat washer (8) in recessed area on housings assembled in
previous step.
(c) Install multiple-piece bushing assemblies into HPCS cases as follows:
CAUTION
MULTIPLE-PIECE BUSHING ASSEMBLIES WITH CUTOUTS ARE

INSTALLED AT BORESCOPE LOCATIONS. IMPROPER
INSTALLATION WILL PREVENT BORESCOPE USE.
NOTE
Once assembled, the new multiple-piece bushing assemblies are installed
in the same manner as the one-piece bushing.
1 Install multiple-piece bushing assemblies, pre-assembled in step 16.D.(1)(b) HPCS

stages 3 and 4 high-boss case outer bores.

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2 Install multiple-piece bushing assemblies with cutouts, pre-assembled in step 16.D.(1)(b)

into HPCS stages 3 and 4 high-boss case outer bores adjacent to borescope ports.
3 Verify that borescope ports in stages 3 and 4 are not blocked. If blocked, repeat
step 16.D.(1)(c)1 and step 16.D.(1)(c)2. If not blocked, perform remaining installation
steps.
4 Install multiple-piece bushing assemblies, pre-assembled in step 16.D.(1)(b) into HPCS
stage 5 high-boss case outer bores.
CAUTION
ENSURE ALL STAGES 3-5 STATOR VANES HAVE THE LETTER V

MARKED AT TOP OF VANE STEM. APEX OF V SHALL POINT
FORWARD. FAILURE TO COMPLY MAY RESULT IN PART DAMAGE.
(d) Install vane (9) into high-boss case (12). Ensure vane has the letter V marked on top of vane
stem and the apex of the V is pointing forward.
(e) Install spacer (5) and alignment sleeve (4) onto vane (9). Flat on alignment sleeve faces
forward.
(f) Install jamnut (3) onto vane (9). Using holding tool from holding VSV tool set, 2C6018, and
torque wrench, tighten jamnut to 60-70 lb in. (6.8-7.9 N·m) of torque. Replace jamnut if run-on
torque is more than 20 lb in. (2.3 N·m).
(g) Install lever arm (2) and locknut (1) onto vane (9) by hand. If nut can be run onto vane without
stopping, self-locking feature is not adequate. Replace nut with new nut.
CAUTION
DO NOT USE LEVER ARM TO HOLD VANE WHEN TORQUING
LOCKNUT, OR LEVER WILL BE DAMAGED.
(h) Using holding tool from holding VSV tool set, 2C6018, and torque wrench, tighten locknut to
60-70 lb in. (6.8-7.9).
(2) Measure individual vane (9) rotational torque as follows:

(a) Manually rotate vane (9) several times to ensure assembly is seated.
CAUTION
FAILURE TO MEET PROPER VANE ROTATIONAL TORQUE MAY
CAUSE BINDING AND RESULT IN BENT LEVER ARM.
NOTE
A 0.0 lb in. (0.0 N·m) torque limit implies that vane can rotate with a minimum
force applied. However, it is important to ensure that the vane assembly is not
loose after assembly as a result of a spacer that is too thin. Vane assembly
should be tight and should not rattle or demonstrate any looseness.

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(b) Ensure vane (9) rotational torque on high-boss case (12) is within 0-10 lb in. (0.0-1.1 N·m).
(c) On high-boss case (12) installation, obtain vane (9) rotational torque as follows:
1 If rotational torque is below limits, replace spacer (5).
2 If rotational torque is above limits, spacer (5) thickness may be reduced by lapping spacer
face, using figure eight motion to remove material. Final surface finish shall match
original.
(d) Record final rotational torque of each vane (9). Torque value will be required for checking total
actuation load for half-ring segments.
(3) Ensure actuation travel limits of replacement vanes (9) as follows:
binds, check for interference adjacent to casing bore.
(b) Vane areas adjacent to casing bore may be blended to obtain clearance at travel limits
(figure 24). Remove only enough material to eliminate interference. Do not use power tools.
Gap in reworked area shall not exceed 0.005 inch (0.13 mm). Original finish is required. No
undercutting is allowed.
E. Connect lever arms (2, figure 27) to actuation rings (11) as follows:
(1) Loosen locknuts (1) enough to allow lever arm (2) pins to be inserted into actuation ring
sleeves (10).
(2) Insert lever arm (2) pins into actuation ring sleeves (10).
CAUTION
DO NOT USE LEVER ARM TO HOLD VANE WHEN TORQUING LOCKNUT OR
LEVER WILL BE DAMAGED.
(3) Hold stages IGV-2 vane with holding tool from holding VSV tool set, 2C6018, or VSV holder set,
2C6171, and tighten locknut (1) to 69-81 lb in. (7.8-9.1 N·m) of torque. Use torque wrench,
2C6965.
(4) Hold stages 3-5 vane with holding tool from holding VSV tool set, 2C6018, or VSV holder set,
2C6171, and tighten locknut (1) on high-boss case (12) to 60-70 lb in. (6.8-7.9 N·m) of torque.
F. Check actuation ring segment installation as follows (figure 28):
(1) Inspect stages IGV-4 actuation ring for presence of washers under spacer locknuts. Install washer, if
missing.
(2) Position vanes so lever arms point aft. Measure dimension M at each spacer for all stages.
(3) Adjust spacers, as required, to dimension M limits. Tighten locknut to 69-81 lb in. (7.8-9.1 N·m) of
torque.

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G. Perform actuation ring pull check as follows:
(1) Using torque measuring fixture set, 1C9408, perform pull check on stages IGV-5 as follows:
NOTE
To perform pull check using a pull scale rather than torque measuring fixture set, 1C9408,
proceed to step 16.G.(2).
(a) Remove parts from vane near center of actuation ring as shown in figure 29.
(b) Remove sleeve from actuation ring.
(c) Install dummy lever arm, locator plug, and drive adapter from torque measuring fixture set,
1C9408.
Figure 28. Actuation Ring Spacer Clearance

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Figure 29. VSV Actuation Ring Pull Check

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(d) On stages IGV-2, tighten locator plug to 69-81 lb in. (7.8-9.1 N·m) of torque. On stages 3-5
high-boss case, tighten locator plug to 60-70 lb in. (6.8-7.9 N·m) of torque.
(e) Measure torque required to move actuation ring +5 degrees from axial position as shown in
figure 30. On stages IGV-4, torque required shall not exceed 140 lb in. (15.8 N·m). On stage 5,
torque required shall not exceed 204 lb in. (23.0 N·m).
(2) Perform pull check using a pull scale as follows:
(a) Install slave bolt into actuation ring connecting link bolthole.
(b) Attach pull scale to slave bolt.
(c) Measure force required to move actuation ring +5 degrees from axial position as shown in
figure 30. Multiply reading by the following scale factors to obtain torque:
Stage Scale Factor

IGV 2.80 in. (71.1 mm)
1 2.72 in. (69.1 mm)
2 2.53 in. (64.3 mm)
3 2.18 in. (55.4 mm)
4 1.92 in. (48.8 mm)
5 1.46 in. (37.1 mm)
Figure 30. VSV Actuation Ring Travel

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(d) On stages IGV-4, torque required shall not exceed 140 lb in. (15.8 N·m). On stage 5, torque
(3) Actuate each stage by hand, through complete open and closed mechanical travel. Each stage shall
move freely with no catching or binding.
(4) If pull check requirements are not met, perform the following:
(a) Check actuation ring spacer clearance per step 16.F. Adjust as required.
(b) On stages IGV-2, check for vane binding at shrouds and HPC stator casing bore. Correct, as
required, per step 16.A or step 16.B.
(c) On stages 3-5, check for vane binding at HPC stator casing bore. Correct, as required, per
step 16.D.
(d) Check recorded rotation torques for individual vanes (step 16.D.(3)). Replace or rework
spacers on vanes with high torques, as required, per step 16.A or step 16.D.
H. Select and grind replacement stages 6-13 stator vanes as follows:
(1) Select replacement vane of equal length to, or slightly longer than, vane being replaced. If replaced
vane length cannot be determined, use length of shorter of two adjacent vanes.
CAUTION
POWER BLENDING SHALL BE ACCOMPLISHED SO NO EXCESSIVE HEAT

AND THERMAL STRESSES ARE GENERATED. FAILURE TO COMPLY MAY
RESULT IN PART DAMAGE.
(2) Hand-grind replacement vane to length of original vane +0.000 to -0.005 inch (+0.00 to -0.13 mm).
Maintain proper length and angle across vane tip. Stages 6-13 vanes have double angles on tip.
Power tools may be used to shorten grinding time but last 0.005 inch (0.13 mm) must be hand
ground.
I. Install stage 13 stator vanes as follows (figure 31):
CAUTION
USE CARE SO END-STOP DOES NOT FALL OUT OF THE LINER SEGMENTS
AND LEAF SEALS DO NOT BECOME DISENGAGED.
(1) Install one end-stop and seven standard vanes into liner. Install vanes with borescope cutouts into
liner with borescope hole.
(2) With liner end-stop fully seated into liner slot, check position of last vane. Last vane platform edge
shall be 0.000-0.015 inch (0.00-0.38 mm) inside end of liner. If end gap is not within limits, proceed
as follows:
(a) Replace standard vanes with wide platform vanes, as required, to meet end gap.

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Figure 31. Stage 13 Vane Installation (Sheet 1 of 2)

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Figure 31. Stage 13 Vane Installation (Sheet 2 of 2)

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(b) Vane platform edges of replacement vanes may be ground a maximum of 0.006 inch (0.15 mm)
per side to meet end gap. Surface finish and contour to match original platform.
(3) Remove seven stator vanes from liner and reinstall with new spring retainers as follows (figure 32):
CAUTION
• MAKE SURE VANE SPRING RETAINERS ARE INSTALLED
CORRECTLY. SPRING RETAINERS CAN BE INSTALLED
INVERTED AND MAY RESULT IN PARTS FAILURE.
• DO NOT REUSE VANE SPRING RETAINERS FROM A

PREVIOUSLY OPERATED ENGINE. FAILURE TO COMPLY MAY
NOTE
Vane spring retainers are not installed under end vanes or borescope vanes.
(a) Install new spring retainer behind platform edge of installed stator vane. Ensure spring retainers
are installed per figure 32.
(b) Install next stator vane until further movement requires force. Use nylon drift or driver from
compressor stator vane driver set, 2C6019, to drive against vane platform, not airfoil. Drive
stator vane over spring retainer until vane platforms contact.
(c) Install remaining stator vanes per step 16.I.(3)(a) and step 16.I.(3)(b) until all vanes are
installed.
(d) Check that end gap is still within limits per step 16.I.(2).
CAUTION
DO NOT ALLOW THREAD LUBRICANT ON AIRFOIL OR CASE FLOWPATH.
(4) Apply thread lubricant to rails of liners. Lubricant is not permitted on vane airfoils or case flowpath.
(5) Position honeycomb seal in place with seal lip forward and install assembled liner into stator case
slots. Install remaining liners and install honeycomb seals to bridge liner segments. Install
honeycomb seal segments at horizontal flanges. Install liner and honeycomb seal with borescope
holes in bottom case, to align with case borescope hole.
(6) Apply thread lubricant onto threads and washer faces of bolts. Secure liners with bolts. Tighten bolts
(7) Check installation of liners as follows:
(a) Measure gap between liners, four places per HPC stator case half. Gap shall not be less than
0.040 inch (1.02 mm).
(b) Measure gap between end liners and HPC stator case horizontal flange, two places per case
half. Gap shall not be less than 0.020 inch (0.51 mm).

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Figure 32. Vane Spring Retainer Installation
(c) On lower HPC stator case, check that a 0.405-inch (10.29 mm) diameter rod will pass freely
through case, liner, and vane borescope holes.
(d) Loosen bolts and adjust position of liners, as required. Tighten bolts to 276-324 lb in.
(31.2-36.6 N·m) of torque.
(8) Install borescope plug into lower HPC stator case as follows:
(a) Apply thread lubricant onto threads and washer face of borescope plug.
(b) Install plug and tighten to 95-105 lb in. (10.8-11.8 N·m) of torque. Safety-wire plug.
J. Install stages 6-12 stator vanes as follows:
(1) On upper HPC stator case half, install retaining key on 3:00 o’clock horizontal flange position and
secure with two C-clamps (figure 33). On lower HPC stator case half, install parallel bar on
3:00 o’clock horizontal flange position and secure with two C-clamps.
CAUTION
DO NOT ALLOW THREAD LUBRICANT ON AIRFOIL OR CASE FLOWPATH.

(2) Apply two thin coats of thread lubricant onto vane dovetails. Lubricant is not permitted on vane
airfoils or case flowpath.

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Figure 33. Stages 6-12 Stator Vanes Installation (Sheet 1 of 2)

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Figure 33. Stages 6-12 Stator Vanes Installation (Sheet 2 of 2)

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(3) Install stages 7 and 11 stator vanes as follows:
CAUTION
IF A SCRAP VANE IS USED AS A DRIVER, ENSURE SCRAP VANE IS

NOT INSTALLED. FAILURE TO COMPLY MAY RESULT IN PART
DAMAGE.
(a) Slide vane into retaining slot until flush against key or parallel bar. Use nylon drift or
compressor stator vane driver set, 2C6019, as required. Tool shall drive against vane base, not
airfoil.
(b) Continue installing vanes until all vanes are installed. Number of vanes per case half shall
comply with table 8.
Table 8. Stages 6-12 Vane Requirements

Vane Quantity Stage Platform End Gap
(Per Stator Half) Minimum Platform Width (Per Stator Half)
6* 32 1.293 in. (32.84 mm) 0.080-0.120 in. (2.04-3.04 mm)
7 36 1.134 in. (28.80 mm) 0.090-0.130 in. (2.28-3.30 mm)
8* 34 1.202 in. (30.53 mm) 0.105-0.145 in. (2.67-3.68 mm)
9* 38 1.073 in. (27.25 mm) 0.105-0.145 in. (2.67-3.68 mm)
10* 40 1.017 in. (25.83 mm) 0.115-0.155 in. (2.93-3.93 mm)
11 40 1.017 in. (25.83 mm) 0.120-0.160 in. (3.05-4.06 mm)
12* 42 0.989 in. (25.12 mm) 0.060-0.100 in. (1.53-2.54 mm)
* Vane platform gap requirements shall be met with vane retainers installed.
(4) Install stages 6, 8, 9, 10, and 12 vanes as follows:
CAUTION
IF A SCRAP VANE IS USED AS A DRIVER, ENSURE SCRAP VANE IS
NOT INSTALLED. FAILURE TO COMPLY MAY RESULT IN PART
DAMAGE.
(a) Slide vane into retaining slot until flush against key or parallel bar. Use nylon drift or
compressor stator vane driver set, 2C6019, as required. Tool shall drive against vane base, not
airfoil.

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CAUTION
• MAKE SURE VANE SPRING RETAINERS ARE INSTALLED

CORRECTLY. SPRING RETAINERS CAN BE INSTALLED
INVERTED AND MAY RESULT IN PARTS FAILURE.
• DO NOT REUSE VANE SPRING RETAINERS FROM A

PREVIOUSLY OPERATED ENGINE. FAILURE TO COMPLY MAY
(b) Install new spring retainer behind platform edge of installed vane. Ensure spring retainers are
installed per figure 32.
(c) Install next vane into retaining slot until further movement requires force. Use nylon drift or
compressor stator vane driver set, 2C6019, to drive against vane platform, not airfoil. Drive
vane over spring retainer until vane platforms contact figure 33.
(d) Install remaining vanes per step 16.J.(4)(b) and step 16.J.(4)(c) until all vanes are installed.
Install vanes with borescope platform cutouts, to align with HPC stator case borescope holes.
Number of vanes per case half shall comply with table 8.
(5) Check installation of borescope vanes as follows:
(a) On stages 6 and 10, check that a 0.405-inch (10.29 mm) diameter rod will pass freely through
HPC stator case and platform of vanes.
(b) On stage 12, check that a 0.320-inch (8.13 mm) diameter rod will pass freely through HPC
stator case and platform of vanes.
K. Measure stages 6-12 vane total platform end-gap as follows:
(1) Push all vanes circumferentially toward retaining key or parallel bar, until no gaps exist between
vane platforms.
(2) Measure gap between last vane and case flange. Refer to table 1 for required clearances. If end gap
is not within limits of table 8, proceed as follows:
(a) Adjust quantity of wide and standard platform vanes to obtain required vane platform end gap
clearance. Each stage must contain quantity of vanes called out in table 8.
(b) Vane platform edges of replacement vanes may be ground a maximum of 0.005 inch (0.13 mm)
per side to meet end gap. See table 8 for minimum platform widths. Surface finish and contour
to match original platform.
L. Install vane retaining keys onto upper HPC stator case half flanges as follows:
(1) Install key onto each horizontal flange of upper HPC stator case half. Chamfered side of key goes
into case flange mating slot.
(2) Stake each key two places at each end and between adjacent vane slots between stages 6 and 12
(figure 34).

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(3) Using sharpening stone, remove any high metal caused by staking.
M. Install borescope plugs as follows:
(1) Apply thread lubricant to threads and washer face of borescope plug.
(2) Install plug into borescope port.
(3) Tighten plugs to 95-105 lb in. (10.8-11.8 N·m) of torque. Safety-wire plugs.
Figure 34. Top Case Vane Retainer Key Installation

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HIGH PRESSURE COMPRESSOR (HPC) STATOR OUTLET
GUIDE VANES REPLACEMENT
())(&7,9,7</03)*$6785%,1(02'(/6

Page No. Change No.
1 - 12 ........................................................................................................................................................ 0
Alphabetical Index
Subject Page
HPC Outlet Guide Vane (OGV) Removal. .............................................................................................. 3

HPC Outlet Guide Vane Visual Inspection. ............................................................................................. 5
HPC Outlet Guide Vane Blending............................................................................................................ 6
HPC Outlet Guide Vane Installation. ...................................................................................................... 10
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1. Introduction.
NOTE
HPC outlet guide vanes are located in the compressor rear frame.
This work package contains instructions for removing and installing the high pressure compressor (HPC) stator
outlet guide vanes.
Title Number
Maintenance Considerations Chapter 11
High Pressure Compressor (HPC) Upper and Lower Stator Case SWP 2411 01
Opening/Closing
High Pressure Compressor (HPC) Rotor Blades Replacement WP 2413 00

Cloth, Abrasive Aluminum Oxide, Various Grit
Stone, Abrasive Local Purchase
Tape, Masking Local Purchase
Tape, Plastic NT-580, Patco No. 110-50, or
Shurtape PC-623

Clip, Vane Liner 9232M47P02 4
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6. HPC Outlet Guide Vane (OGV) Removal.
A. Open upper or lower HPC stator case per SWP 2411 01.
B. Remove stage 14 and, if required, stage 13 blades to gain access to OGVs per WP 2413 00.
C. Remove HPC OGVs as follows:
WARNING
INSULATION BLANKETS CONTAIN FIBERGLASS. DO NOT INHALE THE

FIBERGLASS OR LET IT TOUCH YOU. PERSONAL PROTECTIVE EQUIPMENT
REQUIRED. ALLERGEN AND IRRITANT. WELL-VENTILATED.
(1) Bend OGV liner clips down (radially inward) (figure 1).
(2) Unseat OGV liner assemblies from OGV liner rails in CRF assembly. Secure OGVs into liners using
masking tape at end of liner that is not keyed.
WARNING

(3) Using No. 10-32 thread jackscrew, lubricated with oil, remove OGV liner assemblies from CRF
assembly one at a time.
(4) Remove liner clips and discard.
(5) Remove OGVs and dovetail liners from OGV liner.
(6) Remove four insulation blankets from between OGV liner rails in CRF assembly.
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Figure 1. Outlet Guide Vane Removal
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7. HPC Outlet Guide Vane Visual Inspection.
A. Visually inspect outlet guide vanes per table 1 and figure 2.
Table 1. HPC Outlet Guide Vane Visual Inspection

1. Outlet Guide Vanes for:
a. Missing OGV Not serviceable Not repairable Replace vane or
airfoils segment
b. All areas for:
(1) Cracks Not serviceable Not repairable Replace vane or
segment
(2) Surface None allowed Any amount Remove deposits
deposits with fine emery
cloth. No scratches
allowed
c. Areas A for:
(1) Nicks and Any number, 0.005 inch 0.010 inch (0.25 mm) Repair per
scratches (0.13 mm) deep after deep paragraph 8
removal of high metal
(2) Dents Any number, 0.010 inch Not repairable Replace vane or
(0.25 mm) deep segment
d. Area B (leading and trailing edges) for:
(1) Nicks, pits 0.005 inch (0.13 mm) Within minimum Repair per
and deep Chord V for vane paragraph 8
scratches
(2) Dents Any number, 0.020 inch Within minimum Repair per
(0.51 mm) deep Chord V for vane paragraph 8
(3) Erosion of Any amount provided Any amount provided Repair per
airfoil at minimum root chord is minimum root chord is paragraph 8
dovetail V inches or greater, and V inches or greater,
leading and trailing edge and leading and
thicknesses are 0.012 inch trailing edge
(0.30 mm) or greater thicknesses are
0.012 inch (0.30 mm)
or greater
e. Airfoil tip Not serviceable Any amount Repair per
damage 0.060 inch (1.52 mm) paragraph 8
deep over 20 percent
of OGVs
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Table 1. HPC Outlet Guide Vane Visual Inspection (Continued)

f. Vane platform for:
(1) Nicks and Any number 0.015 inch Not repairable Replace vane or
scratches (0.38 mm) deep after segment
other than removal of high metal
dovetail
scratches
(2) Fretting Wear not into airfoil root Not repairable Replace vane or
radius fillet segment
(3) Wear from 0.060 inch (1.52 mm) Not repairable Replace vane or
retaining deep segment
key
(4) Buckled Any amount provided Not repairable Replace three-vane
three-vane difference in tip spacing segment
segments does not exceed
0.150 inch (3.81 mm)
8. HPC Outlet Guide Vane Blending.
NOTE
Blending may be accomplished using step 8.A, step 8.B, or step 8.C.
A. Remove high metal by blending down to the machined surface. Use abrasive stones or papers. Coarse
grades of abrasive may be used for fast removal of metal. Then use a fine grade abrasive for the finish.
B. Blend to remove damage with a fine file, abrasive cloth or abrasive stone as follows (figure 3):
(1) Blend and polish in a longitudinal direction, parallel with the airfoil of the blades.
(2) The leading and trailing edge radius of the blend repaired area must conform to the original contour
with the airfoil of the blades (figure 4).
(3) When blending on an area involving a radius, maintain the radius as specified or as near as possible
to the original radius.
(4) The finish must be 16-32 microinches (0.41-0.81 micrometer).
CAUTION
POWER BLENDING MUST BE ACCOMPLISHED IN SUCH A MANNER THAT NO
EXCESSIVE HEAT AND THERMAL STRESSES WILL BE GENERATED.
C. If a large or deep blend is required, blend to remove the damage with a slow speed power tool to shorten
the time required for repair as follows (figure 3):
(1) Blend and polish in a longitudinal direction, parallel with the airfoil of the blades.
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Figure 2. OGV Inspection Areas
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Figure 3. Outlet Guide Vane - Blending
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Figure 4. Leading and Trailing Edge Blending
(2) The leading and trailing edge radius of the blend repaired area must conform to the original contour
(figure 4).
(3) When blending on an area involving a radius, maintain the radius as specified or as near as possible
to the original radius.
(4) The finish must be 16-32 microinches (0.41-0.81 micrometer).
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9. HPC Outlet Guide Vane Installation.
A. Assemble OGVs to liners (figure 5) as follows:
CAUTION
DO NOT FORCE OGVS INTO LINERS. OGVS SHOULD ASSEMBLE WITHOUT

ADDITIONAL FORCE. IF OGVS CANNOT BE INSTALLED EASILY, CHECK
FOR CORRECT VANE ORIENTATION.
NOTE
• All dimensions involving OGV key in liner are taken with key bottomed in slot.
• Vanes that are to be reinstalled in the same casing from which they were removed,
should have been numbered sequentially to permit reinstallation in the same
circumferential location.
(1) Install forward and aft vane dovetail liners into OGV liner as follows:
(a) Install vane dovetail liners into OGV liner per figure 5.
(b) With OGV key bottomed into slot in OGV liner, push dovetail liners so liners are against OGV
key. Check vane dovetail liners are 0.005-0.050 inch (0.13-1.27 mm) inside end of OGV liner.
(2) Install vanes into OGV liner as follows:
NOTE
The number of wide and narrow vanes is to be adjusted to obtain the required
gap between the liner and last vane installed.
(a) Install one 3-vane OGV segment into end opposite key of each liner and slide to key end of
liner.
(b) Install 25 OGVs into each of OGV liners. Ensure all vane leading edges are forward.
(c) Check OGVs extend 0.000-0.012 inch (0.00-0.30 mm) beyond end of OGV liner with vanes
rotated against OGV key and with OGV key bottomed in slot against OGV liner. Use alternate
wide and narrow OGVs to achieve this dimension.
(d) Secure OGVs in liners with plastic tape until ready for installation into CRF assembly.
B. Install OGV assemblies into CRF assembly as follows:
WARNING
INSULATION BLANKETS CONTAIN FIBERGLASS. DO NOT INHALE THE

FIBERGLASS OR LET IT TOUCH YOU. PERSONAL PROTECTIVE EQUIPMENT
REQUIRED. ALLERGEN AND IRRITANT. WELL-VENTILATED.
(1) Install four insulation blankets between OGV liner rails. Use masking tape to hold insulation
blankets in place. Do not align butt ends of insulation blankets with butt ends of OGV liners.

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Figure 5. HPC Outlet Guide Vane Installation

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(2) Locally crush insulation blanket at slots in CRF rail to permit engagement of key. Tearing of
insulation blanket skin is not permitted.
(3) Using OGV liner assemblies as guide, mark locations on CRF that require liner clips. Use marking
pen.
(4) Install one OGV liner clip onto each marked location. Prebend clip and snap into place. Liner clip
should protrude forward after installed over rail.
NOTE
Outboard forward hook of liner must not protrude axially forward of CRF forward flange.
(5) Install each OGV liner assembly, engaging liner key into slot in CRF rail. Rotate liner
counterclockwise (before seating), forward looking aft, so key contacts slot in CRF rail.
NOTE
Ensure that OGV liner clips protrude through slots of the OGV liner assembly.
(6) Seat OGV liner assembly onto OGV liner rails by lightly tapping with plastic or rubber mallet.
(7) Bend OGV liner clips outboard to secure OGV liner assembly into CRF. Tabs must not protrude
forward of CRF forward flange.
(8) Remove tape that secures OGV segments in liners.
(9) Check for radial looseness of OGV liner assemblies with 0.005 inch (0.13 mm) feeler stock.
(10) Assure forward liner does not protrude axially forward of CRF forward flange.
(11) Measure gap between adjacent liners at four locations. Minimum gap shall be 0.044 inch (1.12 mm).
(12) If gap between adjacent liners is less than minimum, verify liner key is in contact with CRF rail slot.
Obtain gap by reworking end of liner without key. Rework per Chapter 11, paragraph 11-3.22.2
(13) Use feeler stock to verify minimum gap of 0.030 inch (0.76 mm) between OGVs and CRF forward
inner diffuser.
(14) If minimum gap between OGVs and CRF forward inner diffuser is less than minimum, rework vane
tips to obtain 0.030 inch (0.76 mm) clearance. Rework vane tips per Chapter 11,
paragraph 11-3.22.2.
C. Reinstall stages 13 and 14 HPC blades per WP 2413 00.
D. Close upper and lower HPC stator cases per SWP 2411 01.

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COMBUSTION CHAMBER REPLACEMENT
())(&7,9,7</03)*$6785%,1(02'(/6

Page No. Change No.
1 - 13 ........................................................................................................................................................ 0
14 Blank ................................................................................................................................................... 0
Alphabetical Index
Subject Page
Combustion Chamber Installation........................................................................................................... 10

Combustion Chamber Removal ............................................................................................................... 3
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1. Introduction.
A. This work package contains instructions for removing and installing the combustion chamber.
Title Number
Gas Fuel System Replacement WP 1510 00
Ultraviolet Flame Sensor, Flame Sensor Sight Glass, WP 1515 00
and Flame Sensor Bracket Replacement
Igniter Plug Replacement WP 1516 00
Acoustic Sensor Replacement WP 1611 00
Heat Shields Replacement WP 1915 00
Stage 1 High Pressure Turbine (HPT) Nozzle Replacement WP 2511 00
High Pressure Turbine (HPT) Module Replacement WP 2610 00
Low Pressure Turbine (LPT) Module Replacement WP 2710 00

Adapter, Lift - Combustor, Stage 1 or 2 HPT Nozzle 1C9362G02
Fixture, Installation/Removal - CRF Aft Case 1C9422G02
Guide, Installation/Removal - Combustion Chamber Assembly 1C9423G04
Tool Set, Removal - CRF Aft Case 1C9429G01
Marking Pen Sharpies T.E.C. (Black or Blue)
None required.
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6. Combustion Chamber Removal
A. Remove low pressure turbine (LPT) module per WP 2710 00.
B. Remove ultraviolet flame sensor, flame sensor sight glass, sight adapter, and flame sensor bracket per
WP 1515 00.
C. Remove acoustic sensors and adapters per WP 1611 00.
D. Remove forward, mid, and aft heat shields per WP 1915 00.
E. Remove bolts and nuts securing brackets to extended flange brackets on compressor rear frame (CRF) aft
case forward flange per SWP 1913 02.
F. Remove high pressure turbine (HPT) module per WP 2610 00.
G. Remove stage 1 HPT nozzle per WP 2511 00.
H. Remove igniter plugs per WP 1516 00.
I. Remove borescope plugs from borescope ports S6-1 and S6-4 in CRF (figure 1).
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Figure 1. Combustion Chamber and HPT Borescope Ports
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J. Remove CRF aft case as follows:
(1) Using marking pen, position mark top vertical centerline on CRF aft case forward flange.
(2) Attach an overhead hoist to lift adapter, 1C9362, link.
(3) Attach lift adapter to lift tube on installation/removal fixture, 1C9422, with quick-release pin
(figure 2). Adjust center of gravity (CG) as required.
WARNING
(4) Lift and turn installation/removal fixture, 1C9422, to horizontal.
(5) Attach installation/removal fixture, 1C9422, onto aft flange of CRF aft case and secure with eight
washers and screws. Tighten screws to 83-97 lb in. (9.4-10.9 N·m) of torque.
(6) Remove 137 nuts, 28 extended flange brackets, and 137 bolts that secure CRF aft case onto CRF aft
flange (figure 3).
(7) Install removal tool set, 1C9429, segments at six equally spaced locations on CRF aft case to CRF
aft flange as follows (figure 4):
(a) Place spacer segment onto forward side of flange (section B-B).
(b) Install puller segment over flange (section A-A) so that lip engages forward edge of CRF aft
case flange and secure onto spacer segment with four screws. Tighten screws finger-tight.
(c) Install jackscrew into center hole of puller segment and tighten finger-tight.
WARNING
USE THERMAL GLOVES WHEN YOU MOVE OR TOUCH HOT OR COLD PARTS.
HOT OR COLD PARTS CAN CAUSE INJURY.
(8) Tighten jackscrews evenly, in small increments, to remove CRF aft case. If difficulty is encountered,
heat CRF aft case forward flange using heat gun.
(9) Remove removal tool set, 1C9429, segments.
(10) Carefully remove CRF aft case and store in a safe place.
(11) Remove lift adapter, 1C9362, from installation/removal fixture, 1C9422. Leave installation/removal
fixture attached onto CRF aft case. Leave overhead hoist attached to lift adapter link (figure 2).
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Figure 2. CRF Aft Case Installation/Removal Fixture, 1C9422
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Figure 3. CRF Aft Case to CRF Flange
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Figure 4. CRF Aft Case Removal Tool Set, 1C9429
K. Attach lift adapter, 1C9362, onto lift tube on combustion chamber assembly guide, 1C9423, support ring
with quick-release pin (figure 5). Adjust CG as required.
WARNING
L. Lift and turn combustion chamber support ring to horizontal position.
M. Install combustion chamber assembly guide, 1C9423, as follows (figure 5):
(1) Install guide ring onto No. 5 bearing housing flange in CRF and secure to slab-head bolts with six
captive retainer nuts. Tighten retainer nuts finger-tight.
(2) Guide support ring over guide ring, and position support ring onto combustion chamber inner
support.
(3) Secure three plates of support ring onto combustion chamber inner support with six screws. Tighten
screws to 60-70 lb in. (6.8-7.9 N·m) of torque.
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Figure 5. Combustion Chamber Assembly Guide, 1C9423
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N. Remove combustion chamber as follows:
WARNING

PROLONGED CONTACT. USE WITH GOOD VENTILATION.
(1) Apply penetrating oil to 30 threaded retaining pins that secure combustion chamber in CRF. Allow
penetrating oil to soak for 20 minutes.
(2) Cut safety wire and remove 30 threaded retaining pins.
WARNING
(3) Carefully move combustion chamber aft, out of CRF, guiding combustion chamber support ring
over guide ring. If difficulty is encountered, heat CRF aft flange using heat gun.
O. Remove combustion chamber assembly guide, 1C9423, support ring from combustion chamber.
P. Remove lift adapter, 1C9362, from combustion chamber support ring. Leave overhead hoist attached to lift
adapter link.
7. Combustion Chamber Installation
A. Install combustion chamber assembly guide, 1C9423, as follows (figure 5):
(1) Install guide ring onto No. 5 bearing housing flange in CRF and secure to slab-head bolts with six
captive retainer nuts. Tighten retainer nuts finger-tight.
(2) Guide support ring over guide ring, and position support ring onto combustion chamber inner
support. Align lift tube with top mark on combustion chamber.
(3) Secure three plates of support ring to combustion chamber inner support with six screws. Tighten
screws to 60-70 lb in. (6.8-7.9 N·m) of torque.
B. Attach lift adapter, 1C9362, onto lift tube on support ring of combustion chamber assembly guide,
1C9423, with quick-release pin (figure 5). Adjust CG as required.
WARNING
C. Lift and turn combustion chamber to the horizontal position.
D. Inspect interior area of CRF for dirt and foreign material. No dirt or foreign materials are allowed.

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E. Install combustion chamber as follows:
(1) Coat pin-shafts, threads, and faces of 30 threaded retaining pins with thread lubricant.
(2) Coat the lead-in area of the combustion chamber dome mounting pin bushings (where threaded
retaining pins engage) with thread lubricant.
(3) Align combustion chamber with CRF. Align top to top. Ensure ultraviolet flame sensor, borescope,
and igniter holes in combustion chamber are aligned with the ultraviolet flame sensor, borescope,
and igniter holes in CRF.
WARNING
(4) Carefully move combustion chamber forward into CRF, guiding combustion chamber assembly
guide, 1C9423, support ring over guide ring. If difficulty is encountered, heat CRF aft flange using
heat gun.
(5) Carefully and evenly tap combustion chamber forward until seated.
(6) Secure combustion chamber onto CRF with 30 threaded retaining pins as follows:
NOTE
Do not turn any pin more than four turns until all pins are installed.
(a) Install pin at 12:00 o’clock position. Turn pin four turns.
(b) Install pin at 6:00 o’clock position. Turn pin four turns.
(c) Install pin at 3:00 o’clock position. Turn pin four turns.
(d) Install pin at 9:00 o’clock position. Turn pin four turns.
(e) Install remaining pins using alternating method used for first four.
(f) Seat pins around outer diameter of CRF using alternating method.
(g) Tighten pins to 525-615 lb in. (59.4-69.4 N·m) of torque and safety-wire.
F. Remove six screws that secure support ring (figure 5) of combustion chamber assembly guide, 1C9423,
onto combustion chamber inner support.
G. Carefully move support ring aft, out of CRF, guiding over guide ring.
H. Remove lift adapter, 1C9362, from combustion chamber assembly guide, 1C9423. Leave overhead hoist
attached to lift adapter link.
I. Remove guide ring from No. 5 bearing housing flange in CRF.

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J. Insert a 0.400-0.407 inch (10.17-10.33 mm) diameter rod through borescope holes in compressor rear
frame and into holes in combustion chamber. Holes must align to ensure access for engine borescope tool.
Remove rod.
K. Install CRF aft case as follows:
(1) Coat threads of 137 bolts with thread lubricant.
(2) Attach lift adapter, 1C9362, onto lift tube on installation/removal fixture, 1C9422, with
quick-release pin (figure 2). Adjust CG as required.
WARNING

(3) Lift and turn CRF aft case to horizontal position.
(4) Align position mark made at removal with top vertical centerline of CRF and move CRF aft case
forward until forward flange engages CRF aft flange.
(5) Install three-legged extended flange bracket onto aft side of flange at 12:00 o’clock position, with
wide leg at bolthole No. 1 (figure 3). Secure bracket onto flange with three bolts, boltheads aft, and
nuts. Tighten nuts finger-tight.
(6) Install four-legged extended flange bracket onto aft side of flange at boltholes Nos. 23 through 26
with wide leg at bolthole No. 25. Secure bracket onto flange with four bolts, boltheads aft, and nuts.
Tighten nuts finger-tight.
(7) Install 26 five-legged extended flange brackets onto aft side of flange. Secure brackets onto flange
with 130 bolts, boltheads aft, and nuts. Tighten nuts finger-tight.
WARNING
(8) Using a crisscross pattern, tighten nuts to 69-81 lb ft (93.6-109.8 N·m) of torque. If flanges do not
seat easily, heat CRF aft case forward flange using heat gun.
(9) Remove installation/removal fixture, 1C9422, from CRF aft case.
(10) Remove lift adapter, 1C9362, from installation/removal fixture.
(11) Remove overhead hoist from lift adapter.
L. Install igniter plugs per WP 1516 00.

/03) *(.
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M. Install borescope plug as follows (figure 1):
(1) Ensure borescope plug threads are clean.
(2) Coat borescope plug threads and mating surfaces with thread lubricant.
(3) Install borescope plugs into borescope ports S6-1 and S6-4 hand-tight.
(4) Tighten borescope plugs to 115-135 lb in. (13.0-15.2 N·m) of torque and safety-wire.
N. Install stage 1 HPT nozzle per WP 2511 00.
O. Install HPT module per WP 2610 00.
P. Attach brackets onto extended flange brackets on CRF aft case forward flange per SWP 1913 02.
Q. Install forward, mid, and aft heat shields per WP 1915 00.
R. Install adapters and acoustic sensors per WP 1611 00.
S. Install flame sensor, sight adapter, sight glass, and flame sensor bracket per WP 1915 00.
T. Install LPT module per WP 2710 00.
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/03) *(.
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HIGH PRESSURE TURBINE (HPT) MODULE
REPLACEMENT
())(&7,9,7</03)*$6785%,1(02'(/6

Page No. Change No.
1 - 39 ........................................................................................................................................................ 0
40 Blank ................................................................................................................................................... 0
Alphabetical Index
Subject Page
High Pressure Turbine (HPT) Module Installation. ................................................................................ 21

High Pressure Turbine (HPT) Module Removal...................................................................................... 4
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1. Introduction.
This work package contains instructions for removing and installing the high pressure turbine (HPT) module.
Title Number

Fixture, Assy, Lift - HPT Rotor, Horizontal 1C9358G03
Holder, Shim - HPT Pressure Tube Adapter 1C9397G01
Stand, HPT Rotor Stage 2 Nozzle - Horizontal 1C9417G01
Fixture, Install/Remove - HPT Module 1C9608G02
Pilot, LP Mid Shaft - Aft 1C9610G01
Torque Adapter, Pressure Tube/Coupling Nut - HPT Rotor 1C9626G01
Torque Adapter Set, No. 5R Bearing Inner Race Nut 1C9774G01
Deleted
Deleted
Deleted
Pusher Set, Races/Seals - HPTR Stage 1 2C14025G05
Fixture, Seat Check - No. 4B Bearing and Seal 2C14094G06
Fixture, Seat Check - HPT Rotor 2C14131G02
Stand, Shipping/Storage - HPT Module 2C14193G03
Fixture, Install/Remove - HPT Module Assembly 2C14199G10
Fixture Assy, Lift - HPT Rotor Horizontal 2C14220G01
(Alternate to 1C9358G03)
Sleeve, Retaining - No. 4B Bearing Stack-up 2C14679P01
Deleted
Puller, Races and Seals - HPT Rotor Stage 1 2C14688G05
Fixture, Pull - HPT Rotor Aft Air Seals 2C14785G02
Torque Multiplier Sweeney Model 8112B, or equivalent
Torque Multiplier Sweeney Model 8200, or equivalent
Torque Multiplier Sweeney Model 8202A, or equivalent
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Safety Cable 736L680G01 (ALT)
Safety Wire (0.032 inch) R297P04

Nut, Self-locking 9283M41P04 24
Shim 9219M19P04 AR
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6. High Pressure Turbine (HPT) Module Removal.
A. Remove the low pressure turbine (LPT) module to gain access per WP 2710 00.
B. Disconnect and connect electrical leads and connecting tubes between HPT module and gas turbine per
SWP 1913 02.
NOTE
After a HPTR seal fracture event in which pieces of the seal have separated/liberated, the HPTR
stage 2 disk can be exposed to elevated temperatures. HPTR seal separation/liberation is an abnormal
condition that requires special inspection and disposition.
C. If engine has experienced a HPTR seal fracture with any pieces of the seal separating/liberating, perform
the following:
(1) Document overall seal condition.
(2) Document amount of missing metal (percent of seal separated/liberated).
(3) Document total operating hours and cycles accumulated on seal since new.
(4) Photograph seal.
(5) Provide seal documentation and photographs to GE for review and identification of special
inspection and disposition required on the HPTR beyond manual requirements.
D. Apply penetrating oil onto threads of nuts and bolts that secure aft air seals. Apply penetrating oil onto
threads of nuts and bolts that secure HPT to compressor rear frame (CRF). Allow penetrating oil to soak
for 20 minutes.
E. Remove aft air seals as follows:
(1) Using marking pen, matchmark aft air seals to stage 2 HPT rotor disk. Remove nuts and bolts that
secure aft air seals and pressure tube/coupling nut onto stage 2 HPT rotor disk. Discard nuts.
(2) Remove aft air seal from stage 2 HPT rotor disk using HPT rotor aft air seals pull fixture, 2C14785,
1
(a) Loosen clamp knobs on pull fixture, 2C14785, and move slide clamps inward.
(b) Connect overhead hoist and lift sling through pull fixture, 2C14785, holes.
(c) Install pull fixture, 2C14785, over mid shaft so that rest pads are against stage 2 HPT rotor
disk. Move slide clamps outwards to engage aft air seal. Hand-tighten clamp knobs to secure.
(d) Install guide tube.
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Figure 1. HPT Rotor Aft Air Seal Pull Fixture, 2C14785
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WARNING
ALWAYS USE APPROVED EQUIPMENT AND PROCEDURES TO LIFT

PARTS. STAY OUT FROM BELOW LOADS. IF THE PARTS ACCIDENTALLY
MOVE OR FALL, THEY CAN CAUSE AN INJURY OR DEATH.
(e) Take up slack on hoist to support pull fixture, 2C14785.
(f) Tighten jackscrews slowly and evenly to remove aft air seals.
(3) Deleted.
F. Install rotor locking feature of removal fixture, 1C9608, as follows (figure 2):
NOTE
Inner support, 1C9608P10; clamp plate, 2C14199P96; clamp plug, 2C14199P97; locknut,
2C14199P98; and shoulder bolt, 2C14199P99, are maintained as an assembly.
(1) If installed, remove mid shaft pilot, 1C9610.
(2) Thread inner support, 1C9608P10, onto aft end of mid shaft until fully seated.
(3) Adjust clamp plug, 2C14199P97, forward so that clamp plate, 2C14199P96, rests against inner
support.
(4) Apply thread lubricant onto threads of center shaft, 1C9608P05.
(5) Install center shaft, 1C9608P05, so that male-threaded end engages threads on inside diameter of
compressor rotor aft shaft. Thread center shaft until seated against end of compressor rotor aft shaft,
then back off one-half turn.
(6) Adjust clamp plug, 2C14199P97, aft so clamp plug is seated firmly against inside shoulder of center
shaft, 1C9608P05. Lock into position using locknut, 2C14199P98. Tighten clamp plug to 180 lb in.
/03) *(.
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Figure 2. HPT Module Centering Tools from Fixture, 1C9608
G. Remove pressure tube/coupling nut as follows (figure 3):
(1) Install antitorque tube, 1C9626P02, with leg, 1C9626P05, onto HPT rotor aft flange. Rotate forward
ring of tube to misalign lugs and slots. Install quick-release pin, 1C9626P12.
(2) Using clamp, 1C9626P06, and knob, 1C9626P08, secure leg, 1C9626P05, onto stage 2 HPT nozzle
support flange. Hand-tighten knob.
(3) Install torque tube, 1C9626P03, into pressure tube/coupling nut. Align torque tube so splines engage
splines on pressure tube/coupling nut.
(4) Install torque multiplier, Sweeney Model 8112B, or equivalent, so multiplier splines engage splines
on torque tube, 1C9626P03.
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Figure 3. HPT Rotor Pressure Tube/Coupling Nut Torque Adapter, 1C9626
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WARNING
STAND CLEAR OF ENGINE WHEN USING TORQUE MULTIPLIER. TORQUE IN

EXCESS OF 20,000 LB FT (27,116 N·M) MAY BE REQUIRED TO BREAK
COUPLING NUT LOOSE. IF PARTS SHOULD FAIL, THEY WILL DO SO WITH
EXPLOSIVE FORCE AND COULD CAUSE SERIOUS INJURY.
NOTE
Pressure tube/coupling nut has right-hand threads.
(5) Actuate torque multiplier to loosen pressure tube/coupling nut.
(6) Remove pressure tube/coupling nut and shim (if installed). Remove torque multiplier and all
components of torque adapter, 1C9626.
H. If same HPT rotor will be installed, matchmark stage 2 HPT disk rear face inner diameter in line with X
mark on aft surface of HP compressor rotor aft shaft with marking pen.
I. Using seating check fixture, 2C14131, measure from seating flange of stage 2 HPT rotor disk aft seal
flange to aft surface of HP compressor rotor aft shaft (figure 4). Record as dimension HSA (Before
Disassembly) on HPT worksheet (figure 5).
Figure 4. Measure Seating Check Dimension HSA
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Figure 5. HPT Worksheet

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J. Install HPT module removal fixture, 1C9608, as follows:
CAUTION
ENSURE HPT MODULE REMOVAL FIXTURE, 1C9608, IS USED PROPERLY.

FAILURE TO COMPLY WILL CAUSE TOOL AND/OR ENGINE DAMAGE.
(1) Apply thread lubricant onto threads of bearing adapter shaft, 2C14199P102.
(2) Assemble lift fixture, 2C14199P53, lift fixture, 2C14199P22, and lifteye, 2C14199P36. Attach to
bearing adapter shaft, 2C14199P102.
(3) Thread center plate, 2C14199P103, onto extension shaft, 2C14199P104. Thread assembly into
center shaft, 1C9608P05. See figure 6.
(4) If not already attached, install frame extension, 1C9608P02, onto frame, 2C14199P123.
(5) Install frame, 2C14199P123/1C9608P02, with support shaft, 2C14199P111, onto HPT module as
follows (figure 7):
(a) Position frame, 2C14199P123/1C9608P02, and support shaft, 2C14199P111, at aft end of HPT
module.
(b) Attach lift fixture, 2C14199P126, with lifteye, 2C14199P38, onto frame, 2C14199P123/
1C9608P02, at 6:00 and 12:00 o’clock positions. Secure with thumbscrews.
(c) Attach horizontal lift fixture, 1C9358 or 2C14220, onto frame, 2C14199P123/1C9608P02.
(d) Attach overhead hoists onto lift fixture, 1C9608P11, and horizontal lift fixture, 1C9358 or
2C14220.
WARNING
(e) Lift frame, 2C14199P123/1C9608P02, and support shaft, 2C14199P111 to align with aft end of
HPT module.
(f) Move tooling into HPT module. Support shaft, 2C14199P111, shall fit into rabbet of stage 2
disk aft flange. Frame, 2C14199P123, shall fit into rabbet of stage 2 HPT nozzle support aft
flange.
(g) Using 12 bolts, 2C14199P43, and nut plates, 2C14199P27, secure support shaft, 2C14199P111,
onto stage 2 disk aft flange. Tighten bolts, 2C14199P43, to 70-110 lb in. (7.9-12.4 N·m) of
torque.
(h) Using 30 bolts, 2C14199P43, six nut plates, 2C14199P34, and six nut plates, 2C14199P35,
secure frame, 2C14199P123/1C9608P02, onto stage 2 HPT nozzle support aft flange. Tighten
bolts, 2C14199P43, to 70-110 lb in. (7.9-12.4 N·m) of torque.

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Figure 6. Bearing Adapter Shaft from Fixture, 2C14199

2
(6) Install guide tube, 1C9608P04, over center shaft, 1C9608P05, so that guide tube seats against
compressor rotor aft shaft. See figure 8.
(7) Apply light coat of petrolatum onto No. 5R bearing rollers. Push rollers outward in outer race using
finger pressure.
(8) Install six anti-rotation pins, 2C14199P124, into frame, 2C14199P123, and secure with bolts,
2C14199P125. Tighten bolts to 193-227 lb in. (21.9-25.6 N·m) of torque. See figure 7.
(9) Install pusher shaft, 1C9608P03, as follows (figure 8):
(a) Ensure that the HPTR shaft inner diameter and seating shoulder are clean and free of foreign
material or high metal.
(b) Install lift fixture, 2C14199P22, with lifteye, 2C14199P36, into aft end of pusher shaft,
1C9608P03.
WARNING

(c) Lift pusher shaft, 1C9608P03, to align with HPT module.

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Figure 7. HPT Module Antirotation Tools from Fixture, 2C14199/1C9608

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Figure 8. HPT Module Removal Tools from Fixture, 2C14199/1C9608

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(d) Insert pusher shaft, 1C9608P03, into aft end of HPT module until pusher shaft,1C9608P03,
contacts bearing adapter shaft, 2C14199P102.
(e) Rotate retainer nut, 2C14199P70, clockwise (CW) so that slots in retainer nut align with slots
in support shaft, 2C14199P111, and lugs of pusher shaft, 1C9608P03.
(f) Rotate retainer nut, 2C14199P70, CW to lock.
(g) Rotate bearing adapter shaft, 2C14199P102, by hand, while holding pusher shaft, 1C9608P03,
stationary to move pusher shaft forward until pusher shaft threads engage bearing adapter shaft
threads. Continue hand-tightening until pusher shaft, 1C9608P03, is fully threaded onto
bearing adapter shaft.
(10) Remove lift fixture, 2C14199P22, and lifteye, 2C14199P36.
(11) Position spacer foot, 2C14199P65, aft of HPT. Secure spacer foot, 2C14199P65, onto foot bracket,
2C14199P66, using quick-release pins, 2C14199P74.
(12) Install torque multiplier, Sweeney Model 8200, onto pusher splines, 1C9608P03.
3
(13) Install anti-rotation strap, 2C14199P25, over square shank of bearing adapter shaft, 2C14199P102.
Using four hand knobs, 2C14199P23, secure anti-rotation strap, 2C14199P25, to frame,
2C14199P123/1C9608P02.
(14) Loosen clamp on lift fixture enough to permit support shaft, 2C14199P111, to rotate and still
support module and tooling.

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K. Remove HPT module as follows:
WARNING

LINES AND FITTINGS.
CAUTION
• THE HIGH PRESSURE COMPRESSOR (HPC) AND LOW PRESSURE

COMPRESSOR (LPC) ROTORS WILL ROTATE DURING HPT MODULE
REMOVAL. ENSURE LPC INLET IS CLEAR OF FOREIGN OBJECTS AND
ROTORS ARE FREE TO ROTATE.
• DO NOT EXCEED 900 LB FT (1220 N·M) OF OUTPUT TORQUE.
NOTE
• The HPT rotor and pusher shaft, 1C9608P03, will rotate counterclockwise (CCW) and
move aft during removal. The frame, 2C14199P123/1C9608P02, and torque multiplier
will not rotate, but will move aft.
• The module removal operation may be stopped and started as necessary without
causing bearing damage. Tooling shall remain in place at all times.
(1) Apply CCW input torque to torque multiplier. Pneumatic torque multiplier, Sweeney Model 8202A,
(in direct drive) may be used in combination with torque multiplier, Sweeney Model 8200, at a
pressure of 90 psi (620.5 kPa) to reduce installation time.
(2) Apply torque until 2.0 inch (51 mm) gap is made between CRF/HPT flanges. This will ensure that
the HPT module has moved aft far enough.
(3) Install spacer foot, 2C14199P65 (figure 8), between CRF and HPT stator support. Secure spacer
foot to foot bracket, 2C14199P66, using quick-release pins, 2C14199P74.
(4) Reverse rotation on torque multipliers a minimum of one turn to relieve internal tension on tooling.
(5) Turn retaining nut, 2C14199P70, CCW to unlock pusher shaft, 1C9608P03, lugs.
(6) Reverse Sweeney torque multiplier two or three complete turns to release load on threads between
bearing adapter shaft, 2C14199P102, and pusher shaft, 1C9608P03.
(7) Remove anti-rotation strap, 2C14199P25, and Sweeney torque multiplier.

/03) *(.
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WARNING

(8) Remove pusher shaft, 1C9608P03, as follows:
(a) Rotate bearing adapter shaft, 2C14199P102, in CW direction, aft looking forward.
(b) Attach lift fixture, 2C14199P22, and lifteye, 2C14199P36, to aft end of pusher shaft,
1C9608P03.
(c) Remove pusher shaft, 1C9608P03, from aft end of HPT module.
(9) Remove bolts and six anti-rotation pins, 2C14199P124, from frame, 2C14199P123. See figure 7.
(10) Install eight bolts, 2C14199P43, evenly spaced with bolt heads forward. Tighten bolts,
2C14199P43, to 210-230 lb in. (23.7-26.0 N·m) of torque.
(11) Tighten hand knob, 1C9358P31 or 2C14220P18, of HPT horizontal lift fixture, 1C9358 or
2C14220.
(12) Ensure that lift fixture, 1C9608P11, and horizontal lift fixture, 1C9358 or 2C14220, are still
attached to frame, 2C14199P123/1C9608P02, and overhead hoist for support while moving HPT
module. Tighten clamp on horizontal lift fixture, 1C9358 or 2C14220, if necessary.
(13) Remove HPT module by pulling tooling aft.
(14) Install retaining sleeve, 2C14679P01, to secure No. 4B bearing inner race. Ensure that retaining
sleeve is firmly installed.
NOTE
If same HPT rotor will be installed, disregard step 6.L. and step 6.M.
L. Install HPT module into support stand, 1C9417, as follows (figure 9):
(1) Lower HPT module into support stand, 1C9417, so that frame, 2C14199P123/1C9608P02, sits on
the four vertical supports.
(2) Secure HPT module into support stand, 1C9417, by positioning four swing clamps against frame.

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Figure 9. HPT Module Removal/Installation Fixture and Stand, 1C9417

/03) *(.
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CAUTION
THE NO. 5R BEARING IS A MATCHED ASSEMBLY. ENSURE MATCHED

BEARING COMPONENTS ARE KEPT TOGETHER AS SETS BY SERIAL
NUMBERS. MIXING OF SERVICEABLE MATCHED BEARING COMPONENTS
MAY RESULT IN ENGINE DAMAGE.
M. Remove No. 5R bearing inner race as follows:
(1) Pull heat shield from HPT forward shaft using puller, 2C14688.
(2) Install adapter, 1C9774, onto No. 5R bearing spanner nut. Attach torque multiplier, Sweeney Model
8200, or equivalent, to adapter.
(3) Activate torque multiplier to remove No. 5R bearing spanner nut.
(4) Using puller, 2C14688, remove No. 5R bearing inner race.
N. Install HPT module into shipping/storage stand, 2C14193, as follows (figure 10):
(1) Attach vertical lift fixture, 1C9608P11, with lifteye, 2C14199P38, onto frame at 6:00 and
12:00 o'clock positions. Secure with thumbscrews.
CAUTION
DO NOT LOOSEN SWING CLAMPS UNLESS WEIGHT OF HPT MODULE IS

SUPPORTED BY HORIZONTAL LIFT FIXTURE, 1C9358 OR 2C14220. FAILURE
TO COMPLY MAY CAUSE MODULE DAMAGE.
(2) Ensure that weight of HPT module is supported by horizontal lift fixture, 1C9358 or 2C14220.
Disconnect four swing clamps on support stand, 1C9417.
WARNING

(3) Lift module from support stand.
(4) Connect a second hoist onto vertical lift fixture, 1C9608P11. Turn HPT module so that forward end
is down. Remove horizontal lift fixture, 1C9358 or 2C14220.
(5) Lower HPT module into shipping/storage stand, 2C14193. Using washers and nuts, secure case to
leveling screws. Tighten nuts to 57-67 lb in. (6.5-7.5 N·m) of torque.
(6) Install plug, 2C14193P04, into aft bore of stage 2 HPT rotor disk. Secure plug with rod,
2C14193P05. Safety-wire plug to rod.
(7) Remove HPT module removal fixture, 2C14199.

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Figure 10. HPT Module Shipping/Storage Stand, 2C14193

/03) *(.
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7. High Pressure Turbine (HPT) Module Installation.
A. Remove retaining sleeve, 2C14679P01, from gas turbine core.
NOTE
All dimensions in this WP shall be measured at eight locations. The average of these measurements
shall determine the dimension.
B. Calculate seating dimension HSA as follows:
(1) Measure from aft face of forward HPT rotor shaft inner seating shoulder onto aft face of stage 2
HPT disk aft mounting flange (figure 11). Record as dimension J on HPT worksheet (figure 5). For
reference, dimension J should be 15.783-15.824 inches (400.89-401.92 mm). Remeasure
dimension J if not within the above range.
(2) Using seat check fixture, 2C14094, measure from aft face of No. 4B bearing inner race onto aft face
of compressor rotor aft shaft (figure 12). Record as dimension CCM on HPT worksheet (figure 5). If
dimension CCM is not within 8.921-8.948 inches (226.60-227.27 mm), No. 4B bearing inner race
has backed out, or the measurement is wrong.
CAUTION
WHEN USING 6-INCH PARALLEL BAR ON AFT FACE OF PRESSURE TUBE/
COUPLING NUT SEALING SHOULDER, ASSURE PARALLEL BAR IS NOT
SEATED ON RADIUS.
(3) Measure from forward face of HPT rotor shaft onto aft face of pressure tube/coupling nut sealing
shoulder (figure 13). Record as dimension EHS on HPT worksheet (figure 5). For reference,
dimension EHS should be 7.137-7.147 inches (181.28-181.53 mm). Remeasure if dimension EHS is
not within the range.
(4) Calculate seating dimension HSA using the following formula, and record as HSA (Calculated) on
HPT worksheet (figure 5):
HSA = EHS + J CCM
C. Determine if HPT rotor aft seal shim is required as follows:
(1) Install pressure tube coupling nut into HPT rotor until pressure tube coupling nut is seated into HPT
stage 1 disk.
(2) Using thickness gage, measure gap between HPT rotor stage 2 disk aft flange aft face and pressure
tube coupling nut aft flange forward face, at eight equally spaced locations. If mean gap is equal to
or greater than 0.027 inch (0.69 mm), one shim is required. If mean gap is less than 0.027 inch
(0.69 mm), no shim is required.

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Figure 11. Dimension J Measurement
Figure 12. Dimension CCM Measurement

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Figure 13. Dimension EHS Measurement
D. Install rotor locking feature of removal fixture, 1C9608, as follows (figure 14):
NOTE
Inner support, 1C9608P10; clamp plate, 2C14199P96; clamp plug,
2C14199P97; locknut, 2C14199P98; and shoulder bolt, 2C14199P99, are
maintained as an assembly.
(1) If installed, remove mid shaft pilot, 1C9610.
(2) Thread inner support, 1C9608P10, onto aft end of mid shaft until fully seated.
(3) Adjust clamp plug, 2C14199P97, forward so that clamp plate, 2C14199P96, rests against inner
support.
(4) Apply thread lubricant onto threads of center shaft, 1C9608P05.
(5) Install center shaft, 1C9608P05, so that male-threaded end engages threads on inside diameter of
compressor rotor aft shaft. Thread center shaft until seated against end of compressor rotor aft shaft,
then back off one-half turn.
(6) Adjust clamp plug, 2C14199P97, aft so clamp plate, 2C14199P96, is seated firmly against inside
shoulder of center shaft, 2C14199P29. Lock into position with locknut, 2C14199P98. Tighten clamp
plug to 180 lb in. (20.3 N·m) of torque.

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Figure 14. HPT Module Centering Tools from Fixture, 2C14199
E. Install HPT module installation fixture, 1C9608, as follows (figure 15):
CAUTION
ENSURE HPT MODULE INSTALLATION FIXTURE, 1C9608, IS USED PROPERLY.

FAILURE TO COMPLY WILL CAUSE TOOL AND/OR ENGINE DAMAGE.
(1) Apply thread lubricant onto threads of bearing adapter shaft, 2C14199P102.
(2) Assemble lift adapter, 2C14199P53, lift fixture, 2C14199P22, and lifteye, 2C14199P36. Attach to
bearing adapter shaft, 2C14199P102.
(3) Thread center plate, 2C14199P103, into extension shaft, 2C14199P104. Thread assembly into
center shaft, 1C9608P05.
(4) If installed, remove plug, 2C14193P04, from HPT rotor.
(5) Remove nuts and washers that secure HPT module onto shipping/storage module.
(6) Install frame, 2C14199P123/1C9608P02, with support shaft, 2C14199P111, onto HPT module as
follows:
(a) If not already attached, install frame extension, 1C9608P02, onto frame, 2C14199P123.
(b) Position frame, 2C14199P123/1C9608P02, so three spacer feet, 2C14199P65, face up.

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Figure 15. Bearing Adapter Shaft from Fixture, 1C9608
(c) Attach vertical lift fixture, 1C9608P11, with lifteye, 2C14199P38, onto frame, 2C14199P123/
1C9608P02, at 6:00 and 12:00 o’clock positions. Secure with hand knob, 2C14199P23.
WARNING
(d) Attach hoist to lifteye, 2C14199P38. Lift frame, 2C14199P123/1C9608P02, and support shaft,
2C14199P111, over HPT rotor.
(e) Lower tooling onto HPT module. Support shaft, 2C14199P111, shall fit into rabbet of stage 2
HPT disk aft flange. Frame shall fit into rabbet of stage 2 HPT nozzle support aft flange. See
figure 16.
(f) Install spacer foot, 2C14199P65, onto forward flange of HPT stator support. Using
quick-release pins, 2C14199P74, secure spacer foot onto foot bracket, 2C14199P66. See
figure 17.
(g) Secure support shaft, 2C14199P111, onto stage 2 HPT rotor disk aft rabbet using 12 bolts,
2C14199P43, and nut plate, 2C14199P27. Tighten bolts to 70-110 lb in. (7.9-12.4 N·m) of
torque. See figure 16.
(h) Secure frame onto stage 2 HPT nozzle support aft flange using 30 bolts, 2C14199P43, six nut
plates, 2C14199P34, and six nut plates, 2C14199P35. Tighten bolts to 70-110 lb in.

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Figure 16. Support Shaft from Fixture, 2C14199

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Figure 17. Pusher Tools from Fixture, 2C14199/1C9608

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(7) Install pusher shaft, 1C9608P03, as follows (figure 17):
(a) Ensure HPT rotor shaft inner diameter and seating shoulder are clean and free of foreign
material or high metal.
(b) Remove vertical lift fixture, 1C9608P11.
(c) Install lift fixture, 2C14199P22, with lifteye, 2C14199P36, into aft end of pusher shaft,
1C9608P03. Raise pusher shaft over HPT module.
(d) Rotate retainer nut, 2C14199P70, CCW so that slots in retainer nut align with slots in support
shaft, 2C14199P111.
(e) Insert pusher shaft, 1C9608P03, into aft end of HPT module. Align lugs of pusher shaft with
slots of support shaft, 2C14199P111, and retainer nut, 2C14199P70.
(f) Rotate retainer nut, 2C14199P70, CW.
(g) Remove lift fixture, 2C14199P22, and lifteye, 2C14199P36.
(h) Attach vertical lift fixture, 1C9608P11.
NOTE
If same HPT rotor is being installed, disregard step 7.F and step 7.G.
F. Install HPT module into support stand, 1C9417, as follows (figure 18):
(1) Attach lift fixture, 1C9358 or 2C14220, onto frame, 2C14199P123/1C9608P02.
(2) Connect overhead hoist onto vertical lift fixture, 1C9608P11.
WARNING
(3) Lift HPT module from shipping/storage stand, 2C14193.
(4) Connect second hoist onto shackle on lift fixture, 1C9358 or 2C14220.
(5) Turn HPT module to horizontal position.
(6) Lower HPT module into support stand, 1C9417, so that frame, 2C14199P123/1C9608P02, sits on
the four vertical supports.
(7) Secure HPT module into support stand, 1C9417, by positioning four swing clamps against frame,
2C14199P123/1C9608P02.

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Figure 18. HPT Module Removal/Installation Fixture and Stand

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G. Install No. 5R bearing inner race as follows:
WARNING
(1) If required, heat rotating air seal in oven for 30 minutes at 350°F (176.7°C) and install onto HPT
forward shaft.
(2) Heat No. 5R bearing inner race in oven for 30 minutes at 350°F (176.7°C).
(3) Install bearing inner race onto HPT forward shaft using pusher, 2C14025P08. Do not remove pusher
until temperature of inner race has normalized.
(4) Ensure bearing inner race is seated properly by attempting to insert a 0.002-inch (0.05 mm) thick
shim between inner race and 5R air/oil seal. Shim shall not fit anywhere between parts except at
pusher relief grooves.
(5) Install No. 5R bearing spanner nut as follows:
WARNING

(a) Using isopropyl alcohol, clean threads of HPT forward shaft and spanner nut.
(b) Measure spanner nut minor thread diameter (figure 19). Take measurement at three axial
locations on threads. The average of these three measurements shall not exceed 7.684 inches
(195.17 mm). Replace spanner nut if this requirement is not met.
(c) Apply coat of thread lubricant onto threads of spanner nut.
(d) Install spanner nut over HPT rotor shaft engaging threads just forward of No. 5R bearing inner
race. Chamfer faces forward.
(e) Tighten spanner nut until threads extend through nut locking insert. Use adapter, 1C9774,
torque multiplier, Sweeney Model 8200, or equivalent, and a torque wrench.
(f) Measure torque required to start spanner nut moving (with nut not bottomed out). A minimum
of 25 lb ft (34 N·m) of torque shall be present. Replace spanner nut if this requirement is not
met.
(g) Tighten spanner nut to final torque equal to sum of running torque (step 7.G.(5)(f)) plus
2000-2300 lb ft (2712-3118 N·m) of torque.
(h) Remove excess thread lubricant from spanner nut and inner race.

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Figure 19. No. 5R Bearing Spanner Nut Minor Thread Diameter
(6) Install heat shield as follows:
(a) Place heat shield into oven for 20 minutes at maximum temperature 400°F (204.4°C).
WARNING
USE THERMAL GLOVES WHEN YOU MOVE OR TOUCH HOT OR
COLD PARTS. HOT OR COLD PARTS CAN CAUSE INJURY.
(b) Remove heat shield from oven and install onto stage 1 HPT disk/shaft as follows:
1 Align Z mark on heat shield with Z mark on shaft.
2 Put two tabs on ID of heat shield into two notches on shaft.
3 Seat heat shield by hand.
NOTE
If removal of heat shield is necessary after it has been installed, use puller,
2C14688.
4 After heat shield and shaft have reached same temperature, take drop check from the
forward end of shaft to forward end of heat shield. Drop check dimension must be
0.240-0.350 inch (6.10-8.89 mm).

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H. Install HPT module as follows:
CAUTION
ENSURE THAT HPT ROTOR IS FREE TO ROTATE.
(1) Rotate HPC rotor until X mark is at 6:00 o’clock position.
(2) Transfer X mark from forward surface of stage 1 HPT disk shaft to stage 2 HPT disk rear face inner
diameter.
NOTE
Ensure that X marks on HPC and HPT are at same circumferential location.
(3) Rotate HPT rotor until X mark is at 6:00 o’clock position.
(4) Install guide tube, 1C9608P04, into engine over center shaft, 1C9608P05, until tube seats against
compressor rotor aft shaft. See figure 17.
(5) Apply light coat of petrolatum onto No. 5R bearing rollers. Push rollers outward in outer race using
finger pressure.
(6) Install six antirotation pins, 2C14199P124, and secure with bolts, 2C14199P125.
(7) Remove HPT module support stand, 1C9417, as follows:
(a) Attach horizontal lift fixture, 1C9358 or 2C14220, onto frame, 2C14199P123/1C9608P02.
(b) Connect overhead hoist onto horizontal lift fixture, 1C9358 or 2C14220.
(c) Connect second hoist onto shackle on horizontal lift fixture, 1C9385 or 2C14220.
(d) Release four swing clamps.
WARNING
(e) Slowly lift HPT module from support stand, 1C9417.
(8) Slide HPT module into core engine until guide tube, 1C9608P04, just contacts bearing adapter shaft,
2C14199P102, and antirotation pins, 2C14199P124, pass through extended flange brackets. Do not
slide HPT module any closer than 2.0 inches (51 mm) between CRF/HPT flanges.
(9) Position spacer feet, 2C14199P65, aft. Secure spacer feet in foot bracket, 2C14199P66, with quick-
release pins, 2C14199P74. See figure 17.

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(10) Hold pusher shaft, 1C9608P03, stationary while rotating bearing adapter shaft, 2C14199P102, to
move pusher shaft forward until threads engage bearing adapter shaft threads. Continue hand
threading until antirotation pins, 2C14199P124, pass through extended flange brackets.
(11) Install torque multiplier, Sweeney Model 8200, or equivalent, onto pusher splines. Secure torque
multiplier to frame using two knurled head screws, 2C14199P41.
(12) Install antirotation strap, 2C14199P25, over square shank of bearing adapter shaft, 2C14199P102.
Secure antirotation strap to frame with handknobs, 2C14199P23.
(13) Loosen clamp on lift fixture enough to permit support shaft, 2C14199P111, to rotate and still
support module and tooling.
WARNING

LINES AND FITTINGS.
CAUTION
• THE HPC AND LPC ROTORS WILL ROTATE DURING HPT MODULE
INSTALLATION. ENSURE LPC INLET IS CLEAR OF FOREIGN OBJECTS
AND ROTORS ARE FREE TO ROTATE.
• DO NOT EXCEED 900 LB FT (1220 N·M) OF OUTPUT TORQUE.
NOTE
• The HPT rotor and tooling will rotate CW and move forward during installation. The
frame and torque multipliers will not rotate, but will move forward.
• The installation operation may be stopped and started as necessary without causing
bearing damage. Tooling shall remain in place at all times.
(14) Apply input torque of 80 lb ft (108 N·m) to torque multiplier. Pneumatic torque multiplier, Sweeney
Model 8202A, or equivalent, (in direct drive) may be used in combination with torque multiplier,
Sweeney Model 8200, or equivalent, at a pressure of 90 psi (620.5 kPa) to reduce installation time.
I. Remove tooling as follows:
(1) Rotate retainer nut, 2C14199P70 (figure 17), CCW to unlock pusher shaft lugs. Reverse torque
multiplier two or three revolutions to release load on threads between HPT rotor shaft and pusher
shaft.
(2) Remove antirotation strap, 2C14199P25, and torque multiplier.
(3) Remove pusher shaft, 1C9608P03, as follows:
(a) Rotate bearing adapter shaft, 2C14199P102, (figure 15) CW to back out pusher shaft,
1C9608P03.

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WARNING

(b) Install lift fixture, 2C14199P22, with lifteye, 2C14199P36, into aft end of pusher shaft,
1C9608P03. Remove pusher shaft from HPT module. Rotate shaft CW to back out pusher
shaft, 1C9608P03.
(4) Remove bolts, 2C14199P125, and antirotation pins, 2C14199P124, (figure 16).
(5) Install eight flange bolts, 2C14199P43, as evenly spaced as possible. Bolt heads should face
forward. Tighten bolts to 210-230 lb in. (23.7-26.0 N·m) of torque.
(6) Tighten clamp onto horizontal lift fixture, 1C9358 or 2C14220.
(7) Remove bolts, 2C14199P43, and nut plates, 2C14199P34 and 2C14199P35, from HPT stator
support aft flange. Remove bolts, 2C14199P43, and nut plates, 2C14199P27, from stage 2 disk aft
flange.
(8) Remove frame, 2C14199P123/1C9608P02, and support, 2C14199P111.
(9) Remove guide tube, 1C9608P04.
J. Perform HPT rotor seating check as follows:
(1) Inspect pressure tube/coupling nut threads and forward face for dirt, burrs, or high metal. No dirt,
burrs, or high metal allowed.
CAUTION
DO NOT ALLOW ALIGNMENT PINS TO EXTEND THROUGH THE AFT SIDE

OF THE SHIM. FAILURE TO COMPLY WILL CAUSE DAMAGE TO PRESSURE
TUBE/COUPLING NUT.
(2) If required, install HPT rotor shim, PN 9219M19P04, onto aft flange of stage 2 disk. Install shim
holder, 1C9397, to keep shim holes aligned with flange holes when pressure tube/coupling nut is
tightened.
NOTE
To facilitate pressure tube/coupling nut installation, loosen center shaft, 1C9608P05, two
complete turns. Ensure that rotor locking fixture of removal fixture, 1C9608, is installed
prior to performing next step.
(3) Thread pressure tube/coupling nut onto HP compressor aft shaft. Hand-tighten pressure tube/
coupling nut.
(4) Install antitorque tube, 1C9626P02, (figure 3), onto stage 2 HPT rotor seal flange. Rotate forward
ring on tube to misalign lugs and slots. Install quick-release pin.

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(5) Using clamps, 1C9626P06, and knob, 1C9626P08, secure leg, 1C9626P05, onto stage 2 HPT nozzle
(6) Install torque tube, 1C9626P03, into inside diameter of pressure tube/coupling nut so that splines
engage.
(7) Install torque multiplier, Sweeney Model 8112B, or equivalent, into torque tube.
CAUTION
DO NOT EXCEED MAXIMUM TORQUE. FAILURE TO COMPLY WILL CAUSE

DAMAGE TO PRESSURE TUBE/COUPLING NUT.
(8) Tighten pressure tube/coupling nut to 9500 lb ft (12,880 N·m) of torque.
(9) Break torque on pressure tube/coupling nut. Remove shim and all tooling except rotor locking tools.
Remove pressure tube/coupling nut.
(10) Using seating check fixture, 2C14131G02, measure from seating flange of stage 2 HPT rotor disk
aft seal flange to aft surface of HP compressor rotor aft shaft (figure 20). Record as HSA (After
Assembly) on HPT worksheet (figure 5). This dimension shall be within 0.002 inch (0.05 mm) of
HSA (Calculated) determined in step 7.B.(4) and recorded on HPT worksheet (figure 5). Repeat
step 7.J.(1) through step 7.J.(10) if this requirement is not met.
5
K. Install pressure tube/coupling nut as follows:
WARNING

(1) Using isopropyl alcohol, clean threads of pressure tube/coupling nut.
(2) Measure pressure tube/coupling nut minor thread diameter (figure 21). Take measurement at three
axial locations on threads. The average of these three measurements shall not exceed 6.388 inches
(162.26 mm). Replace pressure tube/coupling nut if this requirement is not met.
(3) Inspect pressure tube/coupling nut threads and forward face for burrs or high metal. Remove burrs
or high metal.
(4) Apply coat of thread lubricant onto threads, forward face, and flange forward face of pressure tube/
coupling nut.

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Figure 20. Seating Check Using Fixture, 2C14131

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Figure 21. Pressure Tube/Coupling Nut Minor Thread Diameter
CAUTION
DO NOT ALLOW ALIGNMENT PINS TO EXTEND THROUGH THE AFT SIDE

OF THE SHIM. FAILURE TO COMPLY WILL CAUSE DAMAGE TO PRESSURE
TUBE/COUPLING NUT.
(5) If required, install HPT rotor aft shim, P/N 9219M19P04, onto seal flange of stage 2 HPT rotor disk.
Install alignment pins, 1C9397P02, to keep shim holes aligned with flange holes when pressure
tube/coupling nut is tightened.
NOTE
Ensure that rotor locking fixture of removal fixture, 1C9608, is installed prior to
performing next step.
(6) Thread pressure tube/coupling nut onto HP compressor aft shaft. Hand-tighten pressure tube/
coupling nut.
(7) Install antitorque tube, 1C9626P02 (figure 3), onto HPT stage 2 rotor flange. Rotate forward ring on
tube to misalign lugs and slot. Install quick-release pin.
(8) Using clamp, 1C9626P06, and knob, 1C9626P08, secure leg, 1C9626P05, onto stage 2 HPT nozzle

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(9) Install torque tube, 1C9626P03, into inside diameter of pressure tube/coupling nut so that splines
engage.
(10) Install torque multiplier, Sweeney Model 8112B, or equivalent, onto torque tube.
(11) Tighten coupling nut to 1000 lb ft (1356 N·m) of torque.
(12) Using marking pen, mark zero point on torque multiplier.
CAUTION
DO NOT EXCEED MAXIMUM TORQUE OF 13,100 LB FT (17,761 N·M).
FAILURE TO COMPLY WILL CAUSE DAMAGE TO PRESSURE TUBE/
COUPLING NUT.
(13) Continue to tighten pressure tube/coupling nut a minimum of 76 degrees beyond zero point to
minimum torque of 9500 lb ft (12,880 N·m). Record angle and torque.
(14) If maximum torque of 13,100 lb ft (17,761 N·m) is reached, remove pressure tube/coupling nut and
perform the following:
(a) Check torque multiplier for excessive drag.
(b) Inspect pressure tube/coupling nut threads and mating faces for dirt, burrs, galling, or high
metal. Clean and deburr threads and mating faces, if necessary.
(c) Inspect outer diameter seal teeth for evidence of contact with HPT rotor shaft inner diameter. If
seal teeth have contacted HPT rotor shaft inner diameter, replace pressure tube/coupling nut.
Remove high metal from HPT rotor shaft inner diameter.
(d) Inspect HPT rotor seating shoulder for dirt or metal pickup. Clean and deburr HPT rotor seating
shoulder, if necessary.
(e) Replace pressure tube/coupling nut if reason for excessive torque cannot be determined.
CAUTION
DO NOT EXCEED A MAXIMUM OF 84 DEGREES BEYOND ZERO POINT OR A
MAXIMUM TORQUE VALUE OF 13,800 LB FT (18,710 N·M). FAILURE TO
COMPLY WILL CAUSE DAMAGE TO PRESSURE TUBE/COUPLING NUT.
(15) Continue tightening to align stage 2 HPT disk and pressure tube/ coupling nut aft flange boltholes to
minimum torque of 9500 lb ft (12,880 N·m). Record final angle and torque.
(16) Remove all tooling.
(17) Inspect pressure tube/coupling nut inner diameter for displaced or damaged damper sleeve. Replace
pressure tube/coupling nut if damage is present.

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L. Install aft air seals as follows:
(1) Apply thread lubricant onto threads and washer faces of bolts and new self-locking nuts,
9283M41P04.
(2) Align matchmarks made at removal on aft air seals and stage 2 HPT rotor disk. Using bolts and new
self-locking nuts, 9283M41P04, secure aft air seals and pressure tube/coupling nut to stage 2 HPT
rotor disk. Tighten nuts to 212-248 lb in. (24.0-28.0 N·m) of torque.
M. Install flange retaining hardware as follows:
(1) Apply thread lubricant onto threads and seating faces of flange retaining bolts.
(2) Install brackets at locations marked at disassembly. Using bolts and nuts, secure brackets onto
flange. Boltheads face forward. Tighten nuts to 210-230 lb in. (23.8-25.9 N·m) of torque.
(3) Install remaining bolts, spacers, and nuts. Boltheads face forward. Spacers mate directly with
boltheads. Tighten nuts to 210-230 lb in. (23.8-25.9 N·m) of torque.
%ODQN
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STAGE 2 HIGH PRESSURE TURBINE (HPT) NOZZLE
(ON ENGINE) REPLACEMENT
())(&7,9,7</03)*$6785%,1(02'(/6

Page No. Change No.
1 - 18 ........................................................................................................................................................ 0
Alphabetical Index
Subject Page
Stage 2 HPT Nozzle Installation. ............................................................................................................ 13

Stage 2 HPT Nozzle Removal.................................................................................................................. 3
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1. Introduction.
A. This work package contains instructions for replacing the stage 2 high pressure turbine (HPT) nozzle when
HPT module is installed on engine.
B. Remove low pressure turbine (LPT) module to gain access per WP 2710 00.
C. Remove external piping, hoses, and electrical connections per WP 1913 00.
Title Number
External Tubing, Hoses, and Electrical Harnesses WP 1913 00
Stage 2 High Pressure Turbine (HPT) Rotor Blades Replacement WP 2614 00

Adapter Assy, Lift - Combustor and Stg 1 or 2 HP Turbine Nozzle 1C9362G02
Adapter, Lift - HPT Nozzle, Stage 2 2C14703G01
Fixture, Pull - HPT Rotor Aft Air Seals 2C14785G02
Nut Plate, Set - Stage 2 HPT Rotor Disk 2C14831G01
Fixture, Install/Remove - Stage 2 Aft Blade Retainer 2C14836G01
Tool, Install/Remove - Retaining Ring, Aft Blade Retainer 2C14839G01
Adhesive Permabond 910
Anti-Seize Compound Milk of Magnesia (Unflavored) A8Y4E1
Dry Ice Fed Spec BB-C-104

Nut, Self-Locking 9283M41P04 24
Seal, Ring 1847M57P03 AR

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6. Stage 2 HPT Nozzle Removal.
A. Remove stage 2 HPT rotor blades as follows:

NOTE
The procedures in this work package for removing and installing stage 2 HPT rotor blades
are to facilitate other maintenance only. If stage 2 HPT rotor blades require replacement,
refer to WP 2614 00.
(1) Remove aft air seals (figure 1):
(a) Apply penetrating oil onto threads of nuts and bolts that secure aft air seals. Allow penetrating
oil to soak for 20 minutes.
(b) Using marking pen, matchmark aft air seals to stage 2 HPT rotor disk. Remove nuts and bolts
that secure aft air seals and pressure tube/coupling nut onto stage 2 HPT rotor disk. Discard
nuts.
(c) Install mid shaft pilot, 1C9610, on mid shaft.
(d) Remove assembled aft air seals from stage 2 HPT rotor disk using pull fixture, 2C14785, as
follows:
1 Loosen clamp knobs, 2C14785P06, on pull fixture, 2C14785, and move slide clamps
inward.
WARNING
2 Connect overhead hoist and lift sling through pull fixture, 2C14785, holes.
3 Install pull fixture, 2C14785, over mid shaft so that rest pads, 2C14785P03, are against
stage 2 HPT rotor disk. Move slide clamps, 2C14785P07, outward to engage aft air seal.
Hand-tighten clamp knobs to secure.
4 Install guide tube, 2C14785P05.
5 Take up slack on hoist to support pull fixture, 2C14785.
6 Tighten jackscrews slowly and evenly to remove aft air seals.
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(2) Remove stage 2 disk blade retainer:

WARNING
THE STAGE 2 HPT DISK IS SENSITIVE TO NICKS AND SCRATCHES THAT

COULD INADVERTENTLY RESULT FROM THIS PROCEDURE. IF THE
STAGE 2 DISK IS DAMAGED, EVEN SLIGHTLY, DURING THIS
PROCEDURE, THE DISK MUST BE REFERRED TO THE APPROPRIATE
FACTORY TECHNICAL SUPPORT REPRESENTATIVE FOR EVALUATION
AND REPAIR RECOMMENDATION. FAILURE TO COMPLY MAY RESULT IN
AN UNCONTAINED ENGINE FAILURE, WHICH COULD CAUSE INJURY OR
DEATH.
(a) Using a marking pen, matchmark blade retainer to face of stage 2 disk (figure 2).
WARNING

WARNING
BE CAREFUL WHEN USING PUSHER/PULLER TO APPLY PRESSURE. MAKE

SURE YOU DO NOT USE MORE THAN THE MAXIMUM HYDRAULIC
PRESSURE. STAY AWAY FROM THE AREA BEHIND OR IN FRONT OF THE
PUSHER/PULLER. A MALFUNCTION CAN CAUSE INJURY OR DEATH.
(b) Fully extend hydraulic cylinder of install/remove fixture, 2C14836 (figure 3). Using hoist, lift
install/remove fixture onto HPT rotor stage 2 disk rotating seal flange.
(c) Using half-rings, 2C14831P02, 24 washers, and 24 bolts, attach push-pull plate, 2C14836P11,
to rotating seal flange. Tighten bolts to 83-97 lb in. (9.4-10.9 N·m) of torque.
(d) Making adjustments in tooling, if required, slowly retract actuator until base, 2C14836P02,
touches stage 2 blade retainer.
NOTE
When install/remove fixture, 2C14836, is hydraulically actuated and touches
blade retainer, there must be access to split in retaining ring, between ribs of
fixture.
(e) Retract hydraulic cylinder to 3000 psi (20,684 kPa) to seat blade retainer.
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Figure 2. Stage 2 HPT Rotor Blade Removal
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Figure 3. Stage 2 Aft Blade Retainer Install/Remove Fixture, 2C14836
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(f) Beginning at one end of retaining ring, use a plastic drift to move ring into groove.
1 Hold end of retaining ring with clip, 2C14836P08.
2 Use ring expander, 2C14839P03, and expander jaw, 2C14839P05, to help move retaining
ring (figure 4).
3 Continue around retaining ring, installing clips, 2C14836P08, approximately every

30 degrees (last clip goes at end of retaining ring).
(g) Perform a visual examination to make sure retaining ring is properly held, and is in a fully
disengaged position.
(h) Remove half-rings, 2C14831P02, washers, bolts, and push-pull plate, 2C14836P11. Do not
remove clips, 2C14836P08.
WARNING
DRY ICE, BB-C-104: DO NOT LET THIS MATERIAL TOUCH YOU. LOW
TEMPERATURE SKIN DAMAGE. CAN DECREASE AVAILABLE AIR.
ASPHYXIANT. PERSONAL PROTECTIVE EQUIPMENT REQUIRED,
ESPECIALLY INSULATED GLOVES AND EYE PROTECTION WHEN
HANDLING MATERIAL. USE IN A WELL-VENTILATED AREA.
(i) Put dry ice only on stage 2 retainer.
Figure 4. Aft Blade Retaining Ring Install/Removal
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WARNING

(j) When retainer is sufficiently cold, remove retainer from stage 2 disk by hand.
(k) Remove seal ring from retainer.
(l) Remove retaining ring from groove in stage 2 disk. Use ring compressor, 2C14839P02, and
compressor jaw, 2C14839P04, if necessary.
(3) Remove HPT stage 2 blades:

WARNING

COULD INADVERTENTLY RESULT FROM THIS PROCEDURE. IF THE
STAGE 2 DISK IS DAMAGED, EVEN SLIGHTLY, DURING THIS
PROCEDURE, THE DISK MUST BE REFERRED TO THE APPROPRIATE
FACTORY TECHNICAL SUPPORT REPRESENTATIVE FOR EVALUATION
AND REPAIR RECOMMENDATION. FAILURE TO COMPLY MAY RESULT IN
AN UNCONTAINED ENGINE FAILURE, WHICH COULD CAUSE INJURY OR
DEATH.
CAUTION
ENSURE BLADE DAMPER ASSEMBLIES ARE MATCHMARKED
ACCURATELY. INCORRECT PLACEMENT AT INSTALLATION WILL
CAUSE ROTOR IMBALANCE.
(a) Use marking pen to number each stage 2 blade and damper, and to matchmark side rails of
blades. Find dovetail tangs marked with a numeral 1. Blade between tangs is blade No. 1, and
damper No. 1 is between blades 1 and 2.
NOTE
There are 74 dovetail slots in stage 2 disk, with a damper between each set of
blades.
(b) Starting at blade No. 1 and damper No. 1 position, mark and remove blades and dampers in
order, moving around stage 2 disk in a clockwise (CW) direction, aft looking forward (ALF).
(c) Store blades and dampers, by position in disk, in sequence of blade, damper, blade, damper
until all blades are removed.
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B. Remove stage 2 HPT nozzle as follows (figure 5):
WARNING

(1) Attach hoist to lift adapter assembly, 1C9362, and position lift adapter, 2C14703, onto stage 2 HPT
nozzle aft flange.
(2) Attach lift adapter, 2C14703, to aft flange of stage 2 HPT nozzle assembly, with three bolts and
three nuts. Tighten nuts to 46-54 lb in. (5.2-6.1 N·m) of torque.
(3) Adjust shackle on lift adapter assembly, 1C9362, so that HPT nozzle assembly will remain
horizontal when removed.
(4) Remove HPT nozzle borescope plug and flat washer, located at 5:00 o’clock position, ALF
(figure 6).
(5) Matchmark bracket locations on HPT nozzle assembly and compressor rear frame flanges. Remove
nuts, spacers, brackets, and bolts from stage 2 HPT nozzle forward flange.
CAUTION
DAMAGE TO HPT ASSEMBLY AND HPT ROTOR WILL OCCUR IF HPT
STATOR IS NOT LEVEL WHEN REMOVED.
(6) Using hoist, move HPT nozzle assembly aft to separate HPT nozzle assembly from compressor rear
frame. Use caution to prevent rotor/stator contact.

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Figure 5. Stage 2 HPT Nozzle Lift Adapter, 2C14703

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Figure 6. Stage 2 HPT Nozzle Forward Flange

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7. Stage 2 HPT Nozzle Installation.
CAUTION
ENSURE STAGE 2 HPT NOZZLE PART NUMBER IS CORRECT PER IPB, GEK 119320,
BEFORE INSTALLATION, OR DAMAGE TO ENGINE COULD RESULT.
A. Install stage 2 HPT nozzle as follows (figure 5):
WARNING

(1) Attach hoist to lift adapter assembly, 1C9362, and position lift adapter, 2C14703, onto stage 2 HPT
nozzle aft flange.
(2) Attach lift adapter, 2C14703, to aft flange of HPT nozzle assembly, with three bolts and three nuts.
(3) Adjust shackle on lift fixture so that HPT nozzle assembly is horizontal when installed.
CAUTION
DAMAGE TO HPT ASSEMBLY AND HPT ROTOR WILL OCCUR IF HPT STATOR
IS NOT LEVEL OR HPT NOZZLE ASSEMBLY CONTACTS HPT ROTOR WHILE
BEING INSTALLED.
(4) Move HPT nozzle assembly forward to install HPT nozzle assembly to compressor rear frame. Use
caution to prevent rotor/stator contact.
(5) Secure HPT nozzle assembly onto compressor rear frame as follows:
(a) Apply lubricant to threads and contact surfaces of flange bolts and nuts.
(b) Install bolts, spacers, brackets, and nuts (figure 6).
1 Install all spacers under boltheads except install spacer under nut at bolthole 48.
2 Install all brackets onto forward side of flange except install bracket onto aft side of flange
at boltholes 79 through 85.
(c) Tighten nuts to 210-230 lb in. (23.8-25.9 N·m) of torque.

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WARNING

(6) Remove nuts and bolts that secure lift adapter, 2C14703, (figure 5) to aft flange of HPT nozzle
assembly. Using hoist, remove lift adapter assembly, 1C9362, and lift adapter, 2C14703, from HPT
nozzle assembly.
(7) Apply anti-seize compound to borescope plug (figure 6) case bore, located at 5:00 o’clock position,
aft looking forward. Install flat washer and borescope plug to HPT case. Tighten borescope plug to
115-135 lb in. (13.0-15.2 N·m) of torque.
B. Install stage 2 HPT rotor blades as follows (figure 2):
WARNING
ADHESIVE IS FLAMMABLE AND TOXIC TO SKIN, EYES, AND RESPIRATORY
TRACT. SKIN AND EYE PROTECTION IS REQUIRED. USE IN A
NOTE
• Use adhesive, if necessary, when installing dampers on blades.
• Blades must be fanned into slots.
(1) Install damper, with angel wing extension aft, on No. 1 blade. With damper No. 1 installed in blade
No. 1, install blade in stage 2 disk. Use 1-1 blade slot as No. 1 blade position.
CAUTION
ENSURE STAGE 2 BLADE DAMPER ASSEMBLIES ARE INSTALLED AT

POSITIONS AS MARKED AT DISASSEMBLY. INCORRECT PLACEMENT WILL
(2) Continue installing blades and dampers in sequence in a CW direction around disk.
(3) Verify there is perceivable circumferential movement of airfoil tip with all dampers, blades, and seal
bodies installed.
(4) Verify there is perceivable circumferential movement of seal bodies with blades held together at
surface AP and outward in dovetail slots (figure 7). Minimum accumulated platform gap at
surface AP shall be 0.44 inch (11.2 mm).

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Figure 7. HPT Rotor Stage 2 Blade Accumulated Gap
C. Install stage 2 blade retainer as follows:
(1) Prepare stage 2 retainer retaining ring for installation as follows:
(a) Prepare a clean, dirt-free surface for assembly of hardware.
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.
(b) Clean tooling and hardware with isopropyl alcohol.

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WARNING
ADHESIVE IS FLAMMABLE AND TOXIC TO SKIN, EYES, AND

RESPIRATORY TRACT. SKIN AND EYE PROTECTION IS REQUIRED. USE IN
CAUTION
IF HEAT IS USED TO CURE ADHESIVE, TEMPERATURE MUST NOT EXCEED

250°F (121.1°C).
NOTE
Adhesive may be used to hold ring seal in place during assembly. Ensure adhesive
is applied in areas 0.5-1.5 inches (13-38 mm) long and spaced not less than 6 inches
(152 mm) apart.
(c) Install new ring seal into stage 2 blade retainer groove (figure 2). Gap between ring seal ends
shall be 0.100-0.150 inch (2.54-3.81 mm).
(d) Lubricate mating surfaces of blade retainer, retaining ring, and stage 2 disk with petrolatum.
(2) Install retaining ring into stage 2 disk blade retainer groove as follows:
(a) Make sure retaining ring stepped face is forward.
(b) Begin at either end of retaining ring. Push retaining ring into groove with a plastic drift.
(c) Install clip, 2C14836P08, at end of ring just pushed into groove (figure 3).
(d) Continue around retaining ring, pushing ring into groove. Install clips, 2C14836P08,
approximately every 30 degrees. Last clip used goes at opposite end of retaining ring.
(3) Install blade retainer into stage 2 disk blade retainer groove. Tap blade retainer into position a soft
mallet. Be careful not to damage seal ridges.

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(4) Move retaining ring into installed position as follows:
WARNING

WARNING
BE CAREFUL WHEN YOU USE THE PUSHER/PULLER APPLY PRESSURE.

MAKE SURE YOU DO NOT USE MORE THAN THE MAXIMUM HYDRAULIC
(a) Fully extend hydraulic cylinder of install/remove fixture 2C14836 (figure 3). Using hoist, lift
install/remove fixture onto HPT rotor stage 2 disk rotating seal flange.
(b) Using half-rings, 2C14831P02, 24 washers, and 24 bolts, attach push-pull plate, 2C14836P11,
NOTE
When install/remove fixture is installed, you must have access to split in
retaining ring between ribs of install/remove fixture. Adjust position of
install/remove fixture or retaining ring as necessary.
(c) Slowly retract actuator until half-rings, 2C14831P02, touch blade retainer.
(d) Examine alignment of fixture and blade retainer, and adjust as necessary.
(e) Retract hydraulic cylinder to 3000 psig (20,684 kPa gage) to install blade retainer.
(f) Remove clips, 2C14836P08, and let retaining ring move out. Use expander jaw, 2C14839P05,
to help expand retaining ring (figure 4).
(g) Remove pressure from actuator.
(5) Remove half-rings, 2C14831P02, bolts, and washers that attach push-pull plate, 2C14836P11, to
stage 2 aft flange.
(6) Using hoist, remove install/remove fixture 2C14836, from stage 2 disk.
(7) Examine retaining ring for correct installation. If necessary, use ring expander, 2C14839P03, and
expander jaw, 2C14839P05, to expand retaining ring.
D. Do a check of stage 2 blade retainer and retaining ring for correct installation as follows (figure 8):
(1) Measure space all around between stage 2 blade retainer and stage 2 disk (dimension BH). Use a
0.002 inch (0.05 mm) feeler stock as a Go-No-Go gage. Feeler stock must not fit into space
dimension BH.

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Figure 8. HPT Rotor Stage 2 Blade Retainer and Retaining Ring Seating
(2) Measure space between stage 2 blade retainer and retaining ring (dimension BG).
(a) Use a 0.030 inch (0.76 mm) feeler stock at open ends of retaining ring. Dimension BG must not
exceed 0.030 inch (0.76 mm) at open ends of retaining ring.
(b) Use a 0.018 inch (0.46 mm) feeler stock at six places equally spaced over remaining part of
retaining ring between places 40 degrees from open ends of retaining ring. Space dimension
BG must not exceed 0.018 inch (0.46 mm) at six previously selected places. If necessary, use
ring expander, 2C14839P03, and expander jaw, 2C14839P05, to help expand retaining ring.
E. Install aft air seals as follows (figure 1):
(1) Apply thread lubricant onto threads and washer faces of bolts and new nuts.
(2) Align matchmarks made at removal on aft air seals and stage 2 HPT rotor disk. Using bolts and new
nuts, secure aft air seals and pressure tube/coupling nut to stage 2 HPT rotor disk. Tighten nuts to
212-248 lb in. (24.0-28.0 N·m) of torque.
F. Remove mid shaft pilot, 1C9610, from mid shaft.

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STAGE 2 HIGH PRESSURE TURBINE (HPT) NOZZLE
(OFF ENGINE) REPLACEMENT
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Alphabetical Index
Subject Page
Stage 2 HPT Nozzle Installation. ............................................................................................................ 10

Stage 2 HPT Nozzle Removal.................................................................................................................. 3
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1. Introduction.
A. This work package contains instructions for replacing the stage 2 high pressure turbine (HPT) nozzle when
HPT module is removed from engine.
B. Remove HPT module and install, forward end down, in HPT module shipping/storage stand,
2C14193G03, and secure with plug, 2C14193P04, to retain stage 2 disk per WP 2610 00.
Title Number
High Pressure Turbine (HPT) Module Replacement WP 2610 00
Stage 2 High Pressure Turbine (HPT) Rotor Blades Replacement WP 2614 00

Nut Plate, Set - Stage 2 HPT Rotor Disk 2C14831G01
Tool, Install/Remove - Retaining Ring, Aft Blade Retainer 2C14839G01
Adapter, Lift - HPT Nozzle, Stage 2 2C14703G01
Anti-Seize Compound Milk of Magnesia (Unflavored)

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6. Stage 2 HPT Nozzle Removal.
A. Remove stage 2 HPT rotor blades as follows (figure 1):

NOTE
The procedures in this work package for removing and installing stage 2 HPT rotor blades
are to facilitate other maintenance only. If stage 2 HPT rotor blades require replacement,
refer to WP 2614 00.
(1) Remove stage 2 disk blade retainer:

WARNING
THE STAGE 2 HPT DISK IS SENSITIVE TO NICKS AND SCRATCHES

THAT COULD INADVERTENTLY RESULT FROM THIS PROCEDURE.
IF THE STAGE 2 DISK IS DAMAGED, EVEN SLIGHTLY, DURING THIS
PROCEDURE, THE DISK MUST BE REFERRED TO THE
APPROPRIATE FACTORY TECHNICAL SUPPORT REPRESENTATIVE
FOR EVALUATION AND REPAIR RECOMMENDATION. FAILURE TO
COMPLY MAY RESULT IN AN UNCONTAINED ENGINE FAILURE,
WHICH COULD CAUSE INJURY OR DEATH.
(a) Using a marking pen, matchmark blade retainer to face of stage 2 disk.
WARNING
BE CAREFUL WHEN USING PUSHER/PULLER TO APPLY PRESSURE.
MAKE SURE YOU DO NOT USE MORE THAN THE MAXIMUM
HYDRAULIC PRESSURE. STAY AWAY FROM THE AREA BEHIND
OR IN FRONT OF THE PUSHER/PULLER. A MALFUNCTION CAN
CAUSE INJURY OR DEATH.
(b) Fully extend hydraulic cylinder of fixture, 2C14836 (figure 2).
(c) Attach a hoist to lift rings of fixture, 2C14836.
WARNING

PARTS. STAY OUT FROM BELOW LOADS. IF THE PARTS
OR DEATH.
(d) Using hoist, lower install/remove fixture, 2C14836, onto HPT rotor stage 2 disk rotating seal
flange.
(e) Using half-rings, 2C14831P02, 24 washers, and 24 bolts, attach push-pull plate, 2C14836P11,
(f) Making adjustments in tooling, if required, slowly retract actuator until base, 2C14836P02,
touches stage 2 blade retainer.
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Figure 1. Stage 2 HPT Rotor Blades
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Figure 2. Stage 2 Aft Blade Retainer Install/Remove Fixture, 2C14836
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NOTE
When install/remove fixture, 2C14836, is hydraulically actuated and touches
blade retainer, there must be access to split in retaining ring, between ribs of
fixture.
(g) Retract hydraulic cylinder to 3000 psi (20,684 kPa) as if to seat blade retainer.
(h) Beginning at one end of retaining ring, use a plastic drift to move ring into groove.
1 Hold end of retaining ring with clip, 2C14836P08.
2 Use ring expander, 2C14839P03, and expander jaw, 2C14839P05, to help move retaining
ring (figure 3).
3 Continue around retaining ring, installing clips, 2C14836P08, approximately every

30 degrees (last clip goes at end of retaining ring).
(i) Perform a visual examination to make sure retaining ring is properly held, and is in a fully
(j) Remove half-rings, 2C14831P02, washers, bolts, and push-pull plate, 2C14836P11. Do not
remove clips, 2C14836P08.
WARNING
DRY ICE, BB-C-104: DO NOT LET THIS MATERIAL TOUCH YOU.

LOW-TEMPERATURE SKIN DAMAGE. CAN DECREASE AVAILABLE
AIR. ASPHYXIANT. PERSONAL PROTECTIVE EQUIPMENT REQUIRED,
ESPECIALLY INSULATED GLOVES AND EYE PROTECTION WHEN
HANDLING MATERIAL. USE IN A WELL-VENTILATED AREA.
(k) Put dry ice only on stage 2 retainer.
WARNING

(l) When retainer is sufficiently cold, remove retainer from stage 2 disk by hand.
(m) Remove seal ring from retainer.
(n) Remove retaining ring from groove in stage 2 disk. Use ring compressor, 2C14839P02, and
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Figure 3. Aft Blade Retaining Ring Install/Remove
(2) Remove HPT stage 2 blades:
WARNING
THE STAGE 2 HPT DISK IS SENSITIVE TO NICKS AND SCRATCHES

THAT COULD INADVERTENTLY RESULT FROM THIS PROCEDURE.
IF THE STAGE 2 DISK IS DAMAGED, EVEN SLIGHTLY, DURING
THIS PROCEDURE, THE DISK MUST BE REFERRED TO THE
APPROPRIATE FACTORY TECHNICAL SUPPORT REPRESENTATIVE
FOR EVALUATION AND REPAIR RECOMMENDATION. FAILURE TO
COMPLY MAY RESULT IN AN UNCONTAINED ENGINE FAILURE,
CAUTION
ACCURATELY. INCORRECT PLACEMENT AT INSTALLATION WILL
(a) Use marking pen to number each stage 2 blade and damper, and to matchmark side rails of
blades. Find dovetail tangs marked with a numeral 1. Blade between tangs is blade No. 1, and
damper No. 1 is between blades 1 and 2.
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NOTE
There are 74 dovetail slots in stage 2 disk, with a damper between each set of
blades.
(b) Starting at blade No. 1 and damper No. 1 position, mark and remove blades and dampers in
order, moving around stage 2 disk in a clockwise (CW) direction, aft looking forward (ALF).
(c) Store blades and dampers, by position in disk, in sequence of blade, damper, blade, damper
until all blades are removed.
B. Remove stage 2 HPT nozzle as follows (figure 4):
(1) Remove HPT nozzle borescope plug and flat washer, located at 5:00 o’clock position, ALF.
(2) Attach hoist to lift holes on lift adapter, 2C14703.
WARNING
(3) Using hoist, lower lift adapter, 2C14703, onto aft flange of HPT nozzle assembly. Secure adapter to
flange with three bolts and three nuts. Tighten nuts to 46-54 lb in. (5.2-6.1 N·m) of torque.
(4) Remove nuts and washers that secure HPT stage 2 nozzle flange to shipping/storage stand,
2C14193, leveling screws.
CAUTION

STAGE 2 NOZZLE IS NOT CENTERED OVER HPT ROTOR WHEN REMOVED.
(5) Using a hoist, carefully lift HPT stage 2 nozzle assembly to separate HPT stage 2 nozzle assembly
from HPT rotor. Use caution to prevent rotor/nozzle contact.
(6) Lower the HPT stage 2 nozzle onto a clean work surface.
(7) Remove nuts, bolts, and lift adapter, 2C14703, from aft flange of HPT nozzle assembly.
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Figure 4. HPT Stage 2 Nozzle Lift Adapter, 2C14703
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7. Stage 2 HPT Nozzle Installation.
CAUTION
ENSURE STAGE 2 HPT NOZZLE PART NUMBER IS CORRECT PER IPB, GEK 119320,
BEFORE INSTALLATION, OR DAMAGE TO ENGINE COULD RESULT.
A. Install stage 2 HPT nozzle as follows (figure 4):
(1) Attach hoist to lift holes on lift adapter, 2C14703.
WARNING

(2) Using hoist, lower lift adapter, 2C14703, onto aft flange of HPT nozzle assembly. Secure adapter to
flange with three bolts and three nuts. Tighten nuts to 46-54 lb in. (5.2-6.1 N·m) of torque.
CAUTION

STAGE 2 NOZZLE IS NOT CENTERED OVER HPT ROTOR WHEN INSTALLED.
(3) Using a hoist, carefully lift HPT stage 2 nozzle assembly and install over HPT rotor. Use caution to
prevent rotor/nozzle contact.
(4) Secure HPT stage 2 nozzle flange to shipping/storage stand, 2C14193. Using washers and nuts,
secure flange to leveling screws. Tighten nuts to 57-67 lb in. (6.5-7.5 N·m) of torque.
(5) Remove nuts and bolts that secure adapter, 2C14703, to aft flange of HPT nozzle assembly. Using
hoist, remove adapter from HPT nozzle assembly.
(6) Apply anti-seize compound to borescope plug case bore, located at 5:00 o’clock position, ALF.
Install flat washer and borescope plug to HPT case. Tighten borescope plug to 115-135 lb in.
(13.0-15.2 N·m) of torque.

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B. Install stage 2 HPT rotor blades as follows (figure 1):
WARNING

CAUTION

NOTE
bodies installed.
surface AP and outward in dovetail slots (figure 5). Minimum accumulated platform gap at surface
AP shall be 0.44 inches (11.2 mm).
C. Install stage 2 blade retainer as follows (figure 1):
WARNING
RESPIRATORY TRACT. SKIN AND EYE PROTECTION IS REQUIRED.
AVOID REPEATED OR PROLONGED CONTACT. USE IN A

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WARNING

CAUTION
IF HEAT IS USED TO CURE ADHESIVE, TEMPERATURE MUST NOT

EXCEED 250°F (121.1°C).
NOTE
Adhesive may be used to hold ring seal in place during assembly. Ensure
adhesive is applied in areas 0.5-1.5 inches (13-38 mm) long and spaced not
less than 6 inches (152 mm) apart.
shall be 0.100-0.150 inch (2.54-3.81 mm).

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(3) Install blade retainer into stage 2 disk blade retainer groove. Tap blade retainer into position with
soft mallet. Be careful not to damage seal ridges.
WARNING
BE CAREFUL WHEN YOU USE THE PUSHER/PULLER TO APPLY

PRESSURE. MAKE SURE YOU DO NOT USE MORE THAN THE
MAXIMUM HYDRAULIC PRESSURE. STAY AWAY FROM THE AREA
BEHIND OR IN FRONT OF THE PUSHER/PULLER. A MALFUNCTION
CAN CAUSE INJURY OR DEATH.
(a) Fully extend hydraulic cylinder of install/remove fixture, 2C14836.
WARNING

OR DEATH.
(b) Using hoist, lift fixture onto HPT rotor stage 2 disk rotating seal flange.
(c) Using half-rings, 2C14831P02, 24 washers, and 24 bolts, attach push-pull plate, 2C14836P11,
NOTE
install/remove fixture or retaining ring as necessary.
(d) Slowly retract actuator until half-rings, 2C14831P02, touch blade retainer.
(e) Examine alignment of install/remove fixture and blade retainer, and adjust as necessary.
(f) Retract hydraulic cylinder to 3000 psig (20,684 kPa gage) to install blade retainer.
(g) Remove clips, 2C14836P08, and let retaining ring move out. Use expander jaw, 2C14839P05,
(h) Remove pressure from actuator.

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(5) Remove half-rings, 2C14831P02, bolts, and washers that attach push-pull plate, 2C14836P11, to
stage 2 aft flange.
(6) Using hoist, remove install/remove fixture, 2C14836, from stage 2 disk.
D. Do a check of stage 2 blade retainer and retaining ring for correct installation as follows (figure 6):
0.002 inch (0.05 mm) feeler stock as a GO-NO-GO gage. Feeler stock must not fit into space
(dimension BH).
retaining ring between places 40 degrees from open ends of retaining ring. Dimension BG must
not exceed 0.018 inch (0.46 mm) at six previously selected places. If necessary, use ring
expander, 2C14839P03, and expander jaw, 2C14839P05, to help expand retaining ring.
NOTE
Deleted.
(3) Deleted.

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STAGE 1 HIGH PRESSURE TURBINE (HPT) ROTOR
BLADES REPLACEMENT
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44 Blank ................................................................................................................................................... 0
Alphabetical Index
Subject Page
Replacement Blades Selection. ............................................................................................................... 19

Stage 1 HPT Rotor Blades Installation. .................................................................................................. 22
Stage 1 HPT Rotor Blades Removal. ....................................................................................................... 4
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1. Introduction.
A. This work package contains procedures for replacing stage 1 HPT rotor blades.
B. Remove stage 2 HPT nozzle to gain access to the HPT rotor per WP 2612 00.
Title Number
Stage 2 High Pressure Turbine (HPT) Nozzle (Off Engine) WP 2612 00
Replacement

Fixture, HPT Lift and Turn, Forward 1C9772G01
Torque Adapter Set, Retainer Nut - No. 5R Bearing Inner Race 1C9774G01
Gage, Length - HPT Rotor Stage 1 Blade 247C5039G01
Fixture, Install/Remove HPT Front Rotating Air Seal 247C5047G01
Stand, Storage - HPT Rotor Assembly 247C5055G01
Pusher Set, Races/Seal - HPT Rotor Stage 1 2C14025G05
Fixture, Lift - HPT Rotor, Aft 2C14038G02
Stand, Rework/Storage HP Turbine Rotor 2C14048G04
(Alternate to 247C5055G01)
Puller Set - Stage 1 HPT Disk, Races and Seals 2C14688G05
Fixture, Install/Remove - HPT Rotor Pressure Balance Seal 2C14838G01
Plate, Anti-torque 9429M17G01
Program, Balance - Blade Replacement 9446M61G03 (or latest CD-
ROM version)
Pump, Hydraulic - 3,000 psi Capacity Local Purchase
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Petrolatum VV-P-236
Shim 1862M56P01 through AR
1862M56P06
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6. Stage 1 HPT Rotor Blades Removal.
A. Turn HPT rotor assembly to forward end up position as follows:
(1) Install HPT rotor aft lift fixture (aft lift fixture) 2C14038, on aft flange of HPT rotor stage 2 disk.
Use bolts and nuts (figure 1). Tighten nuts to 83-97 lb in. (9.4-10.9 N·m) of torque.
WARNING
(2) Attach a hoist to aft lift fixture, 2C14038, and lift HPT rotor assembly off HPT module shipping/
storage stand (stand), 2C14193.
(3) Install HPT forward lift and turn fixture (forward lift fixture), 1C9772, as follows (figure 2):
1
(a) Move forward lift fixture into HPT rotor forward shaft internal splines.
(b) Pull and hold knurled knob out from indexing plate, then turn lift bar to lift position. Release
knurled knob to lock forward lift fixture in forward shaft. Check marking on indexing plate to
confirm lift bar is locked in lift position.
(4) Attach a hoist to forward lift fixture, 1C9772, and rotate HPT rotor assembly to forward end up
position.
(5) Remove hoist and aft lift fixture, 2C14038, from HPT rotor.
(6) Install HPT rotor assembly (forward end up) in HPT rotor assembly storage stand (storage stand),
247C5055 (figure 3) as follows:
(a) Ensure stage 2 aft flange is in groove in ring, 247C5055P03, then clamp stage 2 aft flange with
clamps, 247C5055P04, and hand knobs, 247C5055P05.
(b) Secure stage 2 aft flange to ring, 247C5055P03, with four screws and washers. Tighten screws
(7) Remove forward lift fixture, 1C9772, from HPT rotor.
B. Using stage 1 HPT disk races and seals puller set (puller set), 2C14688, remove No. 5R bearing heat shield
(1) Use a marking pen to match mark No. 5R bearing heat shield to forward shaft.
(2) Install pusher plate, 2C14688P03, and compression plate, 2C14688P02, on end of forward shaft.
(3) Make sure three knobs, 2C14688P11, on puller are fully out radially. Install puller over compression
plate, 2C14688P02, and heat shield. Align knobs with three holes in forward end of heat shield.
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Figure 1. HPT Rotor Aft Lift Fixture, 2C14038
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Figure 2. HPT Forward Lift and Turn Fixture, 1C9772
Figure 3. HPT Assembly Installation in Storage Stand, 247C5055
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Figure 4. No. 5R Bearing Heat Shield Removal
(4) Push knobs radially in to engage pins in holes in heat shield.
WARNING
BE CAREFUL WHEN USING THE PUSHER/PULLER TO APPLY PRESSURE. DO

NOT USE MORE THAN MAXIMUM HYDRAULIC PRESSURE. AVOID THE AREA
SURROUNDING THE PUSHER/PULLER. A MALFUNCTION CAN CAUSE INJURY
OR DEATH.
(5) Operate hydraulic cylinder of puller set, 2C14688, to pull heat shield from forward shaft.
(6) Remove puller set, 2C14688, from forward shaft.
(7) Remove heat shield.
C. Using No. 5R bearing inner race retainer nut torque adapter set (torque adapter set), 1C9774, remove
No. 5R bearing inner race retainer nut (also called No. 5R bearing spanner nut) as follows (figure 5):
(1) Install anti-torque tube, 1C9774P02, into forward shaft.
(2) Install torque tube, 1C9774P03, over anti-torque tube, along with protector ring, 1C9774P06.
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Figure 5. No. 5R Bearing Inner Race Retainer Nut Removal
(3) Align eight knurled screws, 1C9774P04, with holes in No. 5R bearing inner race retaining nut. Twist
knurled screws in to engage pins into holes in retaining nut. Check marking on knurled screws to
confirm proper engagement.
(4) Install spacer ring, 1C9774P05, onto torque tube, 1C9774P03, using two bolts, washers (under
nuts), and nuts supplied in torque adapter set, 1C9774. Tighten nuts to 60-70 lb in.(6.8-7.9 N·m) of
torque.
(5) Install torque multiplier, Sweeney Model 8200, or equivalent, onto splines of torque tube,
1C9774P03.
(6) Install anti-torque plate, 9429M17G01, onto anti-torque tube, 1C9774P02.
(7) Operate torque multiplier to turn No. 5R bearing inner race retainer nut in a counterclockwise
direction to remove nut.
(8) Remove torque adapter set, 1C9774, and torque multiplier, Sweeney Model 8200, or equivalent.
(9) Disengage knurled screws, 1C9774P04, and remove No. 5R bearing inner race retainer nut from
torque adapter set, 1C9774.
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D. Remove No. 5R bearing inner race as follows:

(1) Install compression plate, 2C14688P02, and pusher plate, 2C14688P03, on forward end of forward
shaft.
(2) Install half parts of puller, 2C14688P05, around No. 5R bearing inner race. Hold puller half parts in
position with ring, 2C14688P08.
WARNING

OR DEATH.
(3) Operate hydraulic cylinder to pull inner race from forward shaft.
(5) Remove inner race.
E. Remove No. 5R bearing rotating air/oil seal as follows (figure 6):
WARNING
ESPECIALLY INSULATED GLOVES AND EYE PROTECTION WHEN HANDLING
MATERIAL. USE IN A WELL-VENTILATED AREA.
(1) Put cardboard inside forward shaft to hold dry ice.
(2) Place dry ice in forward shaft to cool area near seals.
shaft.
(4) Install half-rings of puller, 2C14688P31, around No. 5R bearing rotating air/oil seal. Hold puller
half-rings in position with ring, 2C14688P08.
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Figure 6. Rotating Air/Oil Seal and No. 5R Bearing Inner Race Removal

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WARNING

OR DEATH.
(5) Operate hydraulic cylinder to remove air/oil seal.
WARNING
(6) Remove parts of puller set, 2C14688, from forward shaft.
(7) Remove air/oil seal.
F. Remove No. 5R bearing rotating air seal as follows (figure 7):
shaft.
(2) Install puller, 2C14688P31, on forward shaft with fingers in slot of No. 5R bearing rotating air seal.
Hold puller fingers in position with ring.
(3) Operate hydraulic cylinder to remove rotating air seal.
(5) Remove rotating air seal.
G. Remove No. 5R bearing seal spacer:
(1) Turn puller adapter on No. 5R bearing seal spacer (seal spacer).
shaft.
(3) Install puller, 2C14688P31, on forward shaft with fingers engaged in slot in puller adapter,
2C14688P28. Hold puller fingers in position with ring, 2C14688P08.

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Figure 7. Rotating Air Seal and Seal Spacer Removal

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WARNING

OR DEATH.
(4) Operate hydraulic cylinder to remove puller adapter, 2C14688P28, and seal spacer.
(6) Remove puller adapter and seal spacer.
H. Remove No. 5R bearing rotating air seal (pressure balance seal) (figure 8):
(1) Remove 20 bolts that attach pressure balance seal and forward outer seal to forward shaft.
NOTE
Some bolts have balance weights under the head.
(2) Turn disk adapter tube, 2C14838P02, on forward end of forward shaft.
(3) Install cylinder adapter tube, 2C14838P04, as follows:
(a) Attach a hoist to ring on cylinder adapter assembly.
WARNING
LIFT PARTS. STAY OUT FROM BELOW LOADS. IF PARTS
ACCIDENTALLY MOVE OR FALL, THEY CAN CAUSE INJURY OR
DEATH.
(b) Lift cylinder adapter assembly and position it over forward shaft.
(c) Install cylinder adapter assembly over disk adapter tube.
(d) Attach cylinder adapter to disk adapter tube with two shoulder screws. Tighten screws to
170-200 lb in. (19.3-22.5 N·m) of torque.
(4) Install two half-rings of removal adapter, 2C14838P05, around cylinder adapter tube, 2C14838P02,
and forward shoulder of pressure balance seal. Attach half-rings together with four screws.
(5) Operate hydraulic cylinder to remove pressure balance seal.
(6) Release hydraulic pressure. Remove all parts of HPT rotor pressure balance seal install/remove
fixture, 2C14838, from forward shaft.
(7) Remove pressure balance seal, seal damper, and shim.

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Figure 8. No. 5R Bearing Rotating Air Seal (Pressure Balance Seal) Removal
I. Remove forward outer seal as follows:
(1) Install OD segment puller ring, 247C5047P03, as follows (figure 9):
(a) Remove eight screws from segment puller ring and separate four segments of ring.
(b) Carefully move ring segments under outside diameter (OD) lip of forward outer seal.
(c) Be sure number mark (1, 2, 3, or 4) on each ring segment end agrees with number mark on
adjacent ring segment end.
(d) Attach ring segments together with eight screws. Tighten screws hand-tight.
(2) Install disk adapter plate, 247C5047P06, on forward end of forward shaft.
(3) Turn adjustment bolt, 247C5047P07, fully into restraint tube, 247C5047P05.
(4) Release hand retractable plunger and turn ID puller ring, 247C5047P04, to UNLOCK position
(screw head next to word UNLOCK).
(5) Engage hand retractable plunger to lock ID puller ring, 247C5047P04, in UNLOCK position.

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Figure 9. Forward Outer Seal Removal (Sheet 1 of 2)

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Figure 9. Forward Outer Seal Removal (Sheet 2 of 2)
(6) Install restraint assembly (restraint tube, 247C5047P05, restraint plate, 247C5047P02, and ID puller
ring, 247C5047P04) as follows:
(a) Attach a three-leg chain lift to three swivel rings on restraint plate, 247C5047P02.
WARNING

ACCIDENTALLY MOVE OR FALL, THEY CAN CAUSE INJURY OR
DEATH.
(b) Attach a hoist. Lift restraint assembly and put it over forward end of forward shaft.
(c) Lower restraint assembly.
1 Look through 1.5 inch (38 mm) diameter hole in side of restraint tube, 247C5047P05, to
make sure pin in disk adapter plate, 247C5047P06, enters slot (marked ENGAGED and
DISENGAGED) in top of restraint adapter tube.
2 Be sure pin in disk adapter plate, 247C5047P06, is aligned with ENGAGED mark next to
slot in restraint tube, 247C5047P05. Assembly will stop when adjustment bolt,
247C5047P07, touches disk adapter plate.

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(d) Look through angled view hole (marked VIEW WINDOW FOR ENGAGING PIN) in restraint
plate, 247C5047P02. Make sure pin in restraint plate is in a bolthole in forward outer seal
flange.
CAUTION
CAREFULLY TURN THE ADJUSTMENT BOLT OUT TO ENSURE FEET OF ID

PULLER RING ARE NOT ON FORWARD FLANGE OF FORWARD OUTER
SEAL. THE FEET MUST BE DOWN TO THE INSIDE DIAMETER OF FORWARD
OUTER SEAL BETWEEN TANGS OF FORWARD FLANGE.
(7) Slowly turn adjustment bolt out to lower restraint tube, 247C5047P05. Be sure feet of ID puller ring,
247C5047P04, are down into inside diameter of forward outer seal between tangs of forward flange.
(a) When adjustment bolt becomes loose, examine space between restraint plate, 247C5047P02,
and OD of OD segment puller ring, 247C5047P03.
(b) If space is 0.250 inch (6.35 mm) or less, proceed to step 6.I.(8).
(c) If space is more than 0.250 inch (6.35 mm), feet of ID puller ring, 247C5047P04, are on
forward flange of forward outer seal. To get correct positioning of ID puller ring, do the
following:
1 Turn adjustment bolt, 247C5047P07, back in until it touches disk adapter plate,
247C5047P06.
2 Carefully rotate disk adapter plate, 247C5047P06, a small distance until feet of ID puller
ring, 247C5047P04, move off forward outer seal forward flange tangs.
(8) Continue to turn adjustment bolt, 247C5047P07, out until restraint plate, 247C5047P02, touches
forward outer seal.
(9) When adjustment bolt, 247C5047P07, is completely loose, look through angled view hole in
restraint plate, 247C5047P02, to make sure pin in restraint plate is in a forward outer seal flange
bolthole.
(10) Release hand retractable plunger and turn ID puller ring, 247C5047P04, to LOCK position with
screw head next to word LOCK. This will engage ID puller ring tabs with ID flange of forward outer
seal. Engage hand retractable plunger to keep puller ring in position.
(11) Attach restraint plate, 247C5047P02, to OD segment puller ring, 247C5047P03. Use 16 screws and
washers. Tighten screws hand-tight. Adjust OD segment puller ring circumferentially a small
distance if necessary to align screws with boltholes.
(12) Tighten screws in 10 lb ft (14 N·m) of torque increments, to 30-40 lb ft (41-54 N·m) of torque.
Tighten screws in numerical order as marked on restraint plate.
(13) Make sure OD segment puller ring, 247C5047P03, is in full contact with restraint plate,
247C5047P02. Use a 0.005 inch (0.13 mm) shim stock to examine all around adjacent surfaces.
(14) Tighten screws in OD segment puller ring, 247C5047P03, to 180 lb in. (20.3 N·m) of torque.

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(15) Install and tighten ID puller screws, in 15 lb ft (20 N·m) of torque increments. Tighten screws in
numerical order as marked on restraint plate.
(16) Tighten ID puller screws to 50 lb ft (68 N·m) of torque.
(17) Turn restraint assembly and attached forward outer seal until pin in disk adapter plate,
247C5047P06, is next to DISENGAGED mark by slot in restraint tube, 247C5047P05. Forward
outer seal will disengage from stage 1 disk.
WARNING

STAY OUT FROM BELOW LOADS. IF PARTS ACCIDENTALLY MOVE OR FALL,
THEY CAN CAUSE INJURY OR DEATH.
(18) Lift restraint assembly and attached forward outer seal from forward shaft.
(a) Turn in adjustment bolt, 247C5047P07, if necessary, to aid in removal of forward outer seal.
(b) Examine to make sure forward outer seal is disconnected from HPT rotor stage 1 disk.
(c) Turn adjustment bolt, 247C5047P07, fully into disk adapter plate, 247C5047P06.
(19) Remove disk adapter plate, 247C5047P06, from forward end of forward shaft. Install disk adapter
plate on end of set-up base, 247C5047P10.
(20) Lift and remove restraint assembly, with forward outer seal attached, over disk adapter plate,
247C5047P06, on set-up base, 247C5047P10.
(21) Lower restraint assembly:
(a) Look through 1.5 inch (38 mm) hole in side of restraint tube, 247C5047P05, to make sure pin
in disk adapter plate, 247C5047P06, enters slot (marked ENGAGED and DISENGAGED) in
top of restraint adapter tube.
(b) Be sure pin in disk adapter plate aligns with ENGAGED mark next to slot in restraint adapter
tube. Assembly will stop when adjustment bolt touches disk adapter plate.
(c) Turn adjustment bolt, 247C5047P07, fully out.
(22) Loosen each ID puller screw one-half turn in crisscross pattern marked on restraint plate,
247C5047P02. Completely loosen screws.
NOTE
The screws are captive in the restraint plate.
(23) Pull each screw up and turn into restraint plate, 247C5047P02. Do not remove screws.
(24) Loosen each screw one-half turn in crisscross pattern marked on restraint plate, 247C5047P02.
Remove screws and washers.

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(25) Release hand retractable plunger. Turn ID puller ring until shoulder screws are next to word
UNLOCK marked on restraint plate, 247C5047P02.
(26) Engage hand retractable plunger to lock ID puller ring to restraint plate, 247C5047P02.
(27) Turn adjustment bolt all the way in.

WARNING

(28) Lift restraint assembly off forward outer seal and set-up table, 247C5047P10.
(29) Remove OD segment puller ring, 247C5047P03, from forward outer seal as follows:
(a) Remove screws from OD segment puller ring, 247C5047P03, sections.
(b) Remove segments of OD segment puller ring, 247C5047P03, from forward outer seal.
(c) Assemble segments together with screws.
(d) Tighten screws hand-tight.
(30) Remove forward outer seal from set-up table, 247C5047P10.
J. Remove stage 1 blades and seal bodies as follows:
(1) Number eighty stage 1 blades, seal bodies, and dampers by their dovetail locations.
(2) Remove eighty stage 1 blades, seal bodies, and dampers. It is necessary to fan blades to remove first
blade.
A. Measure length of removed blades using HPT rotor stage 1 blade length gage (gage), 247C5039.
Replacement blade length shall be within 0.010 inch (0.25 mm) of length of removed blade but shall not
exceed length of longest blade in stage.
B. Weigh removed blades and record on position map (figure 10).

NOTE
Replacement blades shall be weighed after tip grinding to meet length requirement. For planning
purposes, removal of 0.010 inch (0.25 mm) from blade tip will reduce blade weight by 0.12 gram. Do
not use blade weight marked on new blades by manufacturer.
C. Weigh replacement blades. Using marking pen, mark weight on blade.
D. Select replacement blades within 0.25 gram of original blade. Blades replacing those with portions missing
shall weigh within 0.25 gram of average of two adjacent blades on each side of damaged blade. If
replacement blade within 0.25 gram of original blade is not available, use blade replacement guide
(figure 11).

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Figure 10. HPT Stage 1 Blade/Damper Position Map

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NOTE
For a copy of GE computerized balance program and instructions for use, contact GE customer
service.
E. Calculate blade position using GE computerized blade replacement balance program, 9446M61. Mark
8. Stage 1 HPT Rotor Blades Installation.
A. Install stage 1 blades, seal bodies, and dampers as follows:
(1) Install stage 1 blades as follows:
(a) Install eighty blades from forward side of stage 1 disk.
(b) Airfoil leading edge (thick edge) faces forward.
(c) Push blades aside to install final blade.
(2) Install dampers.
(3) Install seal bodies.
(4) Examine dampers to be sure they will move a small amount with finger pressure.
NOTE
Seal bodies must not bind or move adjacent blades apart during installation.
(5) If necessary, blend forward lower lobe surface of seal body to remove excess material to prevent
binding.
(6) Be sure seal body aft extension (angel wing) can move radially a small amount. Use finger pressure
under the following conditions (conditions apply to blades on each side of seal body examined):
• Condition 1: Hold blades, adjacent to seal body which is examined, together (closing space
between blades at surface BU) (figure 12).
• Condition 2: Pull adjacent blades radially out.
(7) Make sure there is a small circumferential movement of blade tips with all seal bodies and dampers
installed.
(8) Total accumulated gap must be 0.48 inch (12.2 mm) minimum.

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Figure 12. Stage 1 Blades Installation
B. Install forward outer seal as follows:
(1) Install seal ring into groove on aft face of forward outer seal.
(2) Cut seal ring ends to get a 0.10-0.15 inch (2.5-3.8 mm) space between ends of ring (dimension Z)
(figure 13).
WARNING
SYNTHETIC ADHESIVE IS TOXIC AND FLAMMABLE. USE PERSONAL

PROTECTION EQUIPMENT. USE IN A WELL-VENTILATED AREA.
NOTE
Adhesive may be used to hold ring seal in place during assembly. Ensure adhesive is
applied in areas 0.5-1.5 inch (13-38 mm) long and spaced not less than 6 inches (152 mm)
apart. If heat is used to cure adhesive, temperature must not exceed 250°F (121.1°C).
(3) Verify seal ring is flush with or below groove edge.
(4) For hardware assembly, prepare a suitable work surface that is free from contamination.

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Figure 13. Seal Ring Installation

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NOTE
All hardware and tool mating surfaces must be clean and kept clean.
WARNING
(5) Clean tooling and hardware with alcohol.
(6) Lubricate stage 1 disk forward outer seal mating flange and forward outer seal (bayonet) flange with
petrolatum.
WARNING

(7) Using hoist, lift set-up base, 247C5047P10, and place onto a clean metal table.
(8) Remove eight screws that attach four parts of segment puller ring, 247C5047P03, together. Separate
four parts.
(9) Install forward outer seal (aft end down) on set-up base, 247C5047P10.
(a) Align pin in table with any seal flange bolthole.
WARNING

LOW TEMPERATURE SKIN DAMAGE. CAN DECREASE
AVAILABLE AIR. ASPHYXIANT. PERSONAL PROTECTIVE
EQUIPMENT REQUIRED, ESPECIALLY INSULATED GLOVES AND
EYE PROTECTION WHEN HANDLING MATERIAL. USE IN A
(b) Fill space inside of inner seal rake with dry ice.
(10) Carefully move segment puller ring, 247C5047P03, parts under OD lip of forward outer seal. Make
sure ends of adjacent parts have same number marked on them.
(11) Attach segment puller ring, 247C5047P03, parts together with eight screws. Tighten screws hand-
tight.
(12) Install disk adapter plate, 247C5047P06, on end of the dummy shaft of set-up base, 247C5047P10.
Align pin in side of disk adapter plate with slot in set-up table dummy shaft (figure 14).
(13) Turn adjustment bolt all the way into restraint tube, 247C5047P05.

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Figure 14. Front Rotating Air Seal Installation

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(14) Turn ID puller ring to UNLOCK position as follows:
(a) Disengage (lift) hand retractable plunger on restraint tube, 247C5047P05.
(b) Turn ID puller ring to UNLOCK position (bolthead next to word UNLOCK).
(c) Engage hand retractable plunger to keep puller ring from turning.
(d) Install screws to hold restraint tube, 247C5047P05, restraint plate, 247C5047P02, and ID puller
ring, 247C5047P04, together.
WARNING
CAUTION
IF THE RESTRAINT ADAPTER TUBE IS NOT PROPERLY ALIGNED WITH

ENGAGED MARK ADJACENT TO MARK ON PIN IN DISK ADAPTER PLATE,
THE FIXTURE CAN BE ON TOP OF SEAL AND NOT DOWN PAST THE TANGS
OF THE SEAL, DAMAGING PARTS OR TOOLING.
(15) Lift restraint plate, 247C5047P02, restraint tube, 247C5047P05, and ID puller ring, 247C5047P04,
as an assembly. Put assembly over dummy shaft of set-up table base, 247C5047P10, and install as
follows:
(a) Lower assembly carefully until adjustment bolt touches disk adapter plate.
(b) Look through hole in upper side of restraint adapter tube to be sure pin in disk adapter plate,
247C5047P06, will align with slot in top of restraint adapter tube.
(c) Mark on pin in disk adapter plate, 247C5047P06, must align with ENGAGED mark adjacent to
slot in top of restraint tube, 247C5047P05.
(d) Turn adjustment bolt, 247C5047P07, out until restraint plate, 247C5047P02, touches forward
outer seal.
(e) Look through angled hole marked VIEW WINDOW FOR ENGAGING PIN in restraint plate,
247C5047P02, to make sure pin in restraint plate is in a forward outer seal flange bolthole, and
not on top of forward outer seal flange. If pin has not engaged a bolthole, do not continue.
(f) Pull hand retractable plunger to disengage it.
(g) Turn ID puller ring, 247C5047P04, (push on screw heads) until screw heads align with LOCK
position marked on restraint plate, 247C5047P02.
(h) Lower (engage) hand retractable plunger to lock parts in position.

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WARNING

(i) Ensure space outside forward outer seal and inside seal teeth is filled with dry ice. If necessary,
fill space through 1.5 inch (38 mm) diameter holes in restraint plate, 247C5047P02.
(j) Attach OD segment puller ring, 247C5047P03, to restraint plate, 247C5047P02. Use 16
washers and screws. Tighten screws hand-tight.
(16) Bend forward outer seal into installation shape as follows:
(a) Tighten ID puller screws as follows:
1 Use crisscross pattern marked on restraint plate, 247C5047P02, and tighten screws in
10 lb ft (14 N·m) increments.
2 Final-tighten to 50 lb ft (68 N·m) of torque.
(b) Tighten eight screws as follows:
1 Use crisscross pattern marked on restraint plate and tighten in 10 lb ft (14 N·m) of torque
increments.
2 Tighten screws until outer puller ring is pulled up to touch restraint plate, 247C5047P02.
3 Examine all around interface between restraint plate, 247C5047P02, and segment puller
ring, 247C5047P03. Use 0.001 inch (0.03 mm) feeler stock. Feeler must not enter space
between parts.
(c) Tighten eight screws (holding quarters of OD segment puller ring, 247C5047P03, together) to
180 lb in. (20.3 N·m) of torque.
(17) Turn adjustment bolt, 247C5047P07, in to lift seal and installation tool up as high as possible off set-
up base, 247C5047P10.
(18) Attach a hoist to swivel rings on restraint plate, 247C5047P02.
WARNING
(19) Lift forward outer seal and installation fixture off set-up base, 247C5047P10.

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(20) Remove disk adapter plate, 247C5047P06, from end of dummy shaft of set-up base, 247C5047P10.
(21) Install disk adapter plate, 247C5047P06, on forward end of forward shaft. Pin in side of disk adapter
plate must be in slot in forward shaft (which is in line with J mark on stage 1 disk dovetail).
(22) Install a thin plywood blade protector over stage 1 blades.
(23) Lift fixture (with forward outer seal) and put it down over forward shaft. Line in disk adapter plate,
247C5047P06, pin must be aligned with DISENGAGED mark adjacent to slot in restraint tube,
247C5047P05.
(24) Lower hoist to remove load. Do not remove hoist.
(25) Carefully turn adjustment bolt, 247C5047P07, out (CCW) until forward outer seal touches stage 1
disk.
(26) Turn adjustment bolt, 247C5047P07, in (CW) until forward outer seal just begins to lift off stage 1
disk.
(27) Turn installation fixture (with forward outer seal) to align line in disk adapter plate, 247C5047P06,
pin with ENGAGED mark adjacent to restraint tube, 247C5047P05, slot.
(a) Put a bar in holes in outer rim of restraint plate, 247C5047P02, to assist in turning assembly.
(b) If necessary, adjust height of adjustment bolt, 247C5047P07, to let assembly turn as easily as
possible.
(28) Examine alignment. Insert screw in FINAL ALIGNMENT CHECK hole in restraint plate. Bolt
should go into a nut on stage 1 disk.
NOTE
A fine alignment pin is provided as an additional alignment check. If the screw can be
inserted properly, the engine hardware can be assembled correctly and the alignment pin
does not need to be used.
(29) Loosen screws one-half turn in crisscross pattern marked on restraint plate, 247C5047P02. Remove
16 screws and washers. Use crisscross pattern marked on restraint plate.
(30) Remove screw or alignment pin used for an alignment check.
(31) Completely loosen, but do not remove, eight captive ID puller screws in crisscross pattern marked
on restraint plate, 247C5047P02.
(32) Lift (release) hand retractable plunger and turn ID puller ring, 247C5047P04, until boltheads are
adjacent to UNLOCK marks on restraint plate, 247C5047P02.
(33) Lower (engage) hand retractable plunger.
(34) Make sure line mark on pin in disk adapter plate, 247C5047P06, is aligned with ENGAGED mark
adjacent to slot in restraint plate, 247C5047P02.

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WARNING

(35) Turn adjustment bolt, 247C5047P07, in (CW) to lift fixture up approximately 1.0 inch (25 mm).
Carefully lift installation fixture off of stage 1 rotor forward shaft.
(36) Remove disk adapter plate, 247C5047P06, from end of stage 1 rotor forward shaft.
(37) Remove OD segment puller ring, 247C5047P03, as follows:
(a) Remove screws that connect four parts of OD segment puller ring.
(b) Remove outer puller ring parts from forward outer seal.
(c) Attach four parts of outer puller ring together with screws. Tighten screws hand tight.
(38) Measure space, dimension AD, on forward outer seal as follows (figure 15):
(a) Make sure that forward outer seal is correctly installed.
(b) Check space AD between forward face of stage 1 disk and aft face of forward outer seal. Use a
0.001 inch (0.03 mm) feeler stock as a NO-GO gage all around interface.
(39) Install damper ring into ID groove of inner seal rake of forward outer seal.
(40) Rotate split in damper ring to 140-220 degrees away from forward outer seal damper ring entrance
channel.
C. Install pressure balance seal as follows (figure 16):
CAUTION
BE SURE THE SLAVE BOLT SHOULDERS ARE SUFFICIENTLY SHORT SO

THREADS ARE AVAILABLE AT THE NUTS WHEN THE BOLTHEADS ARE
TORQUED.
(1) Attach inner flange of forward outer seal to stage 1 disk forward flange. Use 10 equally spaced slave
bolts tightened in a crisscross pattern. After bolts are hand tight, further tighten to 215 lb in.
(2) Do eight equally spaced measurements of dimension BB on pressure balance seal (from aft flange
aft surface that mates with forward shaft shoulder). Record average dimension.
(3) Do eight equally spaced measurements of dimension BA on forward shaft (pressure balance seal
seating shoulder to forward surface of forward outer seal forward flange). Record average
dimension.

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Figure 15. Forward Seal Gap Check

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Figure 16. Pressure Balance Seal Shim Installation
(4) Subtract dimension BA from dimension BB to determine correct shim thickness.
(5) Get correct shim from list as follows:
Calculated Dimension Shim Part No.

0.015-0.018 inch (0.38-0.46 mm) 1862M56P01
0.019-0.022 inch (0.48-0.56 mm) 1862M56P02
0.023-0.026 inch (0.58-0.66 mm) 1862M56P03
0.027-0.030 inch (0.69-0.76 mm) 1862M56P04
0.031-0.034 inch (0.79-0.86 mm) 1862M56P05
0.034-0.035 inch (0.86-0.89 mm) 1862M56P06
NOTE
The actual shim thickness is not the same as the dimension calculated. An interference
component is included in the formula.
(6) Install seal damper into inner side of pressure balance seal outer rake.

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(7) Install pressure balance seal as follows (figure 17):
(a) Remove slave bolts installed to attach forward outer seal flange to stage 1 disk forward flange.
(b) Install alignment pins, 2C14838P07, into stage 1 disk forward flange nuts.
(c) Install shim down over alignment pins in stage 1 disk forward flange.
WARNING

(d) Put dry ice in ID of forward shaft.
(e) Put pressure balance seal outer rake circumferential ring in dry ice for approximately
15 minutes.
CAUTION
WHEN USING A TORCH, DO NOT HEAT IN ONE LOCATION BUT

APPLY THE HEAT GRADUALLY OVER THE HEATED SURFACE.
HEATING IN ONE LOCATION WILL TWIST THE PART.
(f) Heat ID rabbet of forward outer seal (where outer diameter of pressure balance seal will seat).
Use a torch to heat gradually all around rabbet.
(g) Remove pressure balance seal from dry ice and heat pressure balance seal ID for approximately
1-2 minutes. Use a torch to heat all around ID gradually.
(h) Install pressure balance seal over alignment pins, 2C14838P07, on stage 1 disk forward flange.
(i) Install installation adapter, 2C14838P03, over forward shaft against pressure balance seal.
(j) Turn disk adapter tube, 2C14838P02, on threads of forward shaft.
(k) Install cylinder adapter tube, 2C14838P04, as follows:
1 Attach hoist to lift ring.

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Figure 17. Pressure Balance Seal Installation

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WARNING
ALWAYS USE APPROVED EQUIPMENT AND PROCEDURES

TO LIFT PARTS. STAY OUT FROM BELOW LOADS. IF PARTS
ACCIDENTALLY MOVE OR FALL, THEY CAN CAUSE INJURY
OR DEATH.
2 Lift cylinder adapter tube, 2C14838P04, and pusher assembly and put it over disk adapter
tube, 2C14838P02.
3 Attach cylinder adapter tube, 2C14838P04, to disk adapter tube, 2C14838P02, with two
screws.
WARNING
BE CAREFUL WHEN USING THE PUSHER/PULLER TO APPLY

PRESSURE. DO NOT USE MORE THAN MAXIMUM HYDRAULIC
PRESSURE. AVOID THE AREA SURROUNDING THE PUSHER/
PULLER. A MALFUNCTION CAN CAUSE INJURY OR DEATH.
(l) Operate hydraulic cylinder to seat pressure balance seal.
(m) Remove all parts of install/remove fixture, 2C14838, from stage 1 forward shaft.
(8) Lubricate 20 bolts with thread lubricant.
(9) Install bolts to attach pressure balance seal and forward outer seal to stage 1 disk forward flange.
(10) Tighten bolts in increments, in a crisscross pattern, to 220-240 lb in. (24.9-27.1 N·m) of torque.
Loosen then retighten all bolts, one at a time, to 220-240 lb in. (24.9-27.1 N·m) of torque.
D. Install rotating seals as follows:
(1) Assemble rotating air/oil seal, rotating air seal, and seal spacer on a surface plate.
(2) Install damper ring into aft inboard side of rotating air seal.
WARNING
(3) Put rotating air/oil seal, rotating oil seal, and seal spacer in an oven at 400°F (204°C) for 20 minutes.
(4) Put dry ice in ID of forward shaft.

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(5) Install seal spacer as follows (figure 18):
WARNING
HOT OR COLD PARTS CAN CAUSE INJURY. USE THERMAL

GLOVES WHEN MOVING OR TOUCHING HOT OR COLD PARTS.
(a) Remove seal spacer from oven and put it on forward shaft.
(b) Install pusher ring, 2C14025P02, on forward shaft.
(c) Put pusher, 2C14025P08, on forward shaft with threads forward.
(d) Engage threads of pusher, 2C14025P08, in threads of forward shaft.
(e) Turn pusher, 2C14025P08, until seal spacer is against pressure balance seal. Keep pusher and
pusher ring, 2C14025P20, in position until parts are at room temperature.
(f) Remove all parts of HPT rotor stage 1 races/seal pusher set, 2C14025.
E. Install rotating air seal as follows:
(1) Remove rotating air seal from oven and put on forward shaft.
(2) Align cutouts in rotating air seal with tabs on pressure balance seal.
(3) Install pusher ring, 2C14025P20, on forward shaft.
(4) Put pusher, 2C14025P08, on forward shaft with threads forward.
(5) Engage threads of pusher, 2C14025P08, in threads of forward shaft.
(6) Turn pusher, 2C14025P08, until rotating air seal is against pressure balance seal. Keep pusher and
pusher ring, 2C14025P20, in position until parts are at room temperature.
F. Install rotating air/oil seal as follows (figure 19):
(1) Remove rotating air/oil seal from oven and put on forward shaft.
(2) Align pins in rotating air/oil seal with notches in rotating air seal.
(3) Put pusher, 2C14025P08, on forward shaft with threads forward.
(4) Engage threads of pusher, 2C14025P08, in threads of forward shaft.
(5) Turn pusher, 2C14025P08, until rotating air/oil seal is against rotating air seal. Keep pusher in
position until parts are at room temperature.

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Figure 18. Seal Spacer and Rotating Air Seal Installation

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Figure 19. Rotating Air/Oil Seal and No. 5 Bearing Inner Race Installation

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G. Install slave No. 5R bearing race as follows:
WARNING
HOT OR COLD PARTS CAN CAUSE INJURY. USE THERMAL GLOVES WHEN
MOVING OR TOUCHING HOT OR COLD PARTS.
(1) Put slave No. 5R bearing race in an oven at 350°F (177°C) for 20 minutes.
(2) Remove slave bearing race from oven.
(3) Install slave bearing race on forward end of forward shaft.
(4) Install pusher, 2C14025P08, on forward shaft with threads aft.
(a) Engage threads of pusher, 2C14025P08, in threads of forward shaft.
(b) Turn pusher, 2C14025P08, until slave bearing race is against rotating air/oil seal. Keep pusher
in position until parts are at room temperature.
(5) Remove all parts of HPT rotor stage 1 races/seal pusher set, 2C14025.
(6) Examine gap between slave bearing race and rotating air/oil seal.
(a) Use 0.001 inch (0.03 mm) feeler stock all around.
(b) Feeler must not enter gap at any location.
H. Install No. 5R bearing slave (spanner) nut as follows (figure 20):
WARNING

(1) Clean threads of forward shaft and No. 5R bearing slave nut with alcohol.
(2) Lubricate threads and friction surfaces of slave nut with thread lubricant.
(3) Turn slave nut on threads of forward shaft.
NOTE
The slave nut can be installed in the torque tube of the torque adapter set, 1C9774. The
torque adapter set with slave nut can then be installed on the forward shaft. Use care when
starting slave nut and torque tube down on the shaft.
(4) Install anti-torque tube, 1C9774P02, into forward end of forward shaft, engaging splines.
(5) Install torque tube, 1C9774P03, over anti-torque tube, 1C9774P02, along with protector ring,
1C9774P06.

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Figure 20. No. 5R Bearing Slave Nut Installation
(6) Twist knurled screws, 1C9774P04, in to engage pins into holes in slave nut. Check marking on
knurled screws to confirm proper engagement.
(7) Install spacer ring, 1C9774P05, onto torque tube, 1C9774P03, using two bolts, washers (under
nuts), and nuts supplied in torque adapter set, 1C9774. Tighten nuts to 60-70 lb in. (6.8-7.9 N·m) of
torque.
(8) Install torque multiplier, Sweeney Model 8200, or equivalent, onto splines of torque tube,
1C9774P03.
(9) Install anti-torque plate, 9429M17G01, onto anti-torque tube, 1C9774P02.
(10) Turn slave nut down until vespel insert of nut is fully engaged on threads of forward shaft. Do not
turn nut down fully.
(11) Tighten slave nut to 62-71 lb ft (85-96 N·m) of torque using torque wrench dial reading. Wipe off
any excess lubricant.
NOTE
The actual torque applied to the slave nut through the torque multiplier is 2000-2300 lb ft
(2712-3118 N·m).
(12) Remove torque adapter set, 1C9774, and torque multiplier from forward shaft.
(13) Conduct a slave nut seating check. Use 0.001 inch (0.03 mm) feeler stock all around.

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I. Install heat shield as follows (figure 21):
WARNING
HOT OR COLD PARTS CAN CAUSE INJURY. USE THERMAL GLOVES WHEN
MOVING OR TOUCHING HOT OR COLD PARTS.
(1) Put heat shield in an oven at 350°F (177°C) for 20 minutes.
(2) Remove heat shield from oven and install it on forward shaft as follows:
(a) Align tabs on ID of heat shield with notches on forward end of forward shaft.
(b) Align matchmarks and install heat shield on forward shaft.
(c) Install plate, 2C14025P11, and rod, 2C14025P13, into forward shaft with plate seated against
forward shaft inner lip.
(d) Install support plate, 2C14025P10, over rod, 2C14025P13, and secure with nut.
(e) Install holding plate, 2C14025P12, over rod, 2C14025P13, with holding plate against heat
shield. Secure holding plate with handle.
(f) Turn handle to seat heat shield. Be careful not to overseat heat shield.
(g) Remove pusher set when parts have cooled to room temperature.
(3) Check distance from forward shaft to forward face of heat shield. Distance must be a minimum of
0.240 inch (6.10 mm) (figure 22).
J. Lift HPT rotor assembly off storage stand, 247C5055, as follows:
(1) Install forward lift fixture, 1C9772, as follows (figure 2):
(a) Move forward lift fixture into HPT rotor forward shaft internal splines.
(b) Pull and hold knurled knob out from indexing plate, then turn lift bar to lift position. Release
knurled knob to lock forward lift fixture in forward shaft. Check marking on indexing plate to
confirm lift bar is locked in lift position.
(2) Use hand knobs, 247C5055P05, to loosen and remove clamps, 247C5055P03, from HPT aft flange.
WARNING

(3) Attach a hoist to forward lift fixture, 1C9772, and lift HPT rotor assembly off storage stand,
247C5055.

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Figure 21. Heat Shield Installation
Figure 22. Heat Shield Measurement Check

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(4) Install aft lift fixture, 2C14038, on aft flange of HPT rotor stage 2 disk. Use bolts and nuts
(figure 1). Tighten nuts to 83-97 lb in. (9.4-10.9 N·m) of torque.
WARNING
(5) Attach a hoist to aft lift fixture, 2C14038, and rotate HPT rotor assembly to aft end up position.
(6) Remove hoist and forward lift fixture, 1C9772, from HPT rotor.
(7) Install HPT rotor in HPT module shipping/storage stand, 2C14193, per WP 2610 00.
%ODQN
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STAGE 2 HIGH PRESSURE TURBINE (HPT) ROTOR
BLADES REPLACEMENT
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Page No. Change No.
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Alphabetical Index
Subject Page

Stage 2 HPT Rotor Blades Removal. ....................................................................................................... 3
Stage 2 HPT Rotor Blades Installation. .................................................................................................. 12
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1. Introduction.
A. This work package contains instructions for removing and installing the stage 2 high pressure turbine
(HPT) rotor blades.
B. Remove the low pressure turbine (LPT) module to gain access.
Title Number

Gage, Length-Blade HPT Rotor Stage 2 247C5039G02
Fixture, Pull - HPT Rotor Aft Air Seal 2C14785G02
Nut Plate, Set-Stage 2 HPT Rotor Disk 2C14831G01
Tool, Install/Remove-Retaining Ring, Aft Blade Retainer 2C14839G01
Program, Balance-Blade Replacement 9446M61G03
Dry Ice BB-C-104
Petrolatum VV-P-236
.

Nut, Self-Locking 9283M41P04 24
Seal, Ring 1847M57P03 1
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6. Stage 2 HPT Rotor Blades Removal.
A. Remove aft air seal as follows (figure 1):
(1) Install mid shaft pilot, 1C9610, on mid shaft.
(2) Apply penetrating oil onto threads of nuts and bolts that secure aft air seal. Allow penetrating oil to
soak for 20 minutes.
(3) Using marking pen, matchmark aft air seal to stage 2 HPT rotor disk. Remove nuts and bolts that
secure aft air seal onto stage 2 HPT rotor disk. Discard nuts.
(4) Remove aft air seal from stage 2 HPT rotor disk using pull fixture, 2C14785, as follows:
(a) Loosen clamp knobs, 2C14785P06, on pull fixture, 2C14785, and move slide clamps inward.
WARNING

OR DEATH.
(b) Connect overhead hoist and lift sling through pull fixture, 2C14785, holes.
(c) Install pull fixture, 2C14785, over mid shaft so that rest pads, 2C14785P03, are against stage 2
HPT rotor disk. Move slide clamps, 2C14785P07, outwards to engage aft air seal. Hand-tighten
clamp knobs to secure.
(d) Install guide tube, 2C14785P05.
(e) Take up slack on hoist to support pull fixture, 2C14785.
(f) Tighten jackscrews slowly and evenly to remove aft air seal.
B. Remove stage 2 blade retainer as follows (figure 2):
WARNING
COULD INADVERTENTLY RESULT FROM THIS PROCEDURE. IF THE STAGE 2
DISK IS DAMAGED, EVEN SLIGHTLY, DURING THIS PROCEDURE, THE DISK
MUST BE REFERRED TO THE APPROPRIATE FACTORY TECHNICAL SUPPORT
REPRESENTATIVE FOR EVALUATION AND REPAIR RECOMMENDATION.
FAILURE TO COMPLY MAY RESULT IN AN UNCONTAINED ENGINE FAILURE,
(1) Using a marking pen, matchmark blade retainer to face of stage 2 disk.
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Figure 2. Stage 2 HPT Rotor Blade Replacement
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WARNING

THEY CAN CAUSE AN INJURY OR DEATH.
WARNING
BE CAREFUL WHEN USING PUSHER/PULLER TO APPLY PRESSURE. MAKE

SURE YOU DO NOT USE MORE THAN THE MAXIMUM HYDRAULIC
(2) Fully extend install/remove fixture, 2C14836, hydraulic cylinder (figure 3). Using hoist, lift fixture
onto HPT rotor stage 2 disk rotating seal flange.
(3) Using half-rings, 2C14831P02, 24 washers, and 24 bolts, attach push-pull plate, 2C14836P11, to
rotating seal flange. Tighten bolts to 83-97 lb in. (9.4-10.9 N·m) of torque.
(4) Making adjustments in tooling, if required, slowly retract actuator until base, 2C14836P02, touches
stage 2 blade retainer.
NOTE
When install/remove fixture, 2C14836, is hydraulically actuated and touches blade
retainer, there must be access to split in retaining ring, between ribs of fixture.
(5) Retract hydraulic cylinder to 3000 psi (20,684 kPa) as if to seat blade retainer.
(6) Beginning at one end of retaining ring, use a plastic drift to move ring into groove.
(a) Hold end of retaining ring with clip, 2C14836P08.
(b) Using ring expander, 2C14839P03, and expander jaw, 2C14839P05, to help move retaining
ring (figure 4).
(c) Continue around retaining ring, installing clips, 2C14836P08, approximately every 30 degrees
(last clip goes at end of retaining ring).
(7) Perform a visual examination to make sure retaining ring is properly held, and is in a fully
(8) Remove half-rings, 2C14831P02, washers, bolts, and push-pull plate, 2C14836P11. Do not remove
clips, 2C14836P08.
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Figure 3. Stage 2 Aft Blade Retainer Install/Remove Fixture, 2C14836G01
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Figure 4. Aft Blade Retaining Ring Install/Removal
WARNING
(9) Put dry ice only on stage 2 retainer.
WARNING
(10) When retainer is sufficiently cold, remove retainer from stage 2 disk by hand.
(11) Remove seal ring from retainer.
(12) Remove retaining ring from groove in stage 2 disk. Use ring compressor, 2C14839P02, and
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C. Remove stage 2 HPT rotor blades as follows:
WARNING

COULD INADVERTENTLY RESULT FROM THIS PROCEDURE. IF THE STAGE 2
DISK IS DAMAGED, EVEN SLIGHTLY, DURING THIS PROCEDURE, THE DISK
MUST BE REFERRED TO THE APPROPRIATE FACTORY TECHNICAL SUPPORT
REPRESENTATIVE FOR EVALUATION AND REPAIR RECOMMENDATION.
FAILURE TO COMPLY MAY RESULT IN AN UNCONTAINED ENGINE FAILURE,
CAUTION
ACCURATELY. INCORRECT PLACEMENT AT INSTALLATION WILL CAUSE
ROTOR IMBALANCE.
(1) Use marking pen to number each stage 2 blade and damper, and to matchmark side rails of blades.
Find dovetail tangs marked with a numeral 1. Blade between tangs is blade No. 1. Damper No. 1 is
between blades 1 and 2.
NOTE
There are 74 dovetail slots in stage 2 disk, with a damper between each set of blades.
(2) Starting at blade No. 1 and damper No. 2 position, mark and remove blades and dampers in order,
moving around stage 2 disk in a clockwise (CW) direction, aft looking forward (ALF).
(3) Store blades and dampers, by position in disk, in sequence of blade, damper, blade, damper until all
blades are removed.
A. Measure length of removed stage 2 HPT rotor blades using gage, 247C5039. Replacement blade length
shall be within 0.010 inch (0.25 mm) of length of removed blade but shall not exceed length of longest
blade in stage.
B. Weigh removed stage 2 HPT rotor blades and record on position map (figure 5).
1
NOTE
Replacement stage 2 HPT rotor blades shall be weighed after tip grinding to meet length requirement.
For planning purposes, removal of 0.010 inch (0.25 mm) from blade tip will reduce blade weight by
0.12 gram. Do not use blade weight marked on new blades by manufacturer.
C. Weigh replacement stage 2 HPT rotor blades. Using marking pen, mark weight on blade.
D. Select replacement stage 2 HPT rotor blades within 0.25 gram of original blade. Blades replacing those
with portions missing shall weigh within 0.25 gram of average of two adjacent blades on each side of
damaged blade. If replacement blade within 0.25 gram of original blade is not available, use blade
replacement guide (figure 6).
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Figure 5. HPT Stage 2 Blade/Damper Assembly Position Map

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NOTE
For a copy of GE computerized blade replacement balance program, 9446M61, and instructions for
use, contact GE customer service.
E. Calculate blade position using GE computerized blade replacement balance program, 9466M61. Mark
8. Stage 2 HPT Rotor Blades Installation.
WARNING
THE STAGE 2 HPT DISK IS SENSITIVE TO NICKS AND SCRATCHES THAT COULD
INADVERTENTLY RESULT FROM THIS PROCEDURE. IF THE STAGE 2 DISK IS
DAMAGED, EVEN SLIGHTLY, DURING THIS PROCEDURE, THE DISK MUST BE
REFERRED TO THE APPROPRIATE FACTORY TECHNICAL SUPPORT REPRESENTATIVE
FOR EVALUATION AND REPAIR RECOMMENDATION. FAILURE TO COMPLY MAY
RESULT IN AN UNCONTAINED ENGINE FAILURE, WHICH COULD CAUSE INJURY OR
DEATH.
CAUTION
ENSURE STAGE 2 HPT NOZZLE PART NUMBER IS CORRECT PER IPB BEFORE
INSTALLATION, OR DAMAGE TO ENGINE COULD RESULT.
A. Install stage 2 HPT rotor blades as follows:
WARNING

NOTE
CAUTION
bodies installed.

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surface AP and outward in dovetail slots (figure 7). Minimum accumulated platform gap at AP shall
be 0.44 inch (11.2 mm).
B. Install stage 2 blade retainer as follows:
WARNING
AVOID REPEATED OR PROLONGED CONTACT. USE IN A

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WARNING

CAUTION
IF HEAT IS USED TO CURE ADHESIVE, TEMPERATURE MUST NOT

EXCEED 250°F (121.1°C)
NOTE
Adhesive may be used to hold ring seal in place during assembly. Ensure
adhesive is applied in areas 0.5-1.5 inch (13-38 mm) long and spaced not less
than 6 inches (152 mm) apart.
shall be 0.100-0.150 inch (2.54-3.81 mm).
(3) Install blade retainer into stage 2 disk blade retainer groove. Tap blade retainer into position a soft
mallet. Be careful not to damage seal ridges.

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WARNING

ACCIDENTALLY MOVE OR FALL, THEY CAN CAUSE AN INJURY OR
DEATH.
WARNING
BE CAREFUL WHEN YOU USE THE PUSHER/PULLER TO APPLY
PRESSURE. MAKE SURE YOU DO NOT USE MORE THAN THE
MAXIMUM HYDRAULIC PRESSURE. STAY AWAY FROM THE AREA
BEHIND OR IN FRONT OF THE PUSHER/PULLER. A MALFUNCTION
CAN CAUSE INJURY OR DEATH.
(a) Fully extend install/remove fixture, 2C14836, hydraulic cylinder. Using hoist, lift fixture onto
HPT rotor stage 2 disk rotating seal flange.
(b) Using half-rings, 2C14831P02, 24 washers and 24 bolts, attach push-pull plate, 2C14836P11,
NOTE
install/remove fixture of retaining ring as necessary.
(c) Slowly retract actuator until half-rings, 2C14831P02, touch blade retainer.
(d) Examine alignment of fixture and blade retainer, and adjust as necessary.
(e) Retract hydraulic cylinder to 3000 psig (20684 kPa gage) to install blade retainer.
(f) Remove clips, 2C14836P08, and let retaining ring move out. Use expander jaw, 2C14839P05,
(g) Remove pressure from actuator.
(5) Remove half-rings, 2C14831P02, bolts and washers that attach push-pull plate, 2C14836P11, to
stage 2 aft flange.
(6) Using hoist, remove install/remove fixture, 2C14836, from stage 2 disk.
C. Do a check of stage 2 blade retainer and retaining ring for correct installation as follows (figure 8):
0.002 inch (0.05 mm) feeler stock as a NO-GO gage. Feeler stock must not fit into space BH.

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retaining ring between points 40 degrees from open ends of retaining ring. Space
dimension BG must not exceed 0.018 inch (0.46 mm) at six previously selected points. If
necessary, use ring expander, 2C14839P03, and expander jaw, 2C14839P05, to help expand
retaining ring.
NOTE
Deleted.
(3) Deleted.
D. Install aft air seals as follows (figure 1):
(1) Apply thread lubricant onto threads and washer faces of bolts and new nuts.
(2) Align matchmarks made at removal on aft air seal and stage 2 HPT rotor disk. Using bolts and new
nuts, secure aft air seal and pressure tube/coupling nut to stage 2 HPT rotor disk. Tighten nuts to
212-248 lb in. (24.0-28.0 N·m) of torque.
E. Remove mid shaft pilot, 1C9610, from mid shaft.

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LOW PRESSURE TURBINE (LPT) MODULE
REPLACEMENT
())(&7,9,7</03)*$6785%,1(02'(/6

Page No. Change No.
1 - 40 ........................................................................................................................................................ 0
Alphabetical Index
Subject Page
Bushing Reseating Procedure. ................................................................................................................ 15

Low Pressure Turbine (LPT) Module Inspection.................................................................................... 15
Low Pressure Turbine (LPT) Module Installation. ................................................................................. 16
Low Pressure Turbine (LPT) Module Removal....................................................................................... 5
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1. Introduction.
A. This work package contains instructions for removing and installing the LPT module.
B. Remove gas turbine from enclosure per WP 3010 00 and install in the maintenance dolly or maintenance
support pedestals per WP 3012 00 or WP 3013 00.
C. Disconnect and connect electrical leads and connecting tubes between LPT module and gas turbine per
SWP 1913 03.
Title Number
Commercial Engine Standard Practices Manual GEK 9250
Gas Turbine in Enclosure Replacement WP 3010 00
Gas Turbine Maintenance Dolly Removal and Installation WP 3012 00
Gas Turbine/Support Pedestal Removal and Installation WP 3013 00
Low Pressure Turbine (LPT) Module in Shipping Container Replacement WP 3017 00
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Adapter, Sleeve - LPT Rotor Shaft 1C9316G02
Puller, LPT Module - Mid-Shaft 1C9327G03
Fixture Assembly, Install/Remove - Aft Drive Shaft Nut 1C9336G01
Fixture, Forward Restrain - LPT Rotor/Stator 1C9338G02
Jack Assembly, Support - Compressor Rear Frame 1C9448G01/G02
Adapter Assembly, Drive - Rear 1C9609G01
Pilot, LP Mid-Shaft - Aft 1C9610G01
Strongback, Lift, Turn and Restrain - LPT Module 1C9613G02
Fixture, Seat Check - Coupling Nut, Shaft, LPT Rotor 1C9616G01
Fixture, Start - LPT Coupling Nut 1C9617G01
Fixture, Install/Remove - Retainer Ring LPT/Mid-Shaft 1C9618G01
Fixture, Torque - LPT Shaft Coupling Nut 1C9619G02
Gage Inspection - Fan Shaft to HPT Stator Case 1C9620G01
Mid Shaft Centering and Support Fixture 1C9622G02
Fixture, Adjustable C.G. Horizontal Lift - Heavy Purpose 1C9627G01
Dolly, Storage, LPT Module 1C9632G01
Puller, High Force - LPT Module Mid Shaft 1C9650G01
(Alternate for 1C9327G03)
Pusher, LPT Shaft Bushing 1C9651G01
Tool Set, Install/Remove - LPT Module 2C14693G01
Dynamometer, 10,000 lb (4,536 kg) Capacity Local Purchase
Lifteye (0.500-13UNC-2B Thread) Local Purchase
Load Cell, 10,000 lb (4,536 kg) Capacity Local Purchase
(Alternate to Dynamometer)
Pump, Hand P802 (ENERPAC)
Dry Film Lubricant GE Spec A50TF192, CL-B (Surfkote A-1625 or
Sandstrom 27A)
Masking Tape Local Purchase
Penetrating Oil GE Spec A50TF54, CL-A (L1 Liquid Wrench or
Dag 2404)
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A. Required Material.

Nut, Coupling L47804P01 1
B. The following material may be required to complete this work package:

Bolt (Rear Drive Adapter Cover) L45045P03 28
Nut, Adapter L45017G05 1
Nut (After Shaft Cover) J626P04 7
Nut (Rear Drive Adapter Cover) J626P09 28
Ring, Retainer L47805P03 1
Ring, Shaft L45066P01 1
C. The following material may be required if a new LPT module is being installed:

Spacer, Ring (Shim) L47865P03 1
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6. Low Pressure Turbine (LPT) Module Removal.
A. Remove aft shaft cap as follows:
(1) Remove nuts that secure aft shaft cap to adapter nut.
(2) Using four jackscrews from tool set, 1C6804, remove aft shaft cap.
(3) Remove keyed ring.
B. Matchmark and remove balance weights (bolts/spacers) if installed on spacer seal, L47758P01, in order to
install rear drive adapter assembly, 1C9609.
C. Install strongback, 1C9613, as follows (figure 1):
(1) Install rear drive adapter assembly, 1C9609, onto spacer seal, L47758P01.
(2) Install lifteye in shaft adapter ring, 1C9613P04.
WARNING

NOTE
The rear drive adapter, L38770, has been replaced with spacer seal, L47758. The rear
drive adapter assembly, 1C9609, is a tool that attaches to the spacer seal during removal.
(3) Using overhead hoist, lift shaft adapter ring, 1C9613P04, into position on rear drive adapter
assembly, 1C9609. Secure shaft adapter ring onto adapter assembly with 14 equally spaced bolts and
nuts. Tighten nuts to 55-65 lb ft (75-88 N·m) of torque.
(4) Remove lifteye.
(5) Using horizontal lift fixture, 1C9627, and dynamometer or load cell between hoist and lift fixture,
lift strongback, 1C9613, into position.
CAUTION
DO NOT ALLOW THE WEIGHT OF THE STRONGBACK TO REST ON THE

OUTER SEAL CARRIER OR SHAFT ADAPTER RING BEFORE INSTALLING
STRONGBACK RETAINING SCREWS.
(6) Secure strongback, 1C9613, onto outer seal carrier with screws and washers. Tighten screws to
170-200 lb in. (19.3-22.5 N·m) of torque.
(7) Turn LPT rotor to align alignment hole on shaft adapter ring, 1C9613P04, with radial slot at
10:00 o’clock position on strongback. Install quick-release pin.
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Figure 1. LPT Module Lift, Turn, and Restrain Strongback, 1C9613
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(8) Install nut ring, 1C9613P06, onto shaft adapter ring, 1C9613P04. Tighten nut ring until seated
against shaft adapter ring flange.
(9) Install four lock blocks, 1C9613P05. Secure lock blocks with screws. Tighten screws to
428-502 lb in. (48.4-56.7 N·m) of torque.
D. Remove adapter nut as follows:
(1) Install adapter nut fixture, 1C9336, over adapter nut and secure with nuts (figure 2). Tighten nuts to
57-67 lb in. (6.5-7.5 N·m) of torque.
(2) Install mounting plate, 1C9619P06, over adapter nut fixture, 1C9336. Secure mounting plate,
1C9619P06, to strongback, 1C9613, with two mounting screws. Tighten mounting screws finger-
tight.
(3) Install torque multiplier, Sweeney Model 8200/8112B, or equivalents. Actuate torque multiplier to
loosen adapter nut and locking ring.
(4) If adapter nut will not loosen, proceed as follows:
(a) Remove torque multiplier, mounting plate, 1C9619P06, and aft drive shaft nut install/remove
adapter nut fixture, 1C9336.
WARNING
USE EYE PROTECTION WHEN YOU CUT MATERIAL OR PARTS.

PARTICLES CAN CAUSE DAMAGE TO YOUR EYES.
(b) Cut adapter nut in axial direction, two places 180 degrees apart, on top of castellation,
1.375 inches (34.93 mm) deep. Use care not to cut into LPT rotor shaft threads or rear drive
adapter. Cut adapter nut with high speed cut-off wheel.
(c) Install tooling and loosen adapter nut per step 6.D.(1) through step 6.D.(3). Adapter nut will
split under torque and may be removed and discarded.
(5) Remove torque multiplier, mounting plate, 1C9619P06, and adapter nut fixture, 1C9336. Remove
adapter nut.
E. Install guide protector, 1C9316P04, so that tabs engage slots in LPT rotor shaft (figure 3). Tighten
retaining nut, 1C9316P03, until bottomed against rear drive adapter/spacer seal.
F. Remove LPT coupling nut retaining ring as follows (figure 4):
(1) Using bright light, determine location of two retaining ring tooling holes. Rotate shaft to locate these
holes to 6:00 o’clock position.
(2) Using gage block, 1C9618P14, preset pins on retainer ring install/remove fixture, 1C9618.
(3) Install retainer ring install/remove fixture, 1C9618, into guide protector, 1C9316P04. If necessary,
rotate fixture slightly to engage pins in retaining ring tooling holes.
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Figure 2. Adapter Nut Fixture, 1C9336
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Figure 3. Guide Protector, 1C9316P04
Figure 4. LPT/Mid-Shaft Retainer Ring Install/Remove Fixture, 1C9618
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(4) Insert flexible borescope into guide tube at rear of retainer ring install/remove fixture, 1C9618.
Verify engagement of pins in retaining ring tooling holes. If necessary, reposition fixture to engage
pins in retaining ring tooling holes.
(5) Seat retainer ring install/remove fixture, 1C9618, against retaining ring.
(6) Turn knurled knob of retainer ring install/remove fixture, 1C9618, to compress retaining ring.
(7) Withdraw retainer ring install/remove fixture, 1C9618, with retaining ring. Turn knurled knob to
release retaining ring.
G. Remove LPT module forward flange attaching hardware as follows:
(1) Using marking pen and masking tape, mark location and orientation of brackets on stage 2 high
pressure turbine (HPT) nozzle aft flange.
(2) Soak attaching hardware with penetrating oil to aid in removal.
(3) Remove nuts, bolts, spacers, and brackets that secure LPT module to HPT module.
(4) Install install/remove tool set, 2C14693, onto stage 2 HPT nozzle aft flange at 12:00, 3:00, 6:00, and
9:00 o’clock positions. Tighten thumbscrews.
NOTE
Thumbscrews may require retightening after the LPT flange disengages the HPT flange.
H. Remove LPT coupling nut as follows (figure 5):
(1) Install torque tube, 1C9619P03, and torque fixture, 1C9619, through LPT rotor shaft. Align torque
tube so that teeth of tube engage slots of LPT coupling nut.
(2) Push indexing tube, 1C9619P02, forward and rotate, if necessary, to engage tab on tube with slot in
mid shaft assembly.
(3) Install mounting plate, 1C9619P06, onto strongback, 1C9613, and secure with two mounting
screws. Tighten mounting screws finger-tight.
(4) Install torque multiplier, Sweeney Model 8200/8112B, or equivalents, onto mounting plate,
1C9619P06, so that splines engage splines on torque tube, 1C9619P03. Secure torque multiplier to
mounting plate, 1C9619P06, with two locking screws.
(5) Actuate torque multiplier to loosen coupling nut.
(6) Remove torque multiplier and all components of torque fixture.
(7) Using LPT coupling nut start fixture, 1C9617, remove LPT coupling nut. If difficulty is encountered
engaging locking pins into LPT coupling nut inner snapring groove, remove LPT coupling nut as
follows (figure 6):
(a) Fully retract inner sleeve of start fixture.

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(b) Insert start fixture and loosen LPT coupling nut until nearly disengaged.
(c) Remove start fixture and extend inner sleeve until locking pins are positioned 0.0625 inch
(1.588 mm) beyond wrenching lugs.
(d) Insert start fixture so that locking pins engage LPT coupling nut inner snapring groove.
1
(e) Loosen LPT coupling nut until disengaged from threads. Remove LPT coupling nut and
discard.
I. Separate LPT module from gas turbine as follows (figure 7):
(1) Install plunger tube, 1C9327P11, into LPT rotor shaft so that forward end of tube seats against mid
shaft assembly.
(2) Install remaining portion of LPT module midshaft puller, 1C9327, so that slots in adapter,
1C9327P03, slide over capscrews in LPT rotor shaft sleeve adapter, 1C9316. Turn adapter
counterclockwise to lock.
Figure 5. LPT Shaft Coupling Nut Torque Fixture, 1C9619

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Figure 6. LPT Coupling Nut Start Fixture, 1C9617
Figure 7. LPT Module Mid-Shaft Puller, 1C9327 (Sheet 1 of 2)

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Figure 7. LPT Module Mid-Shaft Puller, 1C9327 (Sheet 2 of 2)
WARNING

NOTE
If LPT module cannot be removed using LPT module midshaft puller, 1C9327, alternate
puller, 1C9650, may be used. Keep tools separate.
(3) Apply hydraulic pressure until LPT module moves aft approximately 0.75 inch (19.1 mm). Ensure
that LPT moves freely, indicating it is not held by press fit diameters. If LPT module breaks free,
proceed to step 6.I.(4). If LPT will not move, proceed as follows:
WARNING

LOW-TEMPERATURE SKIN DAMAGE. CAN DECREASE
(a) Pack mid shaft with dry ice, BB-C-104 and chill for 30 minutes.

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(b) Remove dry ice and re-try LPT module midshaft puller, 1C3927. If LPT module breaks free,
proceed to step 6.I.(4). If LPT will not move, proceed to steps 6.I.(3)(c).
(c) Release pressure. Remove mid shaft LPT module midshaft puller, 1C9327, and plunger tube,
1C9327P11.
CAUTION
USE EXTREME CAUTION WHEN USING PULLER, 1C9650. AFT

THREADS ON THE LPT SHAFT MAY BE DAMAGED DURING USE.
(d) Install plunger tube, 1C9650P02, forward end into LPT shaft until aft end of tube is inside aft
face of LPT shaft.
(e) Attach horizontal lift fixture, 1C9627, to lift ring on hydraulic cylinder and adapter,
1C9650P03, assembly.
WARNING

OR DEATH.
(f) Align large holes in adapter, 1C9650P03, with bolts of adapter, 1C9316P03. Push adapter
against LPT rotor shaft sleeve adapter, 1C9316, and rotate hydraulic cylinder to lock cylinder
to LPT shaft.
(g) Attach hand pump, P802 (ENERPAC), to hydraulic cylinder coupler and actuate cylinder. LPT
module must move 1.0 inch (25 mm) to disengage from rabbet fit.
(h) If LPT module does not break free after reaching 5000 psig (34,474 kPa gage), increase
pressure in increments of 1000 psi (6895 kPa) until LPT module breaks free from mid shaft. Do
not exceed 10,000 psig (68,948 kPa gage).
(i) When LPT module moves freely, remove tool and visually inspect LPT threads for any
damage. Using removed engine hardware aft nut, hand-thread nut on LPT shaft. Nut should
hand-thread to mate face of aft seal adapter. If nut will not hand-thread, fluorescent-penetrant-
inspect aft threads per GEK 9250, Section 70-32-02. If damage is found, route LPT module to
approved LM6000 depot for shaft replacement.
(4) Remove LPT module mid shaft puller, 1C9327, or puller, 1C9650.
(5) Adjust center of gravity on horizontal lift fixture, 1C9627.

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WARNING

(6) Using knurled nut, ensure jack assembly, 1C9448, under compressor rear frame (CRF), is snug in
place. Tighten rod-end nut one additional turn. Lift strongback, 1C9613, until dynamometer or load
cell indicates combined weight of LPT module, strongback, and horizontal lift fixture, 1C9627,
approximately 8600 pounds (3901 kg). Check pins at turbine rear frame (TRF) for easy removal. If
pins cannot be removed, readjust jack assembly. Lift strongback until dynamometer or load cell
indicates combined LPT module, strongback, and lift fixture weight again. Repeat process until pins
at TRF are not loaded. Remove pins and move LPT module aft, taking care to level module during
removal, until clear of engine.
(7) Remove shim from mid shaft rear flange. Record shim part number or thickness.
J. Install LPT module into LPT module storage dolly, 1C9632, or shipping container, per WP 3017 00.
K. If LPT module will not be installed shortly, install aft mid shaft pilot, 1C9610, onto mid shaft.
7. Low Pressure Turbine (LPT) Module Inspection.
NOTE
Some LPT modules contain an LPT aft shaft bushing on the aft shaft inner pilot diameter (figure 8).
Inspection of the shaft for bushing axial movement is required prior to LPT module installation.
A. Inspect LPT aft shaft for steps on surface B (figure 9):
Inspect Max Serviceable Max Repairable Action

Steps on Surface B 0.050 in. (1.27 mm) Any amount Reseat bushing per paragraph 8
B. Alternate Inspection - If step on surface B is present, measure axial position of LPT aft shaft bushing
(figure 9):
Inspect Max Serviceable Max Repairable Action

Axial position of LPT 0.690 in. (17.53 mm) Any amount Reseat bushing per paragraph 8
aft shaft bushing
8. Bushing Reseating Procedure.
A. Assemble pusher, 1C9651, as follows:
(1) For forward portion of pusher, attach push plate (1, figure 10) to nylon guide (2) using three
capscrews (3), provided. Thread handle (4) into push plate.

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NOTE
Ensure small chamfer on backing plate (5) is located facing forward.
(2) For aft portion of pusher, assemble backing plate (5) to guide rod (6). Assemble three guide plates
(7) and seven nuts (8) per figure 10.
B. Reseat LPT aft shaft bushing as follows:
(1) Insert aft portion of pusher, 1C9651, backing plate (5) first, into aft LPT shaft bore until plate seats
on aft face of bushing.
(2) Insert forward portion of pusher, 1C9651, into forward end of LPT shaft, over guide rod (6), and
seat against bushing.
(3) Thread nut (8) onto forward end of guide rod (6) and tighten with hand wrench.
NOTE
Ensure guide rod (6) is centered before applying additional torque.
(4) Tighten nut (8) against LPT aft shaft to 25 lb ft (34 N·m).
NOTE
Each turn of nut (8) is worth approximately 0.090 inch (2.29 mm).
(5) Tighten nut (8) until torque starts to dramatically increase. Back off nut, remove tooling, and inspect
bushing for correct seating.
(6) Repeat reseat procedure until bushing is fully seated.
(7) Remove forward and aft portions of pusher, 1C9651.
9. Low Pressure Turbine (LPT) Module Installation.
A. Install strongback, 1C9613, as follows (figure 1):
(1) If removed, install rear drive adapter assembly, 1C9609, onto aft spacer seal.
(2) Install lifteye in shaft adapter ring, 1C9613P04.
WARNING

(3) Using overhead hoist, lift shaft adapter ring, 1C9613P04, into position on rear drive adapter
assembly, 1C9609. Using 14 equally spaced bolts and nuts, secure adapter ring onto adapter
assembly. Tighten nuts to 55-65 lb ft (75-88 N·m) of torque.

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Figure 8. LPT Aft Shaft Bushing Location

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Figure 9. LPT Aft Shaft Inspection Criteria

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Figure 10. LPT Aft Shaft Bushing Reseating

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(4) Remove lifteye.
(5) Using horizontal lift fixture, 1C9627, and dynamometer or load cell between hoist and lift fixture,
lift strongback, 1C9613, into position.
CAUTION
OUTER SEAL CARRIER OR SHAFT ADAPTER RING BEFORE INSTALLING
(6) Secure strongback, 1C9613, onto outer seal carrier with screws and washers. Tighten screws to
170-200 lb in. (19.3-22.5 N·m) of torque.
(7) Turn LPT rotor to align alignment hole on shaft adapter ring, 1C9613P04, with radial slot at
10:00 o’clock position on strongback. Install quick-release pin.
(8) Install nut ring, 1C9613P06, onto shaft adapter ring, 1C9613P04. Tighten nut until seated against
shaft adapter ring flange.
(9) Install four lock blocks, 1C9613P05. Secure lock blocks with screws. Tighten screws to
428-502 lb in. (48.4-56.7 N·m) of torque.
B. If installed, remove restrain fixture, 1C9338.
NOTE
If same LPT module, stage 2 HPT nozzle, and combustion chamber are installed, disregard step 9.C.
C. Determine required thickness of LPT shim as follows:
(1) Calculate dimension A as follows, using figure 11 and worksheet from figure 12:
(a) Thread gage bar, 1C9620P02, onto LP mid shaft (figure 11). Bar shall be tight against LPT
rotor shaft seating flange (surface AH) of LP mid shaft.
(b) Position mid shaft centering and support fixture, 1C9622, so support frame, 1C9622P02, feet
interface with HPT stator case aft flange. If necessary, lower adjusting plate, 1C9622P03, by
turning hand knob, 1C9622P08. Align countersunk holes in frame feet and flange holes. Insert
capscrews into countersinks and secure onto forward side of stator case flange with washers
and nuts. Tighten nuts to 83-97 lb in. (9.4-10.9 N·m) of torque.
(c) Use hand knob, 1C9622P08, to raise adjusting plate, 1C9622P03, to bring LPTR mid shaft to
required level. If necessary, apply slight upward force at aft end of shaft. Tighten nuts.
(d) Using vernier depth gage, 1C9620P04, take four drop measurements from aft surface of gage
bar, 1C9620P02, (surface AH) to HPT stator support aft face at 2:00, 4:00, 8:00, and
10:00 o’clock positions by turning the assembled core section 90 degrees after each
measurement. Record measurements as dimension A1.

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Figure 11. Dimension A Measurement (Sheet 1 of 2)

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Figure 11. Dimension A Measurement (Sheet 2 of 2)

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Figure 12. LPT Installation Worksheet

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(e) Average four A1 measurements and record as dimension A2.
(f) Subtract thickness of gage bar, 1C9620P02, (stamped on bar) from A2 and record as dimension
A3.
NOTE
The 0.093 inch (2.36 mm) equals stage 2 shroud support thickness (0.063 inch
[1.60 mm]) and depth of HPT stator support cooling scallops (0.030 inch
[0.76 mm]).
(g) Subtract 0.093 inch (2.36 mm) from A3 and record as dimension A.
(2) Obtain dimension J02 from LPT module build record or as marked on LPT case. Dimension J02 is
marked on case at 9:00 o’clock position, adjacent to T48 probe boss, approximately 2.5 inches
(64 mm) aft of case forward flange.
(3) Determine difference between J02 and dimension A. Subtract J02 from dimension A. Record result
as calculated shim thickness. See LPT installation worksheet (figure 12).
(4) Calculate shim thickness based on figure 12. Record result as calculated shim thickness.
(5) Remove gage bar, 1C9620P02, and mid shaft centering and support fixture, 1C9622.
(6) Use calculated shim thickness to select required LPT shim from table 1. If calculated shim is not
within range of shims shown, select shim closest to calculated shim thickness.
Table 1. LPT Shim Thickness
Thickness Shim Part Number
Inch (mm)
0.098-0.102 (2.49-2.59) L47865P03
0.108-0.112 (2.75-2.84) L47865P04
0.118-0.122 (3.00-3.09) L47865P05
0.128-0.132 (3.26-3.35) L47865P06
0.138-0.142 (3.51-3.60) L47865P07
0.148-0.152 (3.76-3.86) L47865P08
0.158-0.162 (4.02-4.11) L47865P09
0.168-0.172 (4.27-4.36) L47865P10
0.178-0.182 (4.52-4.67) L47865P11
0.188-0.192 (4.78-4.88) L47865P12

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D. Determine calculated LPT seating check dimension AJ as follows (see figure 13 and worksheet in
figure 12):
(1) Obtain a new LPT coupling nut.
(2) Measure length of new LPT coupling nut at one location. Mark point of measurement on aft face
with marking pen. Record as dimension THK.
(3) Measure thickness of shim at four equally spaced locations. Average four measurements and record
as dimension AST.
(4) Measure thickness of LPT shaft seating flange at four equally spaced locations. Average four
measurements and record as dimension ST.
(5) Add dimensions THK, AST, and ST and record as dimension TAS.
(6) Measure length from end of LP mid shaft to surface AH at four equally spaced locations. Average
four measurements and record as dimension AG.
(7) Determine difference between dimensions TAS and AG. Record result as calculated dimension AJ.
E. Install install/remove tool set, 2C14693, onto HPT stator case aft flange at 12:00, 3:00, 6:00, and
9:00 o'clock positions. Tighten thumbscrews (figure 14).
F. Install LPT module as follows:
WARNING

CAUTION
ENSURE A NEW LPT COUPLING NUT IS USED, OR DAMAGE DURING GAS

TURBINE OPERATION MAY RESULT.
(1) Clean threads and seating surface of new LPT coupling nut and threads, seating surface, aft pilot,
and splines of mid shaft assembly using clean cloth with isopropyl alcohol.
WARNING

(2) Apply dry film lubricant to mid shaft spline (figure 15).
(a) Apply lubricant to full length of spline bottom and flank surfaces to an approximate thickness
of 0.0005-0.002 inch (0.013-0.05 mm). Full coverage required.
(b) Excess lubricant allowed on spline major diameter and within 0.5 inch (13 mm) and 0.15 inch
(3.8 mm) of spline ends.

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Figure 13. Calculate LPT Seating Check Measurements

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Figure 14. LPT Module Install/Remove Tool Set, 2C14693

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Figure 15. LPT Coupling Nut Inspection

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(c) Apply lubricant to aft pilot diameter.
(d) Excess lubricant not allowed on shaft mating surface F or on shaft threads.
(e) Allow lubricant to dry for one hour before mating LPT module.
(3) Apply generous coat of thread lubricant to threads of mid shaft assembly.
(4) Apply an even coat of thread lubricant to forward face of new LPT coupling nut.
(5) Lubricate preformed packing with thread lubricant and install in preformed packing groove of mid
shaft duct.
(6) If installed, remove aft mid shaft pilot, 1C9610.
NOTE
Ensure there is no thread lubricant on shim.
(7) Install shim into LPT rotor shaft until shim contacts seating shoulder. Align shim so that maximum
thickness is located 180 degrees from H mark on fan mid shaft
(8) Rotate LPC rotor to align forward drive adapter M mark with M mark on spacer seal/rear drive
adapter (figure 16).
Figure 16. Rear Drive Adapter M Mark

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WARNING

(9) With strongback,1C9613, installed and dynamometer or load cell installed, lift LPT module and trial
fit module to mid shaft splines. Move LPT module forward, align and initiate spline engagement.
Do not force module. After spline alignment is verified, pull module away.
WARNING
(10) Heat inside pilot diameter of LPT rotor shaft to 325 to 400°F (163 to 204°C) using dry heat.
CAUTION
• DO NOT REMOVE HOIST LOADING UNTIL PINS AT TRF ARE FULLY
LOADED.
• ENSURE DYNAMOMETER OR LOAD CELL DOES NOT INDICATE LESS

OR MORE THAN WEIGHT OBSERVED IN step 9.F.(2).
(11) Move LPT module forward aligning M marks. Carefully engage splines of mid shaft assembly.
Ensure that M marks remain aligned.
(12) Install several bolts at each clock position to secure LPT module forward flange to stage 2 nozzle aft
flange. Tighten bolts finger-tight.
(13) Install storage dolly, 1C9632, mounting pins at TRF. Snug TRF dolly posts to take weight of LPT
module by adjusting threaded risers. Tighten pedestal retaining nuts to 70-80 lb ft. (95-108 N·m) of
torque.
G. Install guide protector, 1C9316P04, so that tabs engage slots in LPT rotor shaft (figure 17).
H. Start new LPT coupling nut onto mid shaft assembly using LPT coupling nut start fixture, 1C9617
(figure 18).
I. Install LPT coupling nut torque fixture, 1C9619, as follows (figure 19):
(1) Install torque tube, 1C9619P03, through LPT rotor shaft. Align torque tube so that teeth of tube
engage slots of LPT coupling nut.
(2) Push indexing tube, 1C9619P02, forward and rotate, if necessary, to engage tab on tube with slot in
mid shaft assembly.
(3) Install mounting plate, 1C9619P06, onto strongback, 1C9613, and secure with two mounting
screws. Tighten mounting screws finger-tight.

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Figure 17. Guide Protector, 1C9316P04
(4) Install torque multiplier, Sweeney Model 8200/8112B, or equivalents, onto mounting plate,
1C9613P06, so that splines engage torque tube splines. Secure torque multiplier to mounting plate,
1C9619P06, with two locking screws.
J. Tighten LPT coupling nut as follows:
(1) Tighten LPT coupling nut to 4000 lb ft (5423 N·m) of torque. Allow shaft temperature to normalize.
Break torque on LPT coupling nut.
(2) Tighten LPT coupling nut to 2000 lb ft (2712 N·m) of torque. Record wrench angle at this torque.
CAUTION
DO NOT EXCEED 7500 LB FT (10,169 N·M) MAXIMUM TORQUE OR A MAXIMUM

WRENCH ANGLE OF 30 DEGREES FROM ANGLE RECORDED IN step 9.J.(2).
(3) Continue tightening to wrench angle 26 degrees beyond wrench angle recorded in step 9.J.(2). Do
not exceed maximum torque value of 7500 lb ft (10,169 N·m).
(4) Check alignment of LPT coupling nut and mid shaft assembly slots.
(5) Continue tightening until slots align. Marks on tool must align or retaining ring cannot be installed.
Do not exceed maximum torque of 7500 lb ft (10,169 N·m) or maximum angle of 30 degrees
beyond wrench angle recorded in step 9.J.(2).
(6) Remove torque multiplier and all components of torque fixture, 1C9619.

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Figure 18. LPT Coupling Nut Installation

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Figure 19. LPT Shaft Coupling Nut Torque Fixture, 1C9619
K. Check LPT module installation using seat check fixture, 1C9616, as follows (figure 20 and figure 21):
(1) Secure gage master, 1C9616P03, to seat check fixture with thumbscrew. Set dial indicator to zero.
Remove gage master from seat check fixture.
(2) Position seat check fixture into LPT in order to measure from marked LPT coupling nut castellation
aft surface. Hold firmly in place.
NOTE
A negative reading indicates the LPT coupling nut is forward of the LP mid shaft end. A
positive reading indicates the LPT coupling nut is aft of the LP mid shaft end.
(3) Read LPT coupling nut position directly from dial indicator and record as measured dimension AJ.
See figure 21 and worksheet in figure 12.
(4) Measured dimension AJ must be 0.002-0.010 inch (0.06-0.25 mm) less than calculated dimension
AJ. If dimension AJ is not with in limits, proceed as follows:
(a) Verify seat check fixture, 1C9616, with gage master, 1C9616P03, and check LPT module
installation per step 9.K.(1) through step 9.K.(3). Check all calculations used to determine
calculated dimension AJ.
(b) If measured dimension AJ is still not within limits, this indicates that LPT module is not
correctly installed. Remove LPT module and check dimensions per step 9.C and step 9.D
Reinstall LPT module and check installation per this paragraph.

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Figure 20. LPT Coupling Nut Seating Check

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Figure 21. LPT Seating Check Dimension AJ
L. Install LPT coupling nut retaining ring, as follows (figure 22):
(1) Install retaining ring onto pins of retainer ring install/remove fixture, 1C9618.
(2) Turn knurled knob of retainer ring install/remove fixture, 1C9618, to compress retaining ring.
(3) Insert retaining ring into LPT coupling nut and mid shaft assembly slots.
(4) Turn knurled knob of retainer ring install/remove fixture, 1C9618, to release ring.
(5) Optional: Insert flexible borescope into guide tube at rear of retainer ring install/remove fixture,
1C9618, to verify retaining ring is seated in LPT coupling nut.
(6) Rotate retainer ring install/remove fixture, 1C9618, slightly and pull aft to remove from LPT shaft.
M. Remove install/remove tool set, 2C14693, from HPT stator case.
N. Lubricate bolt threads with thread lubricant. Install nuts, bolts, spacers, and brackets that secure LPT
module to HPT module. Tighten nuts to 202-238 lb in. (22.9-26.8 N·m) of torque. Refer to SWP 1913 03.
O. Remove guide protector, 1C9316P04, from LPT rotor shaft.

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Figure 22. LPT Coupling Nut Retaining Ring Installation

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P. If adapter nut was removed, install adapter nut as follows (figure 23):
WARNING

(1) Using isopropyl alcohol, clean threads and mating surfaces of adapter nut and LPT rotor shaft.
Inspect adapter nut threads to ensure threads are free of damage and high metal.
(2) Apply thread lubricant onto threads and forward face of adapter nut and onto threads of LPT rotor
shaft.
CAUTION
ADAPTER NUT SHALL BE ABLE TO BE TIGHTENED BY HAND.
(3) Install adapter nut onto LPT rotor shaft. Hand-tighten nut.
(4) Install adapter nut fixture, 1C9336, over adapter nut and secure with nuts. Tighten nuts to
57-67 lb in. (6.5-7.5 N·m) of torque.
(5) Install mounting plate, 1C9619P06, over adapter nut fixture, 1C9336. Secure mounting plate onto
strongback, 1C9613, with mounting screws. Tighten mounting screws finger-tight.
(6) Install torque multiplier, Sweeney Model 8200/8112B, or equivalents.
(7) Tighten adapter nut as follows:
(a) Seat adapter nut to 2000 lb ft (2712 N·m) of torque. Loosen adapter nut.
(b) Tighten adapter nut to 250 lb ft (339 N·m) above run-on torque. Record wrench angle at this
torque.
(c) Continue tightening to wrench angle 21 degrees beyond wrench angle recorded in
step 9.P.(7)(b).
(d) Check alignment of adapter nut and LPT rotor shaft slots.
CAUTION
DO NOT EXCEED MAXIMUM TORQUE VALUE OF 8500 LB FT

(11,525 N·M) OR A MAXIMUM ANGLE OF 24 DEGREES FROM
WRENCH ANGLE RECORDED IN step 9.P.(7)(b).
(e) Continue tightening until adapter nut slots align with LPT rotor shaft slots. Do not exceed
maximum of 8500 lb ft (11,525 N·m) or maximum angle of 24 degrees from wrench angle
recorded in step 9.P.(7)(b).
(8) Remove torque multiplier, mounting plate, 1C9619P06, and adapter nut fixture, 1C9336.

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Figure 23. Rear Drive Adapter Nut Removal/Installation

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Q. Remove strongback, 1C9613, as follows (figure 24):
(1) Remove bolts that secure lock blocks, 1C9613P05, to strongback. Remove lock blocks.
(2) Remove nut ring, 1C9613P06.
CAUTION

OUTER SEAL CARRIER OR SHAFT ADAPTER RING AFTER REMOVING
(3) Remove washers and screws that secure strongback to outer seal carrier.
WARNING

(4) Move strongback aft, away from LPT module. Lower strongback, forward end down, onto pallet or
store on storage dolly, 1C9632. Remove quick-release pin securing strongback onto horizontal lift
fixture, 1C9627. Remove lift fixture and dynamometer or load cell from overhead hoist.
(5) Install lifteye in shaft adapter ring, 1C9613P04. Connect an overhead hoist to lifteye.
(6) Remove nuts and bolts that secure shaft adapter ring, 1C9613P04, to rear drive adapter assembly,
1C9609. Lower shaft adapter ring to pallet. Remove lifteye.
R. Reassemble balance weights (bolts/spacers) and install per matchmarks on spacer seal, L47758P01, if
previously removed. Torque to Standard Practice requirement per GEK 9250.
S. Install keyed ring.
T. Install aft shaft cap and secure with nuts. Tighten nuts to 57-67 lb in. (6.5-7.5 N·m) of torque.
U. Install electrical leads and tubing per SWP 1913 03.

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Figure 24. Strongback, 1C9613

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REAR DRIVE ADAPTER OR AFT SEAL SPACER
REPLACEMENT
())(&7,9,7</03)*$6785%,1(02'(/6

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16 Blank ................................................................................................................................................... 0
Alphabetical Index
Subject Page
Aft Adapter Nut Installation.................................................................................................................... 13

Rear Drive Adapter or Aft Seal Spacer Installation................................................................................. 7
Rear Drive Adapter or Aft Seal Spacer Removal. ................................................................................... 3
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1. Introduction.
A. This work package contains instructions for removing and installing a rear drive adapter or an aft seal
spacer.
B. This work package also allows switching of a rear drive adapter with an aft seal spacer or an aft seal spacer
with a rear drive adapter.
Title Number

Torque Fixture, LPT Shaft Coupling Nut 1C9309G03
Puller, LPT Module - Mid Shaft 1C9327G03
Strongback Fixture, Lift, Turn and Restrain, Low Pressure Turbine 1C9328G01
Puller Plate, Aft Drive Adapter 1C9329G02
Fixture Assembly, Install/Remove - Aft Drive Shaft Nut 1C9336G01
Adapter Assembly, Drive - Rear 1C9609G01
Strongback, Lift, Turn and Restrain, LPT Module 1C9613G02
Torque Fixture, LPT Shaft Coupling Nut 1C9619G01
Lift and Remove Fixture, Aft Seal Spacer 1C9642G01
Lift and Remove Fixture, Aft Seal Spacer 1C9643G01
Depth Micrometer Local Purchase
Torque Wrench, Model AH-1043, Advanced Hydraulics Local Purchase
Isopropyl Alcohol TT-I-735
Safety Wire R297P04
None required.
/03) *(.
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6. Rear Drive Adapter or Aft Seal Spacer Removal.
A. Remove aft adapter nut per WP 2710 00.
NOTE
For rear drive adapter configuration, perform step 6.B and skip step 6.C. For aft seal spacer
configuration models, skip step 6.B and perform step 6.C.
NOTE
Due to space constraints in package, use of Advanced Hydraulics Model AH-1043 torque wrench is
recommended.
B. Remove rear drive adapter as follows:
(1) Using marking pen, matchmark rear drive adapter to LPT rotor shaft and rear drive adapter to rear
drive adapter flange cover.
(2) Remove bolts and self-locking nuts securing rear drive adapter flange cover to rear drive adapter.
Remove rear drive adapter flange cover. Retain rear drive adapter flange cover, bolts, and self-
locking nuts for reuse.
(3) Install reaction plate, 1C9329P04 (figure 1), into LPT rotor shaft.
(4) Install LPT module mid shaft puller, 1C9327, onto drive adapter puller plate, 1C9329P02, by sliding
mid-shaft puller slots over puller plate capscrews and turning LPT module mid-shaft puller
counterclockwise (CCW) to lock.
WARNING

(5) Using overhead hoist attached to LPT module mid shaft puller lift ring, position drive adapter puller
plate, P02, onto rear drive adapter. Using hex nuts, MS51972-6, and slabbed head bolts,
1C9613P07, obtained from strongback fixture, 1C9613, secure drive adapter puller plate to rear
drive adapter. Do not install bolts in three holes at 12:00 o'clock position.
(6) Using three capscrews, MS35308-446, and hex nuts, MS51972-6, secure aft seal spacer lift and
remove fixture, 1C9643, to drive adapter puller plate, 1C9329P02, and rear drive adapter. Attach
overhead hoist to fixture.
(7) Install hydraulic pressure source to LPT module mid shaft puller, 1C9327.
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Figure 1. Rear Drive Adapter Removal
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WARNING

(8) Apply hydraulic pressure until rear drive adapter is free from LPT rotor shaft.
(9) Release hydraulic pressure.
(10) Remove rear drive adapter and tooling.
C. Remove aft seal spacer as follows:
(1) Using capscrews, NAS1352-8-36 (figure 2), flat washers, AN960-C816, under screwheads, and hex
nuts, MS51971-5, install rear drive adapter onto aft seal spacer.
(2) Install reaction plate, 1C9329P04, into LPT rotor shaft.
(3) Install LPT module mid shaft puller, 1C9327, onto drive adapter puller plate, 1C9329P02, by sliding
mid shaft puller slots over puller plate capscrews and turning LPT module mid shaft puller CCW to
lock.
WARNING

(4) Using overhead hoist attached to LPT module mid shaft puller, 1C9327, lift ring, position drive
adapter puller plate, 1C9329P02, on rear drive adapter assembly, 1C9609. Using hex nuts,
MS51972-6, and slabbed head bolts, 1C9613P07, obtained from strongback fixture, 1C9613, secure
drive adapter puller plate to rear drive adapter assembly. Do not install bolts in three holes at 12:00
o’clock position.
(5) Using three capscrews, MS35308-446, and hex nuts, MS51972-6, secure aft seal spacer lift and
remove fixture, 1C9643, to drive adapter puller plate, 1C9329P02. Attach overhead hoist to fixture
sling link.
(6) Install hydraulic pressure source to LPT module mid shaft puller, 1C9327.
(7) Apply hydraulic pressure until aft seal spacer is free from LPT rotor shaft.
(8) Release hydraulic pressure.
(9) Remove aft seal spacer and tooling.
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Figure 2. Aft Seal Spacer Removal
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WARNING

(10) Using isopropyl alcohol, clean thread and splines of LPT rotor shaft.
(11) Using marking pen, mark area of key slot of balance piston on LPT rotor shaft splines. Move mark
to most aft point of LPT rotor shaft.
7. Rear Drive Adapter or Aft Seal Spacer Installation.
A. Install aft seal spacer/rear drive adapter as follows:
(1) Calculate aft seal spacer/rear drive adapter installation measurement as follows:
NOTE
Refer to figure 3 for rear drive adapter measurements and figure 4 for aft seal
spacer measurements.
(a) Measure stack-up thickness of aft seal spacer or rear drive adapter. Record as dimension AB
(figure 5).
2
1
(b) Measure stack-up thickness of adapter nut. Record as dimension AC.
(c) Measure drop dimension from LPT shaft aft tang to balance piston aft surface. Record as
dimension AD.
(d) Add dimension AB to dimension AC and subtract sum from dimension AD. Record as
calculated dimension AF.
(2) If installed, matchmark rear drive adapter flange cover to rear drive adapter using marking pen.
Remove rear drive adapter flange cover from rear drive adapter.
NOTE
To install rear drive adapter, proceed to step 7.A.(3). To install aft seal spacer, proceed to
step 7.A.(4).
(3) Attach drive adapter puller plate, 1C9329P02, and aft seal spacer lift and remove fixture, 1C9643, to
rear drive adapter as follows (figure 1):
(a) Using capscrews, MS35308-446, and hex nuts, MS51972-6, secure lifting plate, 1C9643P02,
and drive adapter puller plate, 1C9329P02, to rear drive adapter.
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Figure 3. Balance Piston Installation Dimensions (Rear Drive Adapter)
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Figure 4. Balance Piston Installation Dimensions (Aft Seal Spacer)

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Figure 5. Balance Piston/Rear Drive Adapter Installation Worksheet

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WARNING

OR DEATH.
(b) Attach hoist to sling link and raise rear drive adapter to the vertical position.
(c) If CG adjustment is required, loosen jamnuts, MS35691-75, and move lifting plate,
1C9643P02, in direction required. Tighten jamnuts when correct position is attained.
(d) To install rear drive adapter, perform step 7.A.(5) and step 7.A.(6).
(4) Attach fixture, 1C9642, as follows (figure 6):
(a) Using capscrews, 0.375-24 UNF-3A X 1.75 inch long, and flat washers, MS9321-12, secure
lifting plate, 1C9642P02, to three balance weight holes on aft flange of aft seal spacer.
(b) Attach hoist to sling link and raise aft seal spacer to vertical position.
(c) If CG adjustment is required, loosen jamnuts, MS35691-75, and move CG adjusting plate,
1C9642P03, in direction required. Tighten jamnuts when correct position is attained.
(d) To install aft seal spacer, perform step 7.A.(5) and step 7.A.(6).
WARNING
(5) Heat aft seal spacer or rear drive adapter using heat gun to 350°F (176.6°C) for 30 minutes
minimum.
CAUTION
ASSURE BALANCE PISTON SLOT MARKING IS IDENTIFIED ON LPT ROTOR

SHAFT PRIOR TO INSTALLATION OF ADAPTER, OR INCORRECT
INSTALLATION MAY OCCUR.
(6) Install aft seal spacer or rear drive adapter to the LPT rotor shaft, aligning key on rear drive adapter
to slot mark on LPT rotor shaft. Remove tooling used to position aft seal spacer or rear drive adapter.

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Figure 6. Aft Seal Spacer Lift and Remove Fixture, 1C9642

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8. Aft Adapter Nut Installation.
A. For aft seal spacer configurations only, install rear drive adapter assembly, 1C9609, onto aft seal spacer
using capscrews, NAS1352-8-36, flat washers, AN960-C816, and hex nuts, MS51971-5 (figure 2).
WARNING
B. Lift shaft adapter ring, 1C9328P04 or 1C9613P04 (figure 7), into position on rear drive adapter or rear
drive adapter assembly, 1C9609, using an overhead hoist. Secure shaft adapter ring with eight equally
spaced slabbed head bolts, 1C9328P07or 1C9613P07, and hex nuts, MS51972-6. Tighten nuts to
WARNING
C. Clean retaining nut and rotor shaft threads with isopropyl alcohol.
D. Lightly coat threads and forward face of adapter nut and threads of LPT rotor shaft with thread lubricant.
E. Install adapter nut onto LPT rotor shaft. Tighten adapter nut finger-tight.
F. Install adapter nut fixture, 1C9336, over studs in adapter nut and secure using seven nuts, MS51972-1.
G. Install mounting plate, 1C9309P06 for rear drive adapter configurations or 1C9619P06 for aft seal spacer
configurations, over adapter nut fixture, 1C9336. Secure mounting plate to shaft adapter ring, 1C9328P04
or 1C9613P04, using mounting screws, 1C9309P07 or 1C9619P07. Tighten mounting screws finger-tight.
H. Install torque multiplier onto adapter nut fixture, 1C9336, and mounting plate, 1C9309P06 or 1C9619P06.
I. Tighten adapter nut as follows:
(1) Seat adapter nut to 2000 lb ft (2711 N·m) of torque. Loosen adapter nut.
(2) Tighten adapter nut to 250 lb ft (339 N·m) above run-on torque. Record wrench angle at this torque.
(3) Continue tightening to wrench angle 21 degrees beyond wrench angle recorded in step 8.I.(2).
(4) Check alignment of adapter nut and LPT rotor shaft slots.

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Figure 7. Adapter Nut Installation

/03) *(.
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CAUTION
DO NOT EXCEED MAXIMUM TORQUE VALUE OF 8500 LB FT (11,524 N·M)

OF TORQUE OR MAXIMUM ANGLE OF 24 DEGREES FROM WRENCH ANGLE
RECORDED OR DAMAGE TO LPT MODULE MAY RESULT.
(5) Continue tightening until adapter nut slots align with LPT rotor shaft slots. Do not exceed maximum
of 8500 lb ft (11,524 N·m) of torque or maximum angle of 24 degrees beyond wrench angle
recorded in step 8.I.(2).
J. Remove torque multiplier, mounting plate, 1C9309P06 or 1C9619P06, shaft adapter ring, 1C9328P04 or
1C9613P04, and adapter nut fixture, 1C9336.
K. Using depth micrometer, measure from rear face of adapter nut to rear face of LPT rotor shaft. Record as
measured dimension AF (figure 5).
L. Compare measured dimension AF to calculated dimension AF. The two values shall be within 0.005 inch
(0.13 mm) of each other.
M. Install keyed ring to adapter nut and LPT rotor shaft.
N. Using self-locking nuts, J626P04, secure aft shaft cap to LPT rotor shaft. Tighten self-locking nuts to
57-67 lb in. (6.5-7.5 N·m) of torque.
O. If rear drive adapter flange cover was removed in step 6.B.(2), secure rear drive adapter flange cover to
rear drive adapter using bolts, L45045P03 and self-locking nuts, J626P09 as follows:
(1) Ensure matchmarks on rear drive adapter flange cover and rear drive adapter align.
(2) Tighten self-locking nuts to 113-123 lb ft (154-166 N·m) of torque.
(3) Loosen self-locking nuts 1/2 turn, then re-tighten nuts to 113-123 lb ft (154-166 N·m) of torque.
%ODQN
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RADIAL DRIVE SHAFT REPLACEMENT
())(&7,9,7</03)*$6785%,1(02'(/6

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Alphabetical Index
Subject Page
Radial Drive Shaft Installation................................................................................................................. 7

Radial Drive Shaft Removal. ................................................................................................................... 3
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1. Introduction.
This work package contains instructions for removing and installing the radial drive shaft.
Title Number

Tool Set, Radial Drive Shaft 1C6361G01

Ring, Retaining 705B276P5 1
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6. Radial Drive Shaft Removal.
A. Remove radial drive shaft spacer as follows:
WARNING

(1) Position waste fluid container under transfer gearbox drain. Remove drain plug and drain oil
(figure 1). Remove and discard preformed packing from drain plug.
(2) Lubricate new preformed packing with lubricating oil and install on drain plug.
(3) Install drain plug into transfer gearbox assembly. Tighten drain plug to 262-308 lb in.
(29.7-34.7 N·m) of torque. Safety-wire drain plug.
(4) Place waste fluid container under radial cover assembly. Remove nuts and washers that secure radial
cover assembly. Using jackscrews, carefully remove radial cover assembly. Remove and discard
preformed packing.
Figure 1. Drain Plug and Radial Cover Assembly
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(5) Using flat-tipped screwdriver, unwind retaining ring from groove in bottom of bevel gearshaft.
(6) Assemble radial drive shaft tool, 1C6361, as follows (figure 2):
(a) Turn handnut counterclockwise until no threads are visible at end of rod between handnut and
T-handle.
(b) Place sleeve onto rod against handnut.
(c) Assemble washer, expandable plug, and retainer onto socket head screw. Ensure retainer fits
over end of expandable plug. Install socket head screw into end of rod and tighten finger-tight.
(d) Turn handnut clockwise (CW) until seated snugly against sleeve.
(7) Insert radial drive shaft tool, 1C6361, into gearbox opening so expandable plug goes through center
of radial drive shaft spacer. Lift tool upwards as far as possible.
(8) Hold T-handle of rod and turn handnut CW to expand expandable plug snugly inside spacer.
CAUTION
RADIAL DRIVE SHAFT MAY FALL SUDDENLY AFTER REMOVAL OF

RADIAL DRIVE SHAFT SPACER. HAND SHOULD BE HELD UNDER
GEARBOX OPENING TO PREVENT DAMAGE TO DRIVE SHAFT.
(9) Pull down on radial drive shaft tool, 1C6361, to remove radial drive shaft spacer from bevel
gearshaft. Remove radial drive shaft, by hand, if radial drive shaft comes out with radial drive shaft
spacer.
(10) Loosen handnut and remove radial drive shaft spacer from radial drive shaft tool, 1C6361.
(11) Remove preformed packing from radial drive shaft spacer. Remove and discard preformed packing.
(12) Remove socket head screw, retainer, expandable plug, and washer from radial drive shaft tool,
1C6361.
NOTE
If radial drive shaft fails to come out during spacer removal, remove radial drive per
step 6.B.
B. Remove radial drive shaft as follows (figure 3):
(1) Assemble collet and draw screw onto end of rod. Tighten draw screw finger-tight.
(2) Insert radial drive shaft tool, 1C6361, into gearbox opening so that collet enters center of radial
drive shaft.
(3) Hold T-handle of rod and turn handnut CW to expand collet snugly into radial drive shaft.
(4) Pull down on radial drive shaft tool, 1C6361, to remove radial drive shaft from radial drive shaft
tool, 1C6361.
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Figure 2. Radial Drive Shaft Spacer Removal Using Radial Drive Shaft Tool, 1C6361
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Figure 3. Radial Drive Shaft Removal Using Radial Drive Shaft Tool, 1C6361
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NOTE
Radial drive shaft binding during removal indicates possible transfer gearbox assembly
misalignment.
(5) Loosen handnut and remove radial drive shaft from radial drive shaft tool, 1C6361.
7. Radial Drive Shaft Installation.
A. Install radial drive shaft as follows:
(1) Assemble radial drive shaft tool, 1C6361, as follows:
(a) Turn handnut counterclockwise until no threads are visible at end of rod between handnut and
T-handle. Install sleeve onto rod against handnut.
(b) Assemble collet onto draw screw. Install draw screw into end of rod and tighten finger-tight.
(2) Insert radial drive shaft tool, 1C6361, into end of radial drive shaft opposite grooved shear section.
Hand-tighten handnut.
(3) Install radial drive shaft into transfer gearbox opening. Raise radial drive shaft as far as possible.
Slight turning may be required to engage splines.
(4) Move radial drive shaft up and down to ensure free axial movement. No binding is allowed.
(5) If binding exists, perform the following:
(a) Loosen jamnuts on mount links until locking devices are disengaged.
CAUTION
ENSURE LOCKING DEVICES REMAIN DISENGAGED DURING
ADJUSTMENT OF MOUNT LINKS.
(b) Adjust mount links to obtain free movement of drive shaft.
(c) Tighten jamnuts to 115-135 lb in. (13.0-15.2 N·m) of torque.
(d) Move radial drive shaft up and down to ensure that no binding exists.
(e) Check mount links for proper engagement of rod-end bearing threads by trying to insert a
0.032 inch (0.81 mm) diameter wire through witness hole at each end of turnbuckle. Wire shall
not pass through.
(f) Safety-wire jamnuts to locking devices.
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CAUTION
IF LEFT UNSUPPORTED, RADIAL DRIVE SHAFT MAY FALL OUT OF

TRANSFER GEARBOX.
(6) Loosen handnut and carefully withdraw radial drive shaft tool, 1C6361.
(7) Remove draw screw and collet from rod.
B. Using radial drive shaft tool, 1C6361, install radial drive shaft spacer and retaining ring, as follows
(figure 4):
(1) Install new retaining ring into flanged end of retaining ring shaft.
(2) Using ring pusher, push retaining ring through retaining ring shaft to within 0.125-0.250 in.
(3.18-6.35 mm) of end of shaft. Align cutout sections of shaft and pusher.
(3) Install shaft and pusher over rod and sleeve.
(4) Assemble washer, expandable plug, and retainer onto socket head screw. Ensure retainer fits over
end of expandable plug. Install socket head screw into end of rod and tighten finger-tight.
WARNING
(5) Lubricate new preformed packing with lubricating oil and install onto radial drive shaft spacer.
(6) Install radial drive shaft spacer onto expandable plug. Hand-tighten handnut.
(7) Insert radial drive shaft spacer into bottom of radial drive shaft. Turn radial drive shaft tool cutouts
to face aft.
(8) Raise radial drive shaft tool, 1C6361, to position radial drive shaft and radial drive shaft spacer as
far into gearbox as possible.
(9) Hold T-handle and push retaining ring shaft upwards, as far as possible, and hold.
(10) Release T-handle and push ring pusher upwards, as far as possible, to position retaining ring into
groove of bevel gear.
(11) Pull down on radial drive shaft tool, 1C6361, to seat radial drive shaft spacer against retaining ring.
(12) Loosen handnut and remove radial drive shaft tool, 1C6361.
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Figure 4. Radial Drive Shaft Spacer and Retaining Ring Installation Using Radial Drive Shaft Tool, 1C6361
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CAUTION
AN IMPROPERLY INSTALLED RETAINING RING CAN CAUSE RADIAL

DRIVE SHAFT FAILURE AND GAS TURBINE SHUTDOWN.
(13) Ensure retaining ring is properly installed in bevel gearshaft groove.
WARNING

(14) Lubricate new preformed packing with lubricating oil and install onto radial cover assembly
(figure 1).
(15) Using washers and nuts, install radial cover assembly onto bottom of transfer gearbox assembly.

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TRANSFER GEARBOX ASSEMBLY REPLACEMENT
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10 Blank ................................................................................................................................................... 0
Alphabetical Index
Subject Page
Transfer Gearbox Assembly Installation.................................................................................................. 7

Transfer Gearbox Assembly Removal. .................................................................................................... 3
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1. Introduction.
A. This work package contains instructions for removing and installing the transfer gearbox assembly.
B. Deleted.
Title Number
Front Frame Module External Tubing, Harnesses, and SWP 1913 01
Clamping
Radial Drive Shaft Replacement WP 2810 00

Jack, Lowering - Engine Components 1C5654G03
Guide, Expandable Bushing 1C6119G01
Fixture, Installation/Removal - Accessory Gearbox, Horizontal 1C6872G01
Pusher, Bolt - Front Frame/TGB Forward Mounting Bracket 1C6892G01
None required.
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6. Transfer Gearbox Assembly Removal.
A. Remove radial drive shaft per WP 2810 00.
B. Disconnect electrical leads and connecting tubes between transfer gearbox and gas turbine per
SWP 1913 01.
CAUTION
WHEN LOOSENING HOSE CLAMP TO REPOSITION AND RETIGHTEN AROUND
RADIAL DRIVE SHAFT HOUSING, ENSURE CLAMP IS NOT PLACED DIRECTLY ON
BEADED END OF ADAPTER.
C. Loosen lower flexible housing clamp (figure 1). Reposition clamp higher on flexible housing and retighten
to prevent clamp from falling.
D. Install installation/removal fixture, 1C6872 (figure 2), onto jack, 1C5654 (figure 3).
E. Position jack, 1C5654, under transfer gearbox assembly. Raise jack to position installation/removal fixture,
1C6872, against transfer gearbox assembly.
F. Continue raising jack, 1C5654, to support weight of transfer gearbox assembly.
G. Secure strap around forward side of transfer gearbox assembly between forward mount and flexible
housing adapter. Set floor locks on jack, 1C5654.
CAUTION
ENSURE BOLTS ARE FREE TURNING PRIOR TO REMOVAL. FORCEFUL REMOVAL OF

BOLTS MAY DAMAGE GAS TURBINE OR TRANSFER GEARBOX ASSEMBLY.
H. Remove three nuts, washers, and bolts that secures transfer gearbox assembly onto links.
I. Remove nut from expandable bushing that secures front end of transfer gearbox assembly onto gas turbine.
J. Retract screw of pusher, 1C6892, then engage clevis end of pusher around head of expandable bushing.
(figure 4). Ensure that pusher is seated squarely against gearbox mount. Turn pusher screw slowly to push
out expandable bushing.
WARNING
KEEP HANDS CLEAR OF MOVING PARTS WHEN LOWERING JACK OR PERSONAL
INJURY COULD OCCUR.
K. Lower jack, 1C5654, slowly until transfer gearbox assembly is clear of gas turbine.
L. Release floor locks on jack, 1C5654, and remove transfer gearbox assembly.
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Figure 1. Transfer Gearbox Assembly Replacement
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Figure 2. Horizontal Accessory Gearbox Installation and Removal Fixture, 1C6872
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Figure 3. Engine Components Lowering Jack, 1C5654
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Figure 4. Expandable Bushing Removal Using Pusher, 1C6892
7. Transfer Gearbox Assembly Installation.
A. Install installation/removal fixture, 1C6872 (figure 2), onto jack, 1C5654 (figure 3). Set floor locks on
jack.
B. Install transfer gearbox assembly onto installation/removal fixture, 1C6872.
C. Secure strap around forward end of transfer gearbox assembly between forward mount and flexible
housing adapter.
D. Release floor locks on jack, 1C5654. Position transfer gearbox assembly under gas turbine. Set floor locks
on jack.
E. Raise jack, 1C5654, to position transfer gearbox assembly. Align mounting points and flexible housing
adapter with flexible housing.
NOTE
It may be necessary to release floor locks on jacks to position transfer gearbox assembly. Always
engage floor locks before continuing gearbox raising operation.
F. Raise gearbox until flexible housing adapter is engaged in flexible housing and forward mount expandable
bushing can be installed.
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G. Screw guide, 1C6119, onto expandable bushing until seated (figure 5). Do not apply pressure that could
expand bushing. Insert expandable bushing, with guide, into forward gearbox mount so bolthead is to left
(aft looking forward). If necessary, lightly tap bolthead with plastic mallet.
H. Remove guide. Install nut, but do not tighten at this time.
WARNING

I. Apply molybdenum disulfide lubricant onto spherical bearings of mount and sway links.
J. Adjust gearbox, as required, to connect aft left mount link onto gearbox mount (figure 1). Install bolt,
washer, and nut so that bolthead faces left (aft looking forward). Do not tighten nut at this time.
K. Adjust gearbox, as required, to connect right mount link onto gearbox mount. Ensure sleeve bushing is
present. Install bolt, washer, and nut so that bolthead faces right (aft looking forward). Do not tighten nut at
this time.
L. Connect sway link onto gearbox mount. Install bolt, washer, and nut so bolthead faces aft. Do not tighten
nut at this time.
M. Tighten forward mount bushing nut to 147-173 lb ft (200-234 N·m) of torque.
N. Tighten remaining mount and sway link nuts to 147-173 lb ft (200-234 N·m) of torque.
Figure 5. Expandable Bushing Installation Using Guide, 1C6119
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WARNING
KEEP HANDS CLEAR OF MOVING PARTS WHEN LOWERING JACK OR PERSONAL

INJURY COULD OCCUR.
O. Disconnect strap from around transfer gearbox assembly. Slowly lower jack, 1C5654. Release floor locks
and roll jack clear of gas turbine.
CAUTION
DO NOT INSTALL CLAMPS DIRECTLY OVER BEADED END OF ADAPTER. RADIAL

DRIVE SHAFT HOUSING CUTS CAUSED BY CLAMPS CAN OCCUR WHEN CLAMP IS
INSTALLED ON HOUSING SURFACE DIRECTLY OVER BEADED END OF ADAPTER.
P. Ensure that flexible housing is seated over flexible housing adapter (figure 1). Loosen and lower clamp to
secure flexible housing to flexible housing adapter. Ensure clamp is placed on housing per dimensions
shown in figure 1, view A. Tighten clamps at both ends of flexible housing to 64-70 lb in. (7.3-7.9 N·m) of
torque. If clamps are not tight at 70 lb in. (7.9 N·m), discard clamp and replace with new clamp. Housing
material shall not bulge around clamp.
Q. Connect electrical leads and connecting tubes between transfer gearbox and gas turbine per SWP 1913 01.
R. Install radial drive shaft per WP 2810 00.
%ODQN
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SPUR GEARSHAFT ASSEMBLIES REPLACEMENT
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Alphabetical Index
Subject Page
Free Rotation Check................................................................................................................................ 19

Fuel Pump Spur Gearshaft Assembly Installation. .................................................................................. 7
Fuel Pump Spur Gearshaft Assembly Removal....................................................................................... 5
Manual Drive Spur Gearshaft Installation. ............................................................................................. 16
Manual Drive Spur Gearshaft Removal. ................................................................................................. 13
Preparation For Maintenance. .................................................................................................................. 4
Starter Spur Gearshaft Assembly Installation. ........................................................................................ 12
Starter Spur Gearshaft Assembly Removal............................................................................................. 11
Variable Geometry Hydraulic Pump Spur Gearshaft Installation. .......................................................... 18
Variable Geometry Hydraulic Pump Spur Gearshaft Removal............................................................... 17
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1. Introduction.
A. This work package contains instructions for removing and installing transfer gearbox assembly spur
gearshaft assemblies.
B. Remove gearbox mounted accessories as required to gain access per WP 1812 00, and WP 1814 00.
Title Number
Variable Geometry Hydraulic Pump Replacement WP 1812 00
Pneumatic Starter Replacement WP 1814 00
Accessory Gearbox Carbon Seals Replacement WP 2813 00

Tool Set, Assembly/Disassembly - Gearbox 1C6986G01
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Gasket, Seal J219P02A 1
Keywasher 9009M32P01 3
Ring, Internal Retaining 705B276P10 1
Ring, Retaining 705B276P5 1
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6. Preparation For Maintenance.
WARNING

A. Place waste fluid container under transfer gearbox drain. Remove drain plug and drain oil. Discard
preformed packing (figure 1).
B. Lubricate new preformed packing with petrolatum and install onto drain plug.
C. Install drain plug into transfer gearbox assembly. Tighten drain plug to 262-308 lb in. (29.7-34.7 N·m) of
torque.
Figure 1. Preparation for Maintenance
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7. Fuel Pump Spur Gearshaft Assembly Removal.
CAUTION

A. Disconnect seal drain manifold from fitting on fuel pump adapter. Reposition seal drain manifold.
B. Remove fitting and discard preformed packing.
C. If fuel pump cover is used, perform the following:
(1) Remove bolts, washers, fuel pump cover, and gasket from fuel pump drive pad, if required. Discard
gasket (figure 2).
(2) Remove aft shaft seal assembly. Remove and discard preformed packing.
(3) Remove nut, adapter, and preformed packing from aft shaft seal assembly. Discard preformed
packing.
D. Remove safety wire. Remove bolts and washers that secure fuel pump adapter assembly onto gearbox
housing assembly.
CAUTION
DO NOT ALLOW FUEL PUMP ADAPTER ASSEMBLY FLANGE TO COCK DURING
REMOVAL. TURNING JACKSCREWS EVENLY IN SMALL INCREMENTS WILL
PREVENT COCKING.
E. Using three jackscrews from tool set, 1C6986, remove fuel pump adapter assembly and preformed
packing. Discard preformed packing.
F. Using arbor press, remove spur gearshaft assembly from fuel pump adapter assembly.
CAUTION
IF MATING SEAL RING REQUIRES REPLACEMENT, CARBON SEAL MUST ALSO BE

REPLACED. REFER TO WP 2813 00 FOR CARBON SEAL REPLACEMENT.
G. Remove mating seal ring.
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Figure 2. Fuel Pump Spur Gearshaft Assembly Replacement
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CAUTION
INNER AND OUTER RACES OF ROLLER BEARING MUST BE KEPT TOGETHER AS A

MATCHED SET, OR BEARING DAMAGE MAY OCCUR.
H. Using arbor press, remove roller bearing inner race and rollers from spur gearshaft assembly.
I. Remove forward shaft seal assembly from spur gearshaft assembly. Remove and discard preformed
packing.
J. Remove nut, adapter, and preformed packing from forward shaft seal assembly. Discard preformed
packing.
K. Unbend keywasher tabs. Remove bolts and keywashers that secure bearing housing. Discard keywashers.
L. Using puller from tool set, 1C6986, remove bearing housing and roller bearing outer race as follows
(figure 3):
(1) Install puller so three puller feet engage bearing housing.
(2) Turn knurled knob clockwise (CW) to secure puller feet into place.
(3) Tighten jamnut against spreader bar.
(4) Slide hammer against knurled knob with enough force to disengage bearing housing from gearbox
housing assembly.
(5) Loosen jamnut and turn knurled knob counterclockwise (CCW) to release bearing housing from
puller feet.
8. Fuel Pump Spur Gearshaft Assembly Installation.
WARNING

A. Using lubricating oil, lubricate bearing housing and gearbox housing bore. Install bearing housing into
gearbox housing bore. Using nylon drift and soft face hammer, tap bearing housing until seated (figure 3).
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Figure 3. Typical Bearing Housing Removal Using Puller from Tool Set, 1C6986
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CAUTION
• ENSURE PREBENT TABS OF KEYWASHER CONTACT CCW AGAINST BEARING

HOUSING EAR WITH ZERO CLEARANCE. DO NOT USE FORCE OR DISTORT
PREBENT TAB OF KEYWASHER INTO POSITION.
• DO NOT LOOSEN BOLT TO POSITION A FLAT ON THE BOLTHEAD ADJACENT TO

THE TAB.
B. Install bolts and new keywashers (figure 2). Tighten bolts to 32-38 lb in. (3.7-4.2 N·m) of torque.
Determine if flat on bolthead is adjacent to tab of keywasher. If necessary, continue to tighten bolt to a
maximum of 40 lb in. (4.5 N·m) of torque, until flat on bolthead is adjacent to tab. Bend tab into position
(figure 4).
C. Lubricate new preformed packing with petrolatum and install onto forward shaft seal assembly (figure 2).
D. Install adapter and nut onto forward shaft seal assembly. Tighten nut to 193-227 lb in. (21.9-25.6 N·m) of
torque.
Figure 4. Typical Keywasher Installation
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E. Lubricate new preformed packing with petrolatum and install onto forward shaft seal assembly.
F. Install forward shaft seal assembly into fuel pump spur gearshaft assembly.
G. Using arbor press, install roller bearing inner race and rollers onto spur gearshaft assembly.
H. Install mating seal ring so tangs engage slots on roller bearing.
I. Using arbor press, install spur gearshaft assembly into fuel pump adapter assembly.
J. Apply light coat of petrolatum onto roller bearing rollers. Push rollers toward inner race to minimize roller
circle diameter.
K. Install two guide pins from tool set, 1C6986, into fuel pump drive pad.
L. Lubricate new preformed packing with petrolatum and install into groove of fuel pump adapter assembly.
M. Carefully hold spur gearshaft assembly centered in gearbox bore and move assembly inward to engage
guide pins and roller bearing. Rotate gearshaft slightly to engage spur gears.
CAUTION
ENSURE GEAR TEETH MESH PROPERLY AND GEARS ROTATE FREELY TO AVOID
DAMAGING GEARS.
N. Install five bolts and washers. Tighten bolts evenly, in small increments, to draw fuel pump adapter
assembly onto gearbox housing.
O. Perform free rotation check per paragraph 15.
P. Remove guide pins and install remaining bolts and washers. Tighten all bolts to 57-67 lb in. (6.5-7.5 N·m)
of torque. Safety-wire bolts.
Q. If fuel pump cover is used, perform the following:
(1) Lubricate new preformed packing with petrolatum and install onto aft shaft seal assembly.
(2) Install adapter and nut onto aft shaft seal assembly. Tighten nut to 193-227 lb in. (21.9-25.6 N·m) of
torque.
(3) Lubricate new preformed packing with petrolatum and install onto aft shaft seal assembly.
(4) Install aft shaft seal assembly into fuel pump spur gearshaft assembly.
(5) Using bolts, install new round gasket and cover onto fuel pump adapter assembly. Tighten bolts to
57-67 lb in. (6.5-7.5 N·m) of torque.
R. Lubricate new preformed packing with petrolatum and install onto fitting.
S. Install fitting into fuel pump adapter. Tighten fitting to 133-157 lb in. (15.1-17.7 N·m) of torque.

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CAUTION

T. Connect seal drain manifold onto fitting. Tighten coupling nut to 133-157 lb in. (15.1-17.7 N·m) of torque.
9. Starter Spur Gearshaft Assembly Removal.
A. Remove safety wire. Remove bolts and washers that secure starter adapter assembly onto gearbox housing
assembly (figure 5).
CAUTION
DO NOT ALLOW STARTER ADAPTER ASSEMBLY FLANGE TO COCK DURING

PREVENT COCKING.
B. Using three jackscrews from tool set, 1C6986, remove starter adapter assembly and preformed packing.
Discard preformed packing.
C. Using arbor press, remove spur gearshaft assembly from starter adapter assembly.
CAUTION

D. Remove mating seal ring.
CAUTION

E. Using arbor press, remove roller bearing inner race and rollers from spur gearshaft assembly.
F. Remove and discard retaining ring.
G. Unbend keywasher tabs. Remove bolts and keywashers that secure bearing housing. Discard keywashers.

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Figure 5. Starter Spur Gearshaft Assembly Replacement
H. Using puller from tool set, 1C6986, remove bearing housing and roller bearing outer race as follows
(figure 3):
(2) Turn knurled knob CW to secure puller feet into place.
housing assembly.
(5) Loosen jamnut and turn knurled knob CW to release bearing housing from puller feet.
10. Starter Spur Gearshaft Assembly Installation.
WARNING
A. Lubricate bearing housing and gearbox housing bore with lubricating oil. Install bearing housing to

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CAUTION


THE TAB.
B. Install bolts and new keywashers. Tighten bolts to 32-38 lb in. (3.7-4.2 N·m) of torque. Determine if flat on
bolthead is adjacent to tab of keywasher. If necessary, continue to tighten bolt to a maximum of 40 lb in.
(4.5 N·m) of torque until flat on bolthead is adjacent to tab. Bend tab into position (figure 4).
C. Install new retaining ring into forward groove of starter spur gearshaft assembly (figure 5).
D. Using arbor press, install roller bearing inner race and rollers onto starter spur gearshaft assembly.
E. Install mating seal ring so tangs engage slots on roller bearing. Using arbor press, install spur gearshaft
assembly into starter adapter assembly.
F. Lubricate new preformed packing with petrolatum and install into groove of starter adapter assembly.
G. Apply light coat of petrolatum onto roller bearing rollers. Push rollers toward inner race to minimize roller
circle diameter.
H. Install two guide pins from tool set, 1C6986, into starter drive pad.
I. Carefully hold spur gearshaft assembly centered in gearbox bore and move assembly inward to engage
guide pins. Rotate gearshaft slightly to engage gear teeth with idler gear. Continue pushing to engage
bearing rollers with outer race. Using soft face hammer, tap assembly gently until starter adapter assembly
is seated.
J. Remove guide pins and secure starter adapter assembly with bolts and washers. Tighten bolts finger-tight.
K. Perform free rotation check per paragraph 15.
L. Tighten starter adapter assembly retaining bolts to 57-67 lb in. (6.5-7.5 N·m) of torque. Safety-wire bolts.
11. Manual Drive Spur Gearshaft Removal.
A. Remove bolt and clamp that secure scavenge tube and hose assembly onto manual drive pad cover plate
(figure 6).
B. Remove nut, bolt, and clamp that secure scavenge tube and hose assembly onto low pressure drain hose.
C. Remove bolts that secure scavenge tube and hose assembly onto boss on gearbox assembly. Remove and
discard gasket.
D. Disconnect scavenge tube and hose assembly coupling nut from oil tube assembly. Remove scavenge tube
and hose assembly.

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Figure 6. Manual Drive Spur Gearshaft Replacement

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E. Using marking pen, position mark electrical brackets. Remove nuts and washers that secure manual drive
adapter assembly onto gearbox housing assembly. Reposition electrical brackets.
CAUTION
DO NOT ALLOW MANUAL DRIVE ADAPTER ASSEMBLY FLANGE TO COCK DURING
PREVENT COCKING.
F. Using three jackscrews from tool set, 1C6986, remove manual drive adapter assembly and preformed
packing. Discard preformed packing.
CAUTION

G. Remove mating seal ring.
CAUTION

H. Using arbor press, remove roller bearing inner race and rollers from spur gearshaft assembly.
I. Using arbor press, remove spur gearshaft assembly from manual drive adapter assembly.
J. Unbend keywasher tabs. Remove bolts and keywashers that secure bearing housing. Discard keywashers.
K. Using puller from tool set, 1C6986, remove bearing housing and roller bearing outer race as follows
(figure 3):
(2) Turn knurled knob CW to secure puller feet into place.
housing assembly.
(5) Loosen jamnut and turn knurled knob CCW to release bearing housing from puller feet.

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12. Manual Drive Spur Gearshaft Installation.
WARNING

CAUTION


THE TAB.
C. Using arbor press, install roller bearing inner race and rollers onto manual drive spur gearshaft assembly
(figure 6).
D. Install mating seal ring so tangs engage slots on roller bearing.
E. Using arbor press, install manual drive spur gearshaft assembly into manual drive adapter assembly.
F. Lubricate new preformed packing with petrolatum and install into groove of manual drive adapter
assembly.
circle diameter.
H. Install two guide pins from tool set, 1C6986, into manual drive pad.
I. Carefully hold manual drive spur gearshaft assembly centered in gearbox bore and move assembly inward
to engage guide pins and roller bearing. Rotate gearshaft slightly to engage spur gears.
CAUTION
DAMAGING GEARS.
J. Position electrical brackets as marked at removal. Install five bolts and washers. Tighten bolts evenly, in
small increments, to draw manual drive adapter assembly onto gearbox housing.

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K. Perform free rotation check per paragraph 15.
L. Remove guide pins and install remaining bolts and washers. Tighten all bolts to 57-67 lb in. (6.5-7.5 N·m)
M. Install new seal gasket onto scavenge tube and hose assembly. Using bolts, secure scavenge tube and hose
assembly onto boss on gearbox assembly. Tighten bolts to 32-38 lb in. (3.7-4.2 N·m) of torque.
N. Connect scavenge tube and hose assembly coupling nut onto oil tube assembly. Tighten coupling nut to
O. Install clamp onto scavenge tube and hose assembly. Using bolt and nut, secure clamp to clamp on low
pressure drain hose. Tighten nut to 32-38 lb in. (3.7-4.2 N·m) of torque.
P. Install clamp onto scavenge tube and hose assembly. Using bolt, secure clamp to manual drive adapter
assembly. Tighten bolt to 32-38 lb in. (3.7-4.2 N·m) of torque.
13. Variable Geometry Hydraulic Pump Spur Gearshaft Removal.
A. Remove safety wire. Remove bolts and washers that secure variable geometry hydraulic pump adapter
onto variable geometry pump drive pad (figure 7).
2
CAUTION
DO NOT ALLOW VARIABLE GEOMETRY HYDRAULIC PUMP ADAPTER FLANGE TO

COCK DURING REMOVAL. TURNING JACKSCREWS EVENLY IN SMALL
INCREMENTS WILL PREVENT COCKING.
B. Using three jackscrews from tool set, 1C6986, remove variable geometry hydraulic pump adapter and
preformed packing. Discard preformed packing.
C. Using arbor press, remove spur gearshaft assembly from variable geometry hydraulic pump adapter.
CAUTION

D. Remove mating seal ring.
CAUTION

E. Remove roller bearing inner race and rollers from spur gearshaft assembly.
F. Unbend keywasher tabs. Remove bolts and keywashers securing bearing and housing. Discard
keywashers.

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Figure 7. Variable Geometry Hydraulic Pump Spur Gearshaft Replacement
G. Using puller from tool set, 1C6986, remove bearing housing and roller bearing outer race as follows
(figure 3):
(2) Turn knurled knob CW to secure puller feet in place.
housing assembly.
(5) Loosen jamnut and turn knurled knob CCW to release bearing housing from puller feet.
14. Variable Geometry Hydraulic Pump Spur Gearshaft Installation.
WARNING
gearbox housing bore. Using nylon drift and soft face hammer, tap bearing housing until seated.

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CAUTION


THE TAB.
C. Using arbor press, install roller bearing inner race and rollers onto spur gearshaft.
D. Install mating seal ring so that tangs engage slots on roller bearing.
E. Using arbor press, install spur gearshaft assembly into variable geometry hydraulic pump adapter.
F. Lubricate new preformed packing with petrolatum and install into groove of variable geometry hydraulic
pump adapter.
circle diameter.
H. Install two guide pins from tool set, 1C6986, into variable geometry hydraulic pump drive pad.
I. Carefully hold spur gearshaft assembly centered in gearbox bore and move assembly inward to engage
guide pins and roller bearing. Rotate gearshaft slightly to engage spur gears.
CAUTION
DAMAGING GEARS.
J. Install six bolts and washers. Tighten evenly, in small increments, to draw variable geometry hydraulic
pump adapter into gearbox housing.
K. Perform free rotation check per paragraph 15
L. Remove guide pins and install remaining bolts and washers. Tighten all bolts to 57-67 lb in. (6.5-7.5 N·m)
15. Free Rotation Check.
A. Remove horizontal drive shaft as follows (figure 8):
(1) Remove nuts and washers that secure horizontal cover onto transfer gearbox housing assembly.
(2) Tap horizontal cover with nylon drift and soft face hammer. Remove horizontal cover and
preformed packing. Discard preformed packing.

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Figure 8. Horizontal Drive Shaft Removal and Installation
NOTE
If more access space is required for internal retaining ring or horizontal drive shaft
removal, perform step 15.A.(3). If access space for ring or shaft removal is adequate,
proceed to step 15.A.(4).
(3) Remove nuts and washers that secure radial cover assembly. Using two 0.250-28 UNF-3B
jackscrews, remove radial cover assembly. Remove and discard preformed packing.
(4) Remove internal retaining ring from groove on inside forward end of bevel gearshaft. Discard
internal retaining ring.
(5) Remove horizontal drive shaft.
B. Perform free rotation check as follows:
(1) Remove nuts, washers, cover plate, and preformed packing to gain access to manual drive to check
free rotation of newly installed gearshaft. Discard preformed packing.
(2) Insert 3/4-inch drive extension into manual drive gearshaft.
(3) Turn manual drive gearshaft CW and ensure gears mesh properly and no binding exists.
(4) Lubricate new preformed packing with petrolatum and install onto cover plate.

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(5) Install cover plate onto manual drive adapter assembly. Secure with washers and nuts. Tighten nuts
C. Install horizontal drive shaft as follows:
WARNING
(1) Apply light coat of lubricating oil to splines of horizontal drive shaft. Install drive shaft, small spline
aft, through opening in front of transfer gearbox housing into bevel gearshaft. Align splines and
push drive shaft through bevel gearshaft.
(2) Install new internal retaining ring into groove on inside forward end of bevel gearshaft.
(3) Lubricate new preformed packing with petrolatum and install on horizontal cover.
(4) Install horizontal cover onto front of transfer gearbox housing. Secure with washers and nuts.
(5) If radial cover assembly was removed, lubricate new preformed packing with petrolatum and install
onto radial cover assembly. Using washers and nuts, install radial cover assembly onto bottom of
transfer gearbox housing. Tighten nuts to 57-67 lb in. (6.5-7.5 N·m) of torque.
%ODQN
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ACCESSORY GEARBOX CARBON SEALS
REPLACEMENT
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Alphabetical Index
Subject Page
Accessory Gearbox Carbon Seals Installation. ........................................................................................ 6

Accessory Gearbox Carbon Seals Removal............................................................................................. 3
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1. Introduction.
A. This work package contains instructions for removing and installing accessory gearbox carbon seals.
B. Remove starter as required to gain access per WP 1814 00.
Title Number
Pneumatic Starter Replacement WP 1814 00

Fixture Set, Mating Seal Removal 1C8182G01
Guide Pins (Qty 3, 0.190-32 by 1.0 in. bolt with head removed)Locally Fabricated

Keywasher 9009M32P01 9
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6. Accessory Gearbox Carbon Seals Removal.
A. Remove carbon seal as follows (figure 1):
(1) If installed, remove coupling clamp or bolts and washers, cover, and gasket from applicable drive
pad. Discard gasket.
(2) Unbend keywasher tabs.
NOTE
Seal retainer is used at starter pad only.
(3) Remove bolts, keywashers, and seal retainer. Discard keywashers.
NOTE
Some carbon seal configurations contain three slots on the inner face of the flange midway
between the boltholes to aid in seal removal. If slots are present, proceed to step 6.A.(5).
(4) Rotate carbon seal by inserting pin of offset driver from fixture set, 1C8182, into bolthole of seal
flange and tap lightly with light hammer until seal tangs overlap housing boss.
CAUTION
USE CARE TO PREVENT COCKING CARBON SEAL OR DAMAGING
HOUSING DURING REMOVAL.
(5) Remove carbon seal from gearbox housing bore using prybar from fixture set, 1C8182, to apply
leverage.
(6) Remove packing from gearbox housing bore using pick set from fixture set, 1C8182. Discard
preformed packing.
(7) Prior to removal of mating seal ring, obtain drop from gearbox face to mating seal ring surface. Use
this reading for reference at reinstallation of mating seal ring.
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Figure 1. Accessory Gearbox Carbon Seals
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CAUTION
IF CARBON SEAL IS REPLACED, THE MATING SEAL RING SHALL ALSO BE

REPLACED. IF CARBON SEAL IS REUSED, THE MATING SEAL RING SHALL ALSO BE
REUSED.
B. Remove mating seal ring as follows (figure 2):

NOTE
Tool numbers 1C8182P02 through P05 are used at starter pad. Tool numbers 1C8182P10
through P13 are used at fuel pump pad and auxiliary accessory drive pad.
(1) Turn screw, 1C8182P06, counterclockwise (CCW) to end of travel to retract pusher plate,
1C8182P05 or P11.
(2) Slide outer sleeve, 1C8182P04 or P12, back to allow fingers of inner sleeve, 1C8182P03 or P10, to
expand.
(3) Insert tool into seal cavity until plastic stop, 1C8182P02 or P13, contacts mating seal ring.
Figure 2. Mating Seal Removal Fixture Set, 1C8182
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(4) Slide outer sleeve over inner sleeve closing flexible fingers over mating seal ring.
(5) Turn screw clockwise until mating seal ring is pulled free of shaft.
(6) Remove tool and slide outer sleeve back to release mating seal ring.
(7) Remove packing from seal ring packing groove. Discard packing.
7. Accessory Gearbox Carbon Seals Installation.
A. Install mating seal ring as follows:
NOTE
Tool numbers 1C8182P07 and P08 are used at starter pad. Tool numbers 1C8182P14 and
P15 are used at fuel pump pad and auxiliary accessory drive pad.
(1) Using petrolatum, lubricate new preformed packing and install into mating seal ring packing groove.
CAUTION
USE CARE TO AVOID DAMAGING PACKING DURING INSTALLATION OF

MATING SEAL RING.
(2) Using seal ring installation pliers from fixture set, 1C8182, install mating seal ring onto shaft.
Ensure tangs of mating seal ring fully engage slots of bearing inner race. Following installation of
mating seal ring, take drop from gearbox face to aft surface of mating seal ring. Compare to reading
taken during removal.
B. Install new carbon seal as follows:
(1) Using petrolatum, lubricate new preformed packing and install into gearbox housing bore (figure 1).
WARNING

CAUTION
DURING HANDLING, PROTECT MATING SURFACES OF MATING SEAL RING
AND CARBON SEAL FROM CONTAMINATION, INCLUDING FINGERPRINTS.
THE SEAL RING AND CARBON SEAL ARE MATCHED PARTS; DO NOT
INTERCHANGE.
(2) Lubricate internal elements of carbon seal with lubricating oil. Depress and release carbon seal
slowly several times to ensure seal operates smoothly.
(3) Apply light coat of lubricating oil onto carbon seal face, seal housing outside diameter, and face of
mating seal ring.
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(4) Install locally fabricated guide pins into gearbox housing inserts to align seal tang boltholes with
inserts during installation.
CAUTION
• BEFORE INSTALLATION, ENSURE CARBON SEAL IS CLEAN AND FREE
OF DEBRIS. CONTAMINATION MAY CAUSE CARBON SEAL FAILURE.
• TAKE CARE NOT TO DISTURB OR DAMAGE PACKING DURING

INSTALLATION.
• TO PREVENT DAMAGE TO CARBON SEAL, ENSURE THE TANGS OF THE

SEAL RING FULLY ENGAGE SLOTS OF THE BEARING INNER RACE.
(5) Install carbon seal over guide pins and carefully push into housing until seal flange is fully seated
against housing face. Remove guide pins.
NOTE
Perform step 7.B.(6) only if starter pad carbon seal was replaced.
(6) Install seal retainer at starter pad.
CAUTION
ENSURE PREBENT TABS OF KEYWASHER CONTACT CCW AGAINST

BEARING HOUSING EAR WITH ZERO CLEARANCE. DO NOT USE FORCE OR
DISTORT PREBENT TAB OF KEYWASHER INTO POSITION.
(7) Install new keywashers and bolts.
CAUTION
DO NOT LOOSEN BOLT TO POSITION A FLAT ON THE BOLTHEAD

ADJACENT TO THE TAB.
(8) Tighten bolts to 32-38 lb in. (3.7-4.2 N·m) of torque. Determine if flat on bolthead is adjacent to tab
of keywasher. If necessary, continue to tighten bolt to a maximum of 40 lb in. (4.5 N·m) of torque
until flat on bolthead is adjacent to tab. Bend tab into position (figure 3).
(9) Install new gasket, cover, and coupling clamp or bolts and washers, as applicable. Tighten coupling
clamp as follows:
(a) Tighten coupling clamp to approximately 40 lb in. (4.5 N·m) of torque.
(b) Inspect and ensure coupling clamp is seated over both flanges equally.
(c) Using plastic or non-metallic mallet, tap coupling clamp around circumference to distribute
band tension.
(d) Tighten coupling clamp to 79-90 lb in. (9.0-10.1 N·m) final torque. Continue to lightly tap
coupling clamp to prevent unequal loading.
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(e) After full value torque is applied, tap circumference of coupling clamp again. Reapply torque
to ensure coupling clamp is properly tightened.
(10) Tighten bolts to 193-227 lb in. (21.9-25.6 N·m) of torque.
Figure 3. Typical Keywasher Installation
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GAS TURBINE IN ENCLOSURE REPLACEMENT
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Alphabetical Index
Subject Page
Gas Turbine Installation into Enclosure.................................................................................................. 10

Gas Turbine Removal from Enclosure..................................................................................................... 5
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1. Introduction.
A. This work package contains instructions for removing or installing the gas turbine in an enclosure.
B. Disconnect and connect electrical leads and connecting tubes on the gas turbine per SWP 1913 01,
SWP 1913 02, SWP 1913 03, and SWP 1913 04.
NOTE
Testing has demonstrated that failure to complete the following purge procedure will result in residual
fuel within the gas turbine and fuel supply system and the engine cannot be declared non-HAZMAT
for shipping. Similarly, testing shows that, if the procedure is completed, the engine will be free of fuel
and can be declared non-HAZMAT.
C. Normal Shutdown and Cooldown. If the gas turbine including fuel system is to be removed from the
enclosure in preparation for shipment by ground or air, complete the following fuel system drain and purge
procedure. Fuel system removal prior to shipment does not require the purge procedure.
(1) While the engine is still in the enclosure, disconnect all fuel manifolds at the package supply
interface as follows:
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.
(a) Liquid Fuel - If present, should be drained into a container or fuel drain tank when the fittings
are opened. Any locations such as flow splitter, pressurization valve or flow divider should also
be isolated and drained. As an alternative to ventilating, the liquid fuel system can be filled
with MIL-L-6081, Grade 1010 slush oil. This alternative is preferred if the engine is to be
stored for extended periods before or after service.
(b) Gas Fuel - Open the fuel manifold fittings and allow them to ventilate into the enclosure.
(2) Using the Human Machine Interface (HMI), start the enclosure ventilation fan(s).
(3) Initiate a dry crank (no fuel supply) using the HMI and allow the engine to ramp to 2200 rpm HP
rotor speed for 10 minutes. This will ventilate any remaining fuel or vapor into the enclosure using
compressor discharge air.
(4) For DLE units, all staging valves should be normally open. If there are any normally closed valves
in the system, the HMI should be used to open them.
(5) After 10-minute purge, stop dry crank.
(6) Stop ventilation fan(s).
(7) Complete gas turbine removal.
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D. Emergency Shutdown or Engine Failure. If the gas turbine including fuel system is to be removed from
the enclosure in preparation for shipment by ground or air, complete the following fuel system drain and
purge procedure. Fuel system removal prior to shipment does not require the purge procedure.
(1) While the engine is still in the enclosure, disconnect all fuel manifolds at the package supply
interface as well as at all nozzles or premixers.
(2) Using the HMI, start the enclosure ventilation fan(s).
(3) Drain and blow out all fuel lines as follows:
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.
(a) Liquid Fuel - If present, should be drained into an approved container or the fuel drain tank
when the fittings are opened. Any locations such as flow splitter, pressurization valve or flow
divider should also be isolated and drained. As an alternative to ventilating, the liquid fuel
system can be filled with MIL-L-6081, Grade 1010 slush oil. This alternative is preferred if the
engine is to be stored for extended periods before or after service.
(b) Open the combustor case drain fitting and drain any residual fuel into an approved container or
the fuel drain tank.
WARNING
WHEN USING COMPRESSED AIR FOR CLEANING, COOLING, OR

DRYING, DO NOT EXCEED 30 PSIG (207 KPA). WEAR EYE
PROTECTION AND DO NOT DIRECT COMPRESSED AIR AT SELF
OR OTHERS.
(c) After all fuel is drained, blow out each of the lines, hoses and connections with shop air.
(d) Gas Fuel - Open the fuel manifold fittings and blow out each of the lines, hoses and
connections with shop air.
(4) Stop ventilation fan(s).
(5) Reconnect fuel nozzles or premixers.
(6) Complete gas turbine removal.
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Title Number
Front Frame Module External Tubing, Harnesses, and SWP 1913 01
Clamping
Clamping
Rear Drive Adapter or Aft Seal Spacer Replacement WP 2711 00
Gas Turbine Maintenance Dolly Removal and Installation WP 3012 00
Gas Turbine/Support Pedestal Removal and Installation WP 3013 00
Gas Turbine in Shipping Container Replacement WP 3014 00

Fixture Assembly, Horizontal Lift 1C9625G01
Fuel System Preservation Oil MIL-L-6081C, Grade 1010
Packager-supplied gaskets are required to perform the tasks described in this work package (see packager’s
manual).

Ignitor Plug (Blankoff) L44539P01 1
Piston Ring, Outer L45063P16 1
Piston Ring, Outer L45063P13 ALT
Piston Ring, Inner L47833P01 1
Piston Ring, Inner L47833P02 ALT
Washer 9397M22P02 1
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6. Gas Turbine Removal from Enclosure.
CAUTION
ENSURE ALL ELECTRICAL, FUEL, OIL, AND AIR SUPPLIES ARE SHUT OFF BEFORE
DISCONNECTING CUSTOMER INTERFACES. FAILURE TO COMPLY MAY RESULT IN
PART DAMAGE.
A. Disconnect inlet, exhaust, bypass air, and drive interfaces as follows:
(1) Disconnect inlet system from variable inlet guide vane (VIGV) case or inlet frame assembly per
packager’s manual.
(2) Disconnect exhaust system per packager’s manual.
(3) Disconnect bypass air collection system per packager’s manual.
(4) If same gas turbine will be installed, matchmark drive adapter and shaft using marking pen.
(5) Disconnect forward and aft drive adapters per packager’s manual.
B. Disconnect customer electrical interfaces as follows:
WARNING
BEFORE YOU DISCONNECT THE IGNITION LEADS, MAKE SURE THE

IGNITION SYSTEM WAS OFF FOR MORE THAN 2 MINUTES. THE IGNITION
SYSTEM COULD BE CHARGED WITH HIGH VOLTAGE THAT CAN CAUSE
DEATH.
NOTE
Some engines may have only one ignition plug at 3:30 o’clock position and a blankoff
plug at 5:30 o’clock position.
(1) Disconnect igniter cables from igniters as follows:
CAUTION
• ENSURE IGNITER PLUG ADAPTER IS RESTRAINED WHEN

TIGHTENING COUPLING NUT. FAILURE TO COMPLY MAY
• IGNITER PLUG MAY FALL OUT WHEN IGNITION CABLE IS

DISCONNECTED.
(a) Remove safety wire. Disconnect ignition cables from igniter plug adapters. Momentarily
ground ignition cable to remove any residual electrical charge.
(b) Install igniter plug cover or covers. Tighten covers to 23-27 lb ft (32-36 N·m) of torque.
(c) Remove nut, bolt, and clamps that secure ignition cables onto gas turbine bracket.
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(2) Disconnect flame sensor integral leads from packager’s junction box per packager’s manual.
(3) If required, disconnect starter speed switch connector from pneumatic starter per packager’s manual.
(4) Disconnect customer electrical cables as follows:
(a) Using marking pen, matchmark customer electrical cable connections at electrical interface
panels.
(b) Remove bolts, washers, and clamps that secure customer electrical cables onto electrical
interface panels.
WARNING
CIRCUITS SHALL BE OPEN (OFF) AND CAPACITORS

DISCHARGED TO GROUND BEFORE PROCEEDING. ELECTRICITY
CAUSES SHOCK, BURNS, AND DEATH.
(c) Disconnect customer electrical cable connectors from electrical interface panels per packager’s
manual.
C. Disconnect remaining customer hydraulic, pneumatic, lube oil, fuel, and vent/drain interfaces per
SWP 1913 01, SWP 1913 02, SWP 1913 03, and SWP 1913 04.
D. Install fuel manifold support fixture assembly per WP 3015 00.
E. Remove bolts that secure fuel and steam manifold mounts onto packager’s stanchions per packager’s
manual.
F. Remove gas turbine from enclosure as follows (figure 1):
(1) Attach hoist of sufficient lifting capacity to horizontal lift fixture, 1C9625, or equivalent (figure 2).
WARNING
(2) Raise horizontal lift fixture, 1C9625, to working height. Level fixture by adjusting trolley. Record
center of gravity (CG) measurement.
(3) Position horizontal lift fixture, 1C9625, over gas turbine. Using quick-release pins, secure lift fixture
clevis, 1C9625P09, onto rear mounts on turbine rear frame.
(4) Position lift fixture front frame adapter onto front frame forward lift point. Install quick-release pin.
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Figure 1. Gas Turbine Mount Locations
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Figure 2. Horizontal Lift Fixture, 1C9625 (Sheet 1 of 2)
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CAUTION
ENSURE LIFT FIXTURE TROLLEY IS SET TO 30.1 INCHES (765 MM) FOR
ENGINES WITH VIGV INSTALLED, AND 31.8 INCHES (808 MM) FOR
ENGINES WITH INLET FRAME INSTALLED. INCORRECT POSITIONING MAY
CAUSE LIFT FIXTURE/GAS TURBINE DAMAGE.
(5) Position lift fixture trolley to 30.1 inches (765 mm) for engines with VIGV installed, and
31.8 inches (808 mm) for engines with inlet frame installed. Slowly apply small amount of lifting
force on hoist. Ensure lift fixture is properly attached to gas turbine.
WARNING
ENSURE HOIST AND LIFT FIXTURE ARE ALIGNED PRIOR TO REMOVING

REAR MOUNT PINS. FAILURE TO COMPLY MAY RESULT IN GAS TURBINE
SHIFTING, CAUSING SERIOUS INJURY.
(6) Remove trunnion attachments and aft mount attachment per packager’s manual.
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WARNING

CAUTION
ENSURE REAR MOUNT LINKS DO NOT DROP ONTO GAS TURBINE

COMPONENTS WHILE GAS TURBINE IS RAISED FROM ENCLOSURE. GAS
TURBINE DAMAGE MAY RESULT.
(7) Lift gas turbine and maneuver to remove from enclosure.
(8) Install gas turbine into applicable support equipment per WP 3012 00, WP 3013 00, or WP 3014 00.
(9) Install inlet, exhaust, and air collector covers.
G. Using bright light, visually inspect inner and outer piston rings for wear and cracks (figure 3). If rings are
worn or cracked, replace rings.
7. Gas Turbine Installation into Enclosure.
CAUTION
DO NOT OPERATE ENGINE WITH IGNITOR PLUG COVER INSTALLED IN PLACE OF

L44539P01 BLANKOFF PLUG.
A. If engine is being installed with dual ignition system and site is set up for single ignition system, it will be
required that a plug and new washer be installed in the 5:30 o’clock igniter plug position.
B. Verify the rear drive adapter or aft seal spacer, whichever is applicable, is installed. Refer to WP 2711 00.
C. Install gas turbine in enclosure as follows:
WARNING

(1) Position aft mount links outboard.

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Figure 3. Gas Turbine Exhaust Duct Interface

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WARNING

CAUTION

COMPONENTS WHILE GAS TURBINE IS RAISED FROM ENCLOSURE. GAS
TURBINE DAMAGE MAY RESULT.
(2) Lower gas turbine into enclosure and align aft clevis mounts with mount links.
(3) Install trunnion pins into trunnion support stanchions per packager’s manual.
(4) Install trunnion washers and nuts onto gas turbine trunnions. Tighten nuts per packager’s manual.
(5) Install mount bolt and nut through aft left mount link and gas turbine mount. Tighten nut per
(6) Install mount bolt and nut through aft center mount and gas turbine mount. Tighten nut per
(7) Adjust aft right mount link so mount bolt can be inserted freely. Install mount bolt and nut through
aft right mount link and gas turbine mount. Tighten nut per packager’s manual.
(8) Tighten aft right mount link jamnut per packager’s manual.
(9) Slowly release tension on hoist.
WARNING
ENSURE LIFT FIXTURE IS LOCATED AT THE CENTER OF GRAVITY BEFORE

DISCONNECTING FROM GAS TURBINE. FAILURE TO COMPLY MAY RESULT
IN GAS TURBINE DAMAGE OR SERIOUS INJURY.
(10) Position lift fixture trolley at CG. Slowly apply lifting force to allow lift fixture pins to rotate freely
(figure 2).
(11) Remove two turbine rear frame lift fixture quick-release pins. Remove forward lift point quick-
release pin. Raise lift fixture clear of gas turbine.
D. Connect inlet, exhaust, bypass air, and drive interfaces as follows:
(1) If installed, remove inlet, exhaust, and air collector covers.
(2) Connect forward and aft drive adapters per packager's manual.
(3) Connect exhaust system per packager’s manual.
(4) Connect inlet system to VIGV case or inlet frame assembly per packager’s manual.

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(5) Connect bypass air collection system per packager’s manual.
E. Connect customer electrical interfaces as follows:
(1) Connect customer electrical cables as follows:
WARNING
CIRCUITS SHALL BE OPEN (OFF) AND CAPACITORS

DISCHARGED TO GROUND BEFORE PROCEEDING. ELECTRICITY
(a) Connect customer electrical cables to electrical interface panels.
(b) Using bolts, washers, and clamps, secure customer electrical cables onto electrical interface
panels. Tighten bolts to 57-67 lb in. (6.5-7.5 N·m) of torque.
(2) Connect igniter cables to igniters as follows:
CAUTION
IGNITER PLUG MAY FALL OUT WHEN IGNITION CABLE IS

DISCONNECTED OR IGNITER PLUG COVER IS REMOVED.
(a) Remove igniter plug covers at 3:30 o’clock position, and if installed, at 5:30 o’clock position.
(b) Install ignition cables over igniter plug adapters. Tighten coupling nuts to 23-27 lb ft
(32-36 N·m) of torque. Safety-wire coupling nut.
(3) Connect flame sensor integral lead to packager’s junction box per packager’s manual.
CAUTION
DO NOT OPERATE ENGINE WITH IGNITOR PLUG COVER INSTALLED IN

PLACE OF IGNITION PLUG OR BLANKOFF PLUG.
NOTE
Some engines may have only one ignition system (3:30 o’clock position) and a blankoff
plug will then be required at the 5:30 o’clock position.
(4) If required, connect starter speed switch connector to pneumatic starter per packager’s manual.
CAUTION
POSITION HYDRAULIC, PNEUMATIC, LUBE OIL, FUEL, WATER, STEAM, AND VENT/
DRAIN INTERFACES TO AVOID INTERFERENCE WITH ENGINE COMPONENTS THAT
COULD RESULT IN PREMATURE FAILURE.
F. Check for misalignment and interference between engine and package interfaces. Adjust and correct as
required.

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G. Connect remaining customer hydraulic, pneumatic, lube oil, fuel, and vent/drain interfaces per
SWP 1913 01, SWP 1913 02, SWP 1913 03, and SWP 1913 04.
NOTE
Misalignment between the fuel manifolds and the packager’s stanchions may indicate that the
packager’s supporting stanchions are located incorrectly.
H. Install bolts that secure fuel and steam manifolds to packager’s stanchions. Tighten bolts to 106-124 lb in.
(12.0-14.0 N·m) of torque.
I. Remove fuel manifold support fixture per WP 3015 00.

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PRESERVATION/DEPRESERVATION
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Alphabetical Index
Subject Page
Definitions................................................................................................................................................ 4
Engine Depreservation. ........................................................................................................................... 26
Installed Engine for Greater than 30 Days Preservation. ........................................................................ 23
Installed Engine for Up to 30 Days Preservation..................................................................................... 4
Noninstalled Engine for Greater than 30 Days Preservation. ................................................................. 25
Noninstalled Engine for Up to 30 Days Preservation. ............................................................................ 24
Oil-Wetting LM6000 Bearings (Alternate Procedure 1)......................................................................... 13
Oil-Wetting LM6000 Bearings (Alternate Procedure 2)......................................................................... 23
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1. Introduction.
This work package contains instructions for preservation/depreservation of the engine.
Title Number

Drive Motor, Pneumatic 18932
Spline Adapter, Manual or Front Drive Pad 1C8208G02
Drive Motor, Electric (115 VAC 50/60 and 400 Hz, 28 VDC) 2C14764G05
Drive Motor, Electric (220 VAC 50 Hz and 28 VDC) 2C14764G06
Reducer AN919-6
Reducer AN919-10
Reducer AN919-13
Lubricating Stand Local Purchase
Cap MS51532B10S
Reducer MS51525B6-8S
Cap MS51532B6S
Union MS51525B8S
Barrier Paper, Kraft Grade A, Type II, Class II
Corrosion Preventative GE Spec D50TF6 or Brayco 599
Desiccant MIL-P-116
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Packing, Preformed M83248/1-912 3
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6. Definitions.
For purposes of this work package, the following definitions apply:
A. Installed engine - An engine installed in the enclosure.
B. Noninstalled engine - An engine installed in a maintenance dolly or pedestals, or an engine installed in a

shipping container.
7. Installed Engine for Up to 30 Days Preservation.
CAUTION
• ENSURE DRIVEN EQUIPMENT IS PRELUBRICATED OR DRIVE SHAFT IS
DISCONNECTED PRIOR TO MOTORING ENGINE. FAILURE TO COMPLY MAY
RESULT IN DAMAGE TO DRIVEN EQUIPMENT OR LACK OF LOW PRESSURE
ROTOR ROTATION AND SUBSEQUENT INSUFFICIENT BEARING LUBRICATION.
• DO NOT EXCEED STARTER DUTY CYCLE WHEN MOTORING. HYDRAULIC

STARTER HAS NO DUTY CYCLE LIMITATIONS EXCEPT OIL TEMPERATURE
SHALL BE MAINTAINED BELOW 140°F (60°C). PNEUMATIC STARTER DUTY
CYCLE FOLLOWS:
5 MINUTES ON, 2 MINUTES OFF,

OR
10 MINUTES ON, 20 MINUTES OFF.
A. Inspect inlet, exhaust, and variable bleed valve (VBV) discharge.
B. Remove moisture barrier paper, covers, and plugs from engine.
C. Oil-wet bearings using one of the following three procedures:
(1) Oil-wet bearings per step 7.D through step 7.I.
(2) Oil-wet bearings per paragraph 8.
(3) Oil-wet bearings per paragraph 9.
D. Connect lubricating stand as follows:
(1) Install locally manufactured blankoff plates (figure 1) using existing gaskets, bolts, and washers
onto ports L1, L2, and L3 (figure 2). Tighten bolts on port L1 to 428-502 lb in. (48.4-56.7 N·m) of
torque. Tighten bolts on port L2 to 262-308 lb in. (29.7-34.7 N·m) of torque. Tighten bolts on port
L3 to 170-200 lb in. (19.3-22.5 N·m) of torque.
(2) Install cap, MS51532B6S, onto scavenge discharge pressure port L5 fitting.
(3) Remove protective cap from supply pressure port L4 fitting.
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Figure 1. Locally Manufactured Blankoff Plates
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Figure 2. Lubricating Oil Manifold Ports (Sheet 1 of 2)
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Figure 2. Lubricating Oil Manifold Ports (Sheet 2 of 2)
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(4) Remove fitting from supply pressure port L4. Discard preformed packing.
WARNING

(5) Lubricate new preformed packing, PN J221P906, with lubricating oil and install onto reducer,
MS51525B6-8S. Install reducer into supply pressure port L4. Tighten reducer to 175-205 lb in.
(19.8-23.1 N·m) of torque.
(6) Connect lubricating stand supply hose onto reducer at supply pressure port L4. Tighten coupling nut
(7) Remove drain plug from forward side of accessory gearbox.
(8) Lubricate preformed packing, PN J221P908, with lubricating oil and install onto union,
MS51525B8S. Install union into accessory gearbox drain port. Tighten union to 262-308 lb in.
(29.7-34.7 N·m) of torque.
(9) Connect lubricating stand scavenge hose onto union on accessory gearbox drain port. Tighten
coupling nut to 460-540 lb in. (52.0-61.0 N·m) of torque.
(10) Remove transfer gearbox (TGB), B- and C-sump scavenge inlet screen plugs from lube and
scavenge pump. Discard preformed packings.
(11) Lubricate preformed packings, PN M83248/1-912, with lubricating oil and install onto reducers,
MS51525B8-12S. Install reducers into TGB, B- and C-sump scavenge ports. Tighten reducers to
(12) Connect lubricating stand scavenge lines onto TGB, B- and C-sump scavenge port reducers. Tighten
coupling nuts to 460-540 lb in. (52.0-61.0 N·m) of torque.
(13) Disconnect D-sump scavenge hose from D-sump scavenge in port fitting. Install cap,
MS51532B10S, onto fitting. Tighten cap finger-tight.
(14) Install reducer, MS51525B8-10S, onto D-sump scavenge hose. Tighten reducer to 55-65 lb ft
(15) Connect lubricating stand scavenge hose onto reducer on D-sump scavenge hose. Tighten coupling
(16) Disconnect E-sump scavenge hose from E-sump scavenge in port fitting. Install cap,
PN MS5132B10S, onto fitting. Tighten cap finger-tight.
(17) Install reducer, PN MS51525B8-10S onto E-sump scavenge hose. Tighten reducer to 55-65 lb ft
(18) Connect lubricating stand scavenge hose onto reducer on E-sump scavenge hose. Tighten coupling

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E. Install spline adapter and electric/pneumatic drive motor as follows:
(1) Remove nuts and washers securing forward drive pad cover to front of accessory gearbox. Remove
cover. Discard preformed packing.
WARNING
(2) Lubricate spline adapter, 1C8208, with lubricating oil. Install spline adapter into spline adapter
forward drive spline and secure with washers and nuts. Tighten nuts to 106-124 lb in.
(12.0-14.0 N·m) of torque.
(3) Install electric drive motor, 2C14764, or pneumatic drive motor, 18932, onto forward drive pad
aligning square drive with spline adapter. Secure with washers and bolts. Tighten bolts to
428-502 lb in. (48.4-56.7 N·m) of torque.
(4) Connect drive motor to applicable power source.
F. Oil-wet engine bearings as follows:
WARNING
CORROSION PREVENTATIVE, BRAYCO 599: COMBUSTIBLE. DO NOT INHALE,

NOTE
The use of corrosion preventative, Brayco 599, is optional if preservation period is less
than 15 days.
(1) Add 5 percent (by volume) of corrosion preventative, Brayco 599, to lubricating stand oil tank.
CAUTION
ENSURE LUBRICATING STAND SCAVENGE LINES SHOW VISIBLE FLOW

THROUGH VIEWING WINDOWS. IF FLOW IS NOT OBSERVED, STOP
LUBRICATING STAND SUPPLY AND SCAVENGE PUMPS AND CHECK
FITTINGS FOR LEAKS. FAILURE TO COMPLY MAY RESULT IN OVERFLOW
OF OIL SUMPS.
(2) Start lubricating stand supply and scavenge pumps (figure 3). Regulate supply pressure to 5-10 psi
(35-68 kPa). Lube oil temperature shall be maintained between 60°F (16°C) and 100°F (38°C).
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Figure 3. Typical Lubricating Stand

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WARNING
CAUTION
FAILURE TO ROTATE LOW PRESSURE ROTOR WILL RESULT IN

INSUFFICIENT LUBRICATION OF NO. 1, 2, 6, AND 7 BEARINGS.
(3) Rotate high pressure turbine (HPT) rotor, using electric/pneumatic drive motor, in forward direction
a minimum of two revolutions (approximately 12-15 minutes) at maximum rpm. Rotate low
pressure turbine (LPT) rotor, using driven equipment jacking gear (if installed), a minimum of two
revolutions. If jacking gear is not installed, disconnect coupling shaft to driven equipment and rotate
LPT rotor by pulling stage 5 LPT blades minimum of two revolutions.
(4) Stop lubricating stand supply pump. Run scavenge pump until no oil flow is visible in scavenge line
viewing windows. Stop scavenge pump.
G. Disconnect lubricating stand as follows:
(1) Disconnect lubricating stand supply line from supply pressure port L4.
(2) Remove reducer from supply pressure port L4.
WARNING

(3) Lubricate new preformed packing with lubricating oil and install onto fitting. Install fitting in supply
pressure port L4. Tighten fitting to 175-205 lb in. (19.8-23.1 N·m) of torque.
(4) Disconnect lubricating stand scavenge lines from TGB, B-, and C-sump scavenge inlet port fittings.
Remove fittings.
(5) Lubricate three preformed packings with lubricating oil and install on TGB, B- and C-sump
scavenge inlet screen plugs.
(6) Install inlet screen plugs into TGB, B-, and C-sump scavenge inlet ports. Tighten plugs to 46-54 lb ft
(7) Remove cap from main scavenge discharge tube. Install pump scavenge discharge hose onto main
scavenge discharge tube. Tighten coupling nut to 129-151 lb ft (175-204 N·m) of torque.
(8) Disconnect lubricating stand accessory gearbox scavenge hose. Remove accessory gearbox
scavenge hose adapter.

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WARNING

(9) Lubricate preformed packing with lubricating oil and install onto accessory gearbox drain plug.
(10) Install accessory gearbox drain plug. Tighten plug to 262-308 lb in. (29.7-34.7 N·m) of torque.
Safety-wire plug.
(11) Remove caps from D- and E-sump scavenge fittings.
(12) Disconnect lubricating stand scavenge hose from reducer on D-sump scavenge hose. Remove
reducer from D-sump scavenge hose.
(13) Connect D-sump scavenge hose onto D-sump scavenge fitting. Tighten coupling nut to
(14) Disconnect lubricating stand scavenge hose from reducer on E-sump scavenge hose. Remove
reducer from E-sump scavenge hose.
(15) Connect E-sump scavenge hose onto E-sump scavenge fitting. Tighten coupling nut to
(16) Remove cap from scavenge discharge pressure port L5.
H. Remove electric/pneumatic drive motor and spline adapter as follows:
WARNING
USE EXTREME CARE WHEN WORKING WITH ELECTRICITY. ELECTRICITY

(1) Disconnect drive motor from power source.
(2) Remove bolts and washers that secure drive motor onto accessory gearbox. Remove drive motor.
(3) Remove nuts, washers, and spline adapter, 1C8208, from accessory gearbox.
(4) Lubricate preformed packing with lubricating oil and install into preformed packing groove on
cover.
(5) Install forward drive pad cover onto accessory gearbox forward drive pad. Secure with washers and
nuts. Tighten nuts to 106-124 lb in. (12.0-14.0 N·m) of torque.
I. Cover or plug all engine openings and unattached fittings. Cover inlet, exhaust, and VBV openings using
moisture barrier paper, if possible.

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8. Oil-Wetting LM6000 Bearings (Alternate Procedure 1).
A. Oil-wet gearbox bearings as follows:
WARNING

WARNING
NOTE
The use of corrosion preventative, Brayco 599, is optional if preservation period is less
than 15 days.
(1) Thoroughly mix 6 quarts (6 liters) of lubricating oil with 290 cc of Brayco 599 preventative to
obtain 5 percent mixture.
(2) Remove oil from reservoir of hydraulic actuator unit, 1C3569. Pour oil/Brayco 599 mixture into unit
reservoir.
(3) Remove tube-end reducer, nut, -6/-4 reducer, AN919-6, and cap from head-end hose swivel of
hydraulic actuator unit, 1C3569. Head-end and rod-end lines are identified with tag.
(4) Move hydraulic actuator unit, 1C3569, selector valve to head-end position, open supply valve on
head-end line, and close supply valve on rod-end.
(5) Locate gearbox drain plug (figure 4) and place clean container under drain. Remove drain plug
(some packages may have a starter clutch drain attached). Dispose of drained oil and return
container under drain.
(6) Remove four nuts and washers from accessory gearbox manual drive pad cover plate (figure 5).
Remove cover plate.
(7) Insert 3/4-inch by 12-inch drive extension into manual drive pad and attach ratchet.
(8) Remove oil supply manifold as follows (figure 6):
(a) Disconnect gearbox lube oil supply tube.

1
(b) Disconnect A-sump oil supply tube.
(c) Disconnect B-, C-, D-, and E-sump tubes.

2

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Figure 4. Gearbox
WARNING

DISCONNECTING ELECTRICAL CONNECTORS. ELECTRICITY
(d) Remove electrical connector from lube oil supply resistance temperature detector (RTD).
(e) Disconnect other packager connections, as required.
(f) Remove bolts and washers connecting oil supply manifold onto oil manifold. Remove manifold
and store in clean container.
(g) Cap or tape all openings to avoid lube system contamination.
(9) Locate gearbox lube oil supply tube and install reducer, AN919-6. Connect unit pressurizer head-
end line onto reducer.

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Figure 5. Front Frame and Gearbox

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Figure 6. Oil Supply Manifold

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CAUTION
DURING OPERATION OF HYDRAULIC ACTUATOR UNIT, 1C3569, OBSERVE

HEAD-END PRESSURE GAGE TO VERIFY PRESSURE BUILDUP DOES NOT
EXCEED 100 PSI (689 KPA) OR DAMAGE TO GEARBOX SEALS MAY RESULT.
NOTE
• Pump handle of hydraulic actuator unit, 1C3569, shall be operated rapidly through the
full piston stroke to ensure the proper amount of oil/preservative mixture is supplied to
the sump.
• Core rpm can be determined by observing rotation of ratchet drive. A ratchet drive
speed of 7 rpm equals core speed of 10 rpm.
(10) Use ratchet in manual drive pad to rotate core 5-10 rpm clockwise, aft looking forward (ALF), while
hydraulic actuator unit, 1C3569, pump handle (maintain 20 psig [138 kPa] minimum pressure).
Rotate core and activate pump handle for 2 minutes.
(11) Remove hydraulic actuator unit, 1C3569, head-end line from gearbox oil supply line. Cap or tape
gearbox lube oil supply tube to avoid lube system contamination.
WARNING

WARNING
(12) Allow oil/Brayco 599 mixture to drain from gearbox into container. If clean, pour mixture from
container into hydraulic actuator unit, 1C3569, reservoir and replace container under open gearbox
drain. If reservoir does not contain approximately 6 quarts (6 liters) (reservoir capacity), mix an
additional 5 percent mixture and fill reservoir.
B. Oil-wet A-sump bearings as follows:
(1) Locate A-sump oil supply tube and install reducer, AN919-10. Connect hydraulic actuator unit,
1C3569, head-end line to reducer.

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CAUTION

EXCEED 100 PSI (689 KPA) OR DAMAGE TO GEARBOX SEALS MAY RESULT.
NOTE
Pump handle of hydraulic actuator unit, 1C3569, shall be operated rapidly through the full
piston stroke to ensure the proper amount of oil/preservative mixture is supplied to the
sump.
(2) Use ratchet in manual drive pad to rotate core 5-10 rpm clockwise, ALF. Simultaneously rotate low
pressure rotor by hand using rear drive adapter (the gas turbine shall be disconnected from the
electrical generator or drive equipment). Rotate both rotors while operating hydraulic actuator unit,
1C3569, pump handle (maintain 20 psig [138 kPa] minimum pressure). Rotate rotors and activate
pump handle for 2 minutes.
(3) Remove hydraulic actuator unit, 1C3569, head-end line from A-sump oil supply tube. Cap or tape
A-sump oil supply tube to avoid lube system contamination.
(4) Install new preformed packing and drain plug into gearbox. Tighten plug to 262-308 lb in.
(29.7-34.7 N·m) of torque.
WARNING

WARNING

(5) Inspect oil/Brayco 599 mixture. If serviceable, pour mixture from container into hydraulic actuator
unit, 1C3569, reservoir. If reservoir does not contain approximately 6 quarts (6 liters) (reservoir
capacity), mix an additional 5 percent oil/Brayco mixture and fill reservoir.
(6) Attach oil supply manifold as follows:
(a) Install oil supply manifold onto oil manifold with three washers and bolts. Tighten bolts to
57-67 lb in. (6.5-7.5 N·m) of torque.
(b) Connect gearbox lube oil supply tube using new preformed packing. Tighten fitting to
175-205 lb in. (19.8-23.1 N·m) of torque.
(c) Connect A-sump oil supply tube using new preformed packing. Tighten fitting to
262-308 lb in. (29.7-34.7 N·m) of torque.

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(d) Connect B-, C-, D-, and E-sump tube. Tighten fitting to 78-92 lb ft (106-124 N·m) of torque.
WARNING

(e) Connect electrical connector to lube oil supply.
(f) Connect remaining packager connections per packager’s manual.
C. Oil-wet D- and E-sump bearings as follows:
(1) Disconnect the D- and E-sump oil supply line fitting on strut 6 of turbine rear frame (figure 7).
Connect hydraulic actuator unit, 1C3569, head-end line with reducer, AN919-8.
WARNING

(2) Locate D- and E-scavenge lines (figure 8) and place clean container under lines. Disconnect the two
lines. Dispose of drained oil and return container under lines.
4
3
CAUTION
DURING OPERATION OF HYDRAULIC UNIT PRESSURIZER, 1C3569,

OBSERVE HEAD-END PRESSURE GAGE TO VERIFY PRESSURE BUILDUP
DOES NOT EXCEED 100 PSI (689 KPA) OR DAMAGE TO GEARBOX SEALS
MAY RESULT.
NOTE
Pump handle of hydraulic actuator unit, 1C3569, shall be operated rapidly through the full
piston stroke to ensure that the proper amount of oil/preservative mixture is supplied to the
sump.
(3) Using rear drive adapter, rotate low pressure rotor 5-10 rpm clockwise, ALF, while operating
hydraulic actuator unit, 1C3569, pump handle (maintain 20 psig [138 kPa] minimum pressure).
Rotate low pressure rotor and activate pump handle for 2 minutes.
(4) Remove hydraulic actuator unit, 1C3569, head-end line from D- and E-sump oil supply line.
Reconnect oil supply line. Tighten fitting to 460-540 lb in. (52.0-61.0 N·m) of torque.
(5) Reconnect D- and E-scavenge lines and tighten to 55-65 lb ft (75-88 N·m) of torque.

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WARNING

WARNING
(6) Pour oil/Brayco 599 mixture from container into hydraulic actuator unit, 1C3569, reservoir. If
reservoir does not contain approximately 6 quarts (6 liters) (reservoir capacity), mix an additional
5 percent mixture and fill reservoir.
D. Oil-wet B- and C-sump bearings as follows:
(1) Locate B- and C-sump oil supply line (figure 7) and disconnect fitting at main lube supply manifold.
Connect hydraulic actuator unit, 1C3569, head-end line with reducer, AN919-13.
(2) Locate B- and C-scavenge lines and place container under lines. Disconnect two lines. Dispose of
drained oil and return container under lines.
CAUTION

EXCEED 100 PSI (689.4 KPA) OR DAMAGE TO GEARBOX SEALS MAY
RESULT.
NOTE
• Pump handle of hydraulic actuator unit, 1C3569, shall be operated rapidly through the
full piston stroke to ensure the proper amount of oil/preservative mixture is supplied to
the sump.
• Core rpm can be determined by observing rotation of ratchet drive. A ratchet drive
speed of 7 rpm equals core speed of 10 rpm.
(3) Use ratchet in manual drive pad to rotate core 5-10 rpm clockwise, ALF, while operating hydraulic
actuator unit, 1C3569, pump handle (maintain 20 psig [138 kPa] minimum pressure). Rotate core
and activate pump handle for 2 minutes.
(4) Remove hydraulic actuator unit, 1C3569, head-end line from B- and C-sump oil supply line.
Reconnect oil supply line and tighten fitting to 55-65 lb ft (75-88 N·m) of torque.
(5) Reconnect B- and C-scavenge lines and two new gaskets. Tighten bolts and nuts to 57-67 lb in.

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Figure 7. D- and E-Sump Oil Supply Line

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Figure 8. Rear Frame and Scavenge Lines
WARNING

(6) Remove ratchet from gearbox drive pad. Lubricate new preformed packing with lubricating oil, and
install preformed packing onto cover plate.
(7) Reinstall cover plate, four washers, and four nuts. Tighten nuts to 57-67 lb in. (6.5-7.5 N·m) of
torque.
WARNING

(8) Pump all oil/Brayco 599 mixture from hydraulic unit pressurizer, 1C3569, reservoir and agitate
using fresh lubricating oil in reservoir. Pump all oil from reservoir and dispose of oil.
(9) Disconnect reducer from hydraulic actuator unit, 1C3569, line and reinstall -6/-4 reducer, AN919-6,
nut, and cap on head-end line.
E. Cover or plug all engine openings and unattached fittings. Cover inlet, exhaust, and VBV openings using
moisture barrier paper, if possible.

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9. Oil-Wetting LM6000 Bearings (Alternate Procedure 2).
WARNING

WARNING
CORROSION PREVENTATIVE, BRAYCO 599: COMBUSTIBLE. DO NOT INHALE, INGEST,
OR LET THIS MATERIAL TOUCH YOU. IRRITANT. PERSONAL PROTECTIVE EQUIPMENT
NOTE
The use of corrosion preventative, Brayco 599, is optional if preservation period is less than 15 days.
A. Add corrosion preventative, Brayco 599, to lube oil tank to obtain 5 percent mixture.
B. Perform one of the following:
(1) Operate engine at base load for minimum of 10 minutes.
(2) Operate engine at synch idle for minimum of 10 minutes.
(3) Motor engine for minimum of 10 minutes with XN25 greater than 2000 rpm and XN2 greater than
200 rpm.
10. Installed Engine for Greater than 30 Days Preservation.
WARNING

WARNING
CORROSION PREVENTATIVE, BRAYCO 599: COMBUSTIBLE. DO NOT INHALE, INGEST,
OR LET THIS MATERIAL TOUCH YOU. IRRITANT. PERSONAL PROTECTIVE EQUIPMENT
A. Use of corrosion preventative, Brayco 599, in lubricating oil is required.

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CAUTION
• ENSURE DRIVEN EQUIPMENT IS PRELUBRICATED OR DRIVE SHAFT IS

DISCONNECTED PRIOR TO MOTORING ENGINE. FAILURE TO COMPLY MAY
RESULT IN DAMAGE TO DRIVEN EQUIPMENT OR LACK OF LOW PRESSURE
ROTOR ROTATION AND SUBSEQUENT INSUFFICIENT BEARING LUBRICATION.
• DO NOT EXCEED STARTER DUTY CYCLE WHEN MOTORING. HYDRAULIC

STARTER HAS NO DUTY CYCLE LIMITATIONS EXCEPT OIL TEMPERATURE
SHALL BE MAINTAINED BELOW 140°F (60.0°C). PNEUMATIC STARTER DUTY
CYCLE FOLLOWS:

OR
10 MINUTES ON, 20 MINUTES OFF.
B. Perform step 7.A through step 7.C, as applicable.
C. Perform step 7.A through step 7.C, as applicable, every 30 days. Update engine log to include oil-wetting
dates.
11. Noninstalled Engine for Up to 30 Days Preservation.
NOTE
If engine is installed in pedestals or dolly, proceed to step 11.C.
A. Container should be stored in an area shaded from direct sunlight and within limits of normal environment.
Engine storage log should be maintained and updated every 30 days, to include recorded humidity
condition, oil-wetting dates, and desiccant replacement.
B. For gas turbine to be installed in shipping container, perform the following:
(1) Preserve engine per step 7.C.(1) or step 7.C.(2).
(2) Place 75 bags of new desiccant in container.
(3) Install container lid.
(4) Inspect humidity indicator at least once every 30 days. Indicator should appear blue, indicating safe
humidity conditions. If indicator appears pink, the following steps must be complied with within
14 days:
(a) Remove cover.
(b) Remove desiccant.

(c) Preserve engine per step 7.C.(1) or step 7.C.(2).
(d) Place 75 bags of new desiccant in container.
(e) Reinstall container lid.

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C. For gas turbines installed in dolly or pedestals, perform the following:
(1) Engine storage log should be maintained and updated to include oil-wetting dates.
12. Noninstalled Engine for Greater than 30 Days Preservation.
NOTE
If engine is installed in pedestals or dolly, proceed to step 12.C.
A. Container should be stored in an area shaded from direct sunlight and within limits of normal environment.
Engine storage log should be maintained and updated every 30 days, to include recorded humidity
condition, oil-wetting dates, and desiccant replacement.
B. For gas turbine to be installed in shipping container, perform the following:
WARNING

NOTE
The use of corrosion preventative, Brayco 599, is required for preservation period of
greater than 30 days.
(2) Place 75 bags of new desiccant in container.
(3) Install container lid.
(4) Inspect humidity indicator at least once every 30 days. Indicator should appear blue, indicating safe
humidity conditions. If indicator appears pink, the following steps must be complied with within
14 days:
(a) Remove cover.
(b) Remove desiccant.
(c) Preserve engine per step 7.C.(1) or step 7.C.(2).
(d) Place 75 bags of new desiccant in container.
(e) Reinstall container lid.
(f) Inspect humidity indicator at least once every 30 days. If indicator appears pink, complete
corrective actions per step 12.B.(4)(a) through step 12.B.(4)(e) within 14 days and start
humidity inspection period again.

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C. For gas turbines in a dolly or on a pedestal:
(1) Maintain and update engine storage log to include oil-wetting dates.
(3) Repeat gas turbine preservation per step 7.C.(1) or step 7.C.(2) every 30 days.
13. Engine Depreservation.
A. If required, depreserve lubricating oil tank as follows:
WARNING

(1) Drain engine lubricating oil tank per packager’s manual.
(2) Remove drain plug from forward side of accessory gearbox. Drain oil into suitable container.
Discard packing.
(3) Lubricate new preformed packing with lubricating oil and install onto accessory gearbox drain plug.
(4) Install accessory gearbox drain plug. Tighten plug to 262-308 lb in. (29.7-34.7 N·m) of torque.
(5) Fill lubricating oil tank with lubricating oil per packager’s manual.

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GAS TURBINE MAINTENANCE DOLLY
REMOVAL AND INSTALLATION
())(&7,9,7</03)*$6785%,1(02'(/6

Page No. Change No.
1 - 16 ........................................................................................................................................................ 0
Alphabetical Index
Subject Page
Gas Turbine Installation into Maintenance Dolly, 1C9372...................................................................... 3

Gas Turbine Removal from Maintenance Dolly, 1C9372....................................................................... 15
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1. Introduction.
This work package contains instructions for removing and installing gas turbine in maintenance dolly.
None required.

Ring Assembly, VIGV Case Support 1C9371G02
Maintenance Dolly, External Engine 1C9372G07
Adapter Set, Air Collector Support 1C9375G03
Adapter Set, LPC Support 1C9377G01
Adapter Assembly, Engine External Maintenance Dolly 1C9378G03
Jack Assembly, Support - Compressor Rear Frame 1C9448G01
Fixture Assembly, Engine Lift - Horizontal 1C9625G01
Sling, Lift MSE-53
None required.
None required.
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6. Gas Turbine Installation into Maintenance Dolly, 1C9372.
CAUTION
TURBINE REAR FRAME SUPPORTS AND EITHER TRUNNION OR AIR COLLECTOR

SUPPORTS ARE THE MINIMUM SUPPORTS NECESSARY FOR INSTALLING GAS
TURBINE IN MAINTENANCE DOLLY. FAILURE TO USE THE CORRECT SUPPORTS
MAY RESULT IN GAS TURBINE DAMAGE.
A. Install only those supports required for maintenance task being performed. See figure 1 and figure 2 to
determine which supports are required.
B. If required, install trunnion pedestals, 1C9378P02 and P03, onto maintenance dolly, 1C9372, with bolts,
washers, and nuts. Boltheads face up, washers under both bolts and nuts. Tighten nuts to 133-157 lb ft
(181-212 N·m) of torque (figure 3).
C. If required, install air collector support pedestals, 1C9378P10, onto maintenance dolly, 1C9372, with bolts,
washers, and nuts, washers under nuts. Tighten nuts finger-tight (figure 4).
D. Using bolts, washers, and nuts, install turbine rear frame (TRF) support pedestals, 1C9378P06, onto
maintenance dolly, 1C9372. Boltheads face up, washers under nuts. Tighten nuts finger-tight (figure 5).
1
E. Install gas turbine into maintenance dolly, 1C9372, as follows:
NOTE
Height of pedestals can be adjusted to two different positions depending on maintenance required.
(1) Adjust height of pedestals to lower or higher maintenance position. Secure with quick-release pins.
WARNING

(2) Lower gas turbine into maintenance dolly, 1C9372.
(3) If required, secure gas turbine trunnions onto trunnion adapters with locknuts. Tighten locknuts to
50 lb ft (68 N·m) of torque (figure 3).
NOTE
Ensure that forward air collector support adapter, 1C9375, is installed on lower forward air
collector flange.
(4) If required, adjust air collector support pedestal position on maintenance dolly, 1C9372 (figure 4).
Tighten pedestal retaining nuts to 69-81 lb ft (94-109 N·m) of torque.
(5) If required, turn adjusting nut to align air collector support pedestal mount with forward air collector
support adapter, 1C9375. Install quick-release pin.
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Figure 1. Determine Required Support Equipment
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Figure 2. Supports from Maintenance Dolly, 1C9378
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Figure 3. Trunnion Mount Supports (Position 4)
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Figure 4. Air Collector Supports (Position 3)
(6) Adjust TRF support pedestal position on maintenance dolly, 1C9372 (figure 5). Tighten pedestal
retaining nuts to 69-81 lb ft (94-109 N·m) of torque. Turn support pedestal yoke to align TRF
pedestal bracket, 1C9378P35, with gas turbine rear mount.
(7) Using TRF mount pin, secure gas turbine onto TRF support pedestal bracket, 1C9378P35. Install
quick-release pins through TRF mount pins.
F. Remove horizontal lift fixture, 1C9625, as follows (figure 6):

2
WARNING

(1) Slowly release tension on hoist until lift fixture pins rotate freely. Position lift fixture trolley at
center of gravity (CG).
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Figure 5. Turbine Rear Frame Supports (Position 6)
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WARNING

(2) Remove TRF fixture quick-release pins. Remove forward lift point quick-release pin. Raise lift
fixture clear of gas turbine.
G. Install CRF support jack assembly, 1C9448, as follows (figure 7):

3
NOTE
If maintenance dolly supports are positioned at lower height, proceed to step 6.G.(2).
(1) Install spacer, 1C9448P13, onto maintenance dolly, 1C9372, cross plate and secure with screws,
washers, and nuts. Screwheads face up, washers under nuts. Tighten nuts to 428-502 lb in.
(48.4-56.7 N·m) of torque.
(2) Install CRF support jack assembly, 1C9448, onto cross plate or spacer, as required. Secure with
screws, washers, and nuts. Screwheads face up, washers under nuts. Tighten nuts to 428-502 lb in.
(48.4-56.7 N·m) of torque.
(3) Install cradle, 1C9448P10, onto support jack assembly arm, 1C9448P05. Secure with quick-release
pin.

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Figure 7. Compressor Rear Frame Support (Position 5)

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(4) Adjust CRF support jack assembly, 1C9448, position on maintenance dolly, 1C9372, by moving
cross plate. Tighten cross plate nuts to 69-81 lb ft (94-109 N·m) of torque.
(5) Turn nut and rod-end nut, in even increments, until cradle, 1C9448P10, is aligned and touching
compressor rear frame (CRF).
NOTE
Install low pressure compressor (LPC) support adapters only if variable inlet guide vane (VIGV) case
has been removed.
H. Install LPC supports as follows (figure 8):
(1) Install LPC forward support adapters, 1C9377, onto LPC case front flange by aligning splitline
markings on adapter with LPC case splitline. Secure with bolts, washers, and nuts, washers under
nuts. Tighten nuts to 170-200 lb in. (19.3-22.5 N·m) of torque.
(2) Install universal support pedestals, 1C9378P06, and yoke, 1C9378P08, onto maintenance dolly,
1C9372, with bolts, washers, and nuts. Boltheads face up, washers under nuts. Tighten nuts finger-
tight.
(3) Adjust height of universal support pedestals to lower or higher maintenance position. Secure with
quick-release pins.
(4) Adjust universal support pedestal position on maintenance dolly, 1C9372. Tighten pedestal retaining
nuts to 69-81 lb ft (94-109 N·m) of torque. Turn adjusting nut to align yoke with LPC forward
support adapter. Install quick-release pins.
I. Install VIGV stator case supports as follows (figure 9):
WARNING

(1) Position VIGV support ring, 1C9371, onto VIGV case front flange or inlet frame assembly front
flange using 1 ton (907 kg) hoist and lift sling, MSE-53. Secure ring with bolts and washers. Tighten
(2) Using bolts, washers, and nuts, install universal support pedestals, 1C9378P06, and yoke,
1C9378P08, onto maintenance dolly, 1C9372. Boltheads face up, washers under nuts. Tighten nuts
finger-tight.
(3) Adjust height of universal support pedestals to lower or higher maintenance position. Secure with
quick-release pins.
(4) Adjust universal support pedestal, 1C9378P06, position on maintenance dolly, 1C9372. Tighten
pedestal retaining nuts to 69-81 lb ft (94-109 N·m) of torque. Turn adjusting nut to align support
yoke to VIGV support ring, 1C9371. Install quick-release pin.

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Figure 8. Low Pressure Compressor Supports (Position 2)

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Figure 9. VIGV Support Ring (Position 1)

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7. Gas Turbine Removal from Maintenance Dolly, 1C9372.
A. Install horizontal lift fixture, 1C9625, as follows (figure 6):
WARNING
ESTABLISH AND RECORD THE CENTER OF GRAVITY OF THE HORIZONTAL

LIFT FIXTURE TO PREVENT FIXTURE FROM PITCHING WHEN BEING
DISCONNECTED FROM THE GAS TURBINE. FAILURE TO COMPLY MAY
CAUSE SERIOUS INJURY OR GAS TURBINE DAMAGE.
(1) Attach 15 ton (13608 kg) hoist to horizontal lift fixture, 1C9265.
WARNING
CG measurement.
(3) Position horizontal lift fixture, 1C9265, over gas turbine. Secure lift fixture clevis, 1C9625P09, onto
rear mounts on turbine rear frame with quick-release pins.
CAUTION
(6) Apply sufficient lifting force on hoist to allow gas turbine to float in maintenance dolly support
mounts. Mount pins shall turn freely.
B. Remove VIGV support rings as follows (figure 9):
(1) Adjust universal support pedestal adjusting nut to allow quick-release pins to rotate freely. Remove
quick-release pins.
(2) Attach a 1 ton (907 kg) hoist and lift sling, MSE-53, on VIGV support ring, 1C9371. Apply
sufficient lifting force to VIGV support ring for removal.

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WARNING

(3) Remove bolts and washers from VIGV support ring, 1C9371. Remove support ring.
C. Remove LPC forward support adapters, 1C9377, as follows (figure 8):
(1) Adjust universal support pedestal, 1C9378P06, adjusting nut to allow quick-release pins to rotate
freely. Remove quick-release pins.
(2) Remove bolts, washers, and nuts that secure LPC forward support adapters, 1C9377, onto LPC case.
Remove LPC forward support adapters.
D. Remove support jack assembly, 1C9448, as follows (figure 7):
(1) Adjust support jack rod-end nut to release pressure on CRF.
(2) Adjust support jack knurled nut until cradle, 1C9448P10, quick-release pin turns freely. Remove
quick-release pin and cradle.
E. Adjust universal support pedestal, 1C9378P06, to release tension on TRF mount pins (figure 5). Pins shall
rotate freely. Remove quick-release pins. Remove TRF mount pins.
F. Remove forward air collector support adapters, 1C9375, as follows (figure 4):
(1) Adjust air collector support pedestal adjusting nut to allow quick-release pin to rotate freely.
(2) Remove quick-release pin and forward air collector support adapter, 1C9375.
G. Remove locknuts that secure gas turbine trunnions onto trunnion adapters (figure 3).
H. Lift gas turbine free of maintenance dolly, 1C9372.

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GAS TURBINE/SUPPORT PEDESTAL REMOVAL AND
INSTALLATION
())(&7,9,7</03)*$6785%,1(02'(/6

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Alphabetical Index
Subject Page
Gas Turbine Installation onto Support Pedestal. ...................................................................................... 3

Gas Turbine Removal from Support Pedestal......................................................................................... 15
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1. Introduction.
This work package contains instructions for removing and installing the gas turbine in the support pedestals.
Title Number

Ring Assembly, VIGV Case Support 1C9371G02
Adapter Set, LPC Support 1C9377G01
Jack Assembly, Support - Compressor Rear Frame 1C9448G02
Support Pedestals, Storage and Maintenance 1C9384G03/G04
Sling, Lift MSE-53
None required.
None required.
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6. Gas Turbine Installation onto Support Pedestal.
CAUTION
TURBINE REAR FRAME SUPPORTS AND EITHER TRUNNION OR AIR COLLECTOR

SUPPORTS ARE THE MINIMUM SUPPORTS NECESSARY FOR INSTALLING GAS
TURBINE IN SUPPORT PEDESTALS. FAILURE TO USE CORRECT SUPPORTS MAY
RESULT IN GAS TURBINE DAMAGE.
A. Use only those supports required for the maintenance task being performed. See figure 1 and figure 2 to
determine which supports are required.
B. Install gas turbine onto support pedestal, 1C9384, as follows:
(1) If required, secure gas turbine onto trunnion support pedestals, 9448M53, as follows (figure 3):
(a) Align trunnion support pedestals, 9448M53, with gas turbine trunnions.
(b) Using locknuts, secure gas turbine trunnions onto trunnion support pedestals, 9448M53.
Tighten locknuts to 50 lb ft (68 N·m) of torque.
(2) If required, secure gas turbine onto air collector support pedestals, 9448M52, as follows (figure 4):
NOTE
Ensure that forward air collector support adapters, 1C9375, are installed on
lower forward air collector flange.
(a) Align air collector support pedestals, 9448M52, with forward air collector support adapters,
1C9375.
(b) Adjust support pedestal yokes, as required, and install quick-release pins.
(3) Secure gas turbine onto turbine rear frame (TRF) support pedestals, 9448M84, as follows (figure 5):
(a) Align CRF support pedestals, 9448M84, with gas turbine mounts.
(b) Turn support pedestal yokes, as required, and install mount pins. Mount pins shall rotate freely.
Install quick-release pins through mount pins.
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Figure 1. Determine Required Support Equipment
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Figure 2. Maintenance Pedestals from 1C9384
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Figure 3. Trunnion Support (Position 4)
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Figure 4. Air Collector Support (Position 3)
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Figure 5. Compressor Rear Frame (CRF) Support (Position 6)
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C. Remove horizontal lift fixture, 1C9625, as follows (figure 6):
(1) Slowly release tension on hoist until lift fixture pins rotate freely. Position lift fixture trolley at
center of gravity (CG).
WARNING
WARNING
ENSURE GAS TURBINE IS SECURED IN PEDESTALS AND PEDESTALS ARE
FLAT ON FLOOR BEFORE DISCONNECTING LIFT FIXTURE FROM GAS
TURBINE.
WARNING
(2) Remove TRF fixture quick-release pins. Remove forward lift point quick-release pin. Raise
horizontal lift fixture, 1C9625, clear of gas turbine.
D. Support gas turbine with CRF support jack assembly, 1C9448, as follows (figure 7):
(1) Install CRF support jack assembly, 1C9448, onto support pedestal, 9448M85. Using bolts and nuts,
secure support jack. Tighten nuts to 428-502 lb in. (48.4-56.7 N·m) of torque.
(2) Install CRF cradle, 1C9448P10, onto CRF support jack assembly, 1C9448. Secure with
quick-release pin.
(3) Position CRF support jack assembly, 1C9448, under gas turbine. Turn knurled nut and rod-end nut,
in even increments, until cradle is aligned and touching CRF.
NOTE
Install low pressure compressor (LPC) support adapters only if VIGV case has been removed.
E. Install LPC forward support adapters, 1C9377, and secure gas turbine onto LPC support pedestals as
follows (figure 8):
(1) Install LPC forward support adapters, 1C9377, onto LPC case front flange by aligning splitline
markings on adapters with the LPC case splitline. Secure using bolts, washers, and nuts. Tighten
(2) Align gas turbine support pedestals, 9448M51, with LPC forward support adapters, 1C9377.
(3) Adjust support pedestal adjusting nuts, as required, and install quick-release pins.
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s
F. Install VIGV support ring, 1C9371, and secure gas turbine onto VIGV support pedestals as follows
(figure 9):
(1) Position VIGV support ring, 1C9371, on VIGV case front flange or inlet frame assembly front
flange using 1 ton (907 kg) hoist and lift sling, MSE-53. Secure ring assembly with 27 capscrews
and washers. Tighten bolts to 46-54 lb in. (5.2-6.1 N·m) of torque.
(2) Align gas turbine support pedestals, 9448M51, with ring assembly.
(3) Adjust support pedestal adjusting nuts, as required, and install quick-release pins.
G. Remove fuel manifold support fixture per WP 3015 00.

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Figure 7. Compressor Rear Frame Support (Position 5)

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Figure 8. Low Pressure Compressor Support (Position 2)

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Figure 9. VIGV Case Support (Position 1)

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7. Gas Turbine Removal from Support Pedestal.
A. Install horizontal lift fixture, 1C9625, as follows (figure 6):
(1) Attach 15 ton (13,608 kg) hoist onto horizontal lift fixture, 1C9625.
WARNING

WARNING
CG measurement.
(3) Position horizontal lift fixture, 1C9625, over gas turbine. Secure lift fixture clevis, 1C9625P09, onto
rear mounts on TRF using quick-release pins.
(4) Position horizontal lift fixture, 1C9625, front frame adapter onto front frame forward lift point.
Install quick-release pin.
CAUTION
B. Remove fuel manifold support fixture assembly per WP 3015 00.
C. Remove VIGV support ring, 1C9371, as follows (figure 9):
(1) Adjust support pedestal adjusting nuts to allow quick-release pins to rotate freely. Remove
quick-release pins.
(2) Attach 1 ton (907 kg) hoist and lift sling, MSE-53, to VIGV support ring, 1C9371. Take up slack on
hoist.

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WARNING

(3) Remove capscrews and washers from ring assembly. Remove ring assembly.
D. Remove LPC forward support adapters, 1C9377, as follows (figure 8):
(1) Adjust support pedestal adjusting nuts to allow quick-release pins to rotate freely. Remove
quick-release pins. Remove pedestals.
(2) Remove bolts, washers, and nuts that secure LPC forward support adapters, 1C9377, onto LPC case.
Remove LPC support adapters.
E. Remove CRF support jack assembly, 1C9448, as follows (figure 7):
(1) Adjust CRF support jack assembly, 1C9448, rod-end nut to release pressure on CRF.
(2) Adjust CRF support jack assembly, 1C9448, adjusting nut until CRF cradle quick-release pin turns
freely. Remove quick-release pin and CRF cradle.
(3) Remove bolts and nuts that secure CRF support jack assembly, 1C9448, to support pedestal,
9448M54. Remove support jack.
F. Remove CRF support, 1C9448M84, as follows (figure 5):
(1) Adjust support pedestal adjusting nut to release tension on mount pins. Pins shall rotate freely.
Remove quick-release pins. Remove mount pins.
G. Remove air collector support pedestals as follows (figure 4):
(1) Turn support pedestal yoke to allow quick-release pin to rotate freely.
(2) Remove quick-release pin.
H. Remove locknuts that secure gas turbine trunnions onto trunnion adapters on support pedestals,
9448M53P02 (figure 3).
I. Lift gas turbine free of support pedestals.

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GAS TURBINE IN SHIPPING CONTAINER REPLACEMENT
())(&7,9,7</03)*$6785%,1(02'(/6

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18 Blank.................................................................................................................................................. 0
Alphabetical Index
Subject Page
Gas Turbine Installation into Shipping Container................................................................................... 12

Gas Turbine Removal from Shipping Container...................................................................................... 4

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1. Introduction.
This work package contains instructions for removing and installing the gas turbine in the shipping container.
Refer to paragraph 3 for a list of applicable shipping container part numbers.
Title Number

Dolly Assembly, Gas Turbine Changeout 1C9354G03
Container, Shipping and Storage - Gas Turbine See list below

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Weights and Dimensions of the LM6000 Shipping Containers

LM6000 LM6000
*PA, *PB, PC, *PA, *PB, PC,
LM6000 LM6000 LM6000 PD, PF, PF+, LM6000 PD, PF, PG,
PA PA, PB PA, PB PG, PH *PA, *PB, PC PH
106C7154P01 106C7154P02 106C7154P03 106C7154P04 106C7154P05 106C7154P07

MGW 24,790 lb 27,910 lb 27,660 lb 30,619 lb 30,619 lb 30,819 lb
11,245 kg 12,660 kg 12,546 kg 13,892 kg 13,892 kg 13,983 kg
TARE 10,220 lb 10,619 lb 10,369 lb 10,619 lb 10,619 lb 10,819 lb
4,636 kg 4,817 kg 4,703 kg 4,817 kg 4,817 kg 4,907 kg
NET 14,570 lb 17,291 lb 17,291 lb 20,000 lb 20,000 lb 20,000 lb
6,609 kg 7,843 kg 7,843 kg 9,072 kg 9,072 kg 9,072 kg
CUBE 1224 cu ft 1274 cu ft 1224 cu ft 1274 cu ft 1274 cu ft 1274 cu ft
35 cu m 36 cu m 35 cu m 36 cu m 36 cu m 36 cu m
WIDTH 8.5 ft 8.5 ft 8.5 ft 8.5 ft 8.5 ft 8.5 ft
2.6 m 2.6 m 2.6 m 2.6 m 2.6 m 2.6 m
HEIGHT 8.3 ft 8.3 ft 8.3 ft 8.3 ft 8.3 ft 8.3 ft
2.5 m 2.5 m 2.5 m 2.5 m 2.5 m 2.5 m
LENGTH **17.5 ft ***18.2 ft **17.5 ft ***18.2 ft ***18.2 ft ***18.2 ft
5.3 m 5.6 m 5.3 m 5.6 m 5.6 m 5.6 m
* Uprate Engines **210.0 inches (533 cm) ***220.0 inches (559 cm)
NOTE
The installation of an air ride (soft ride) kit adds approximately 2000 lb (907 kg) to the weight, and
48 inches (122 cm) to the length, of a container.
Desiccant MIL-D-3464
None required.

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6. Gas Turbine Removal from Shipping Container.
A. Prepare shipping container for gas turbine removal as follows:

WARNING
RELEASE PRESSURE FROM SHIPPING CONTAINER TO PREVENT INJURY
WHEN SEPARATING CONTAINER HALVES.
CAUTION
ENSURE CRANE IS OF SUFFICIENT LIFTING CAPACITY WHEN MOVING
SHIPPING CONTAINER WITH ENGINE INSTALLED, INTO AND OUT OF
TRUCK.
(1) Depressurize shipping container by pressing button located in center of relief valve (figure 1).
(2) Rotate tee bolts so that boltheads drop into lower flange recess (figure 2).
(3) Attach 4 ton (3629 kg) hoist and sling to two lifting rings along top center of lid. Attach two control
lines to opposite ends of lid.
WARNING

(4) Raise lid straight up until clear of gas turbine and place on wood blocks. Remove hoist and sling.
(5) Lower four corner posts (figure 3).
B. Remove gas turbine from shipping container as follows:
(1) Remove five bolts and nuts from air collector lower forward flange on each side (figure 4).
(2) Remove two aft bolts that secure No. 1 electrical interface panel onto support bracket. Loosen
forward bolt on support bracket and swing bracket clear of air collector flange.
(3) Using five bolts, install air collector support adapters, 1C9375, onto air collector lower forward
flange. Tighten bolts to 483-567 lb in. (54.6-64.0 N·m) of torque (figure 5).
WARNING
(4) Attach 15 ton (13608 kg) hoist onto horizontal lift fixture, 1C9625.
center of gravity (CG) measurement.

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Figure 1. Shipping Container Pressure Relief Valves

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Figure 2. Shipping Container Base

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Figure 3. Shipping Container

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Figure 4. No. 1 Electrical Interface Panel Support Bracket
clevis, 1C9625P09, onto rear mounts on turbine rear frame (figure 6).
CAUTION
(9) Remove nuts, lockwashers, and flat washers from trunnions (figure 7).
(10) Remove four bolts and lockwashers that secure upper pillow blocks. Remove upper pillow blocks
(figure 3).
(11) Apply sufficient lifting force on hoist to allow gas turbine to float in rear mounts. Rear mount pins
shall turn freely.

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Figure 5. Mounting Hardware

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Figure 6. Horizontal Lift Fixture and Changeout Dolly

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Figure 7. Trunnion Mount
WARNING

WARNING

CAUTION

COMPONENTS WHILE GAS TURBINE IS BEING RAISED. GAS TURBINE
DAMAGE MAY RESULT.
(12) Remove rear mount pins and raise gas turbine clear of container.

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C. Install gas turbine into changeout dolly, 1C9354, as follows:
WARNING

(1) Slowly lower gas turbine into changeout dolly, 1C9354. Align air collector support adapters,
1C9375, with changeout dolly forward supports. Install quick-release pin on both sides (figure 5).
(2) Push right rear support clevis pin inboard and align with turbine rear mount. Install mount pin.
Install quick-release pin through mount pin. Install quick-release pin through rear mount support
and clevis pin.
(3) Push left rear support clevis pin inboard and align with turbine rear mount by adjusting support.
Install mount pin. Install quick-release pin through mount pin. Install quick-release pin through rear
mount support and clevis pin.
(4) Position horizontal lift fixture, 1C9625, trolley at CG. Slowly release tension on hoist until lift
fixture pins rotate freely.
WARNING

(5) Remove two turbine rear frame fixture quick-release pins. Remove forward lift point quick-release
pin. Raise horizontal lift fixture, 1C9625, clear of gas turbine.
(6) Remove straight pin, washers, and cotter pin from turbine rear frame sway mount (figure 8).
7. Gas Turbine Installation into Shipping Container.
CAUTION
ENSURE CRANE IS OF SUFFICIENT LIFTING CAPACITY WHEN MOVING SHIPPING
CONTAINER WITH ENGINE INSTALLED, INTO AND OUT OF TRUCK.
NOTE
• Prior to installation of the gas turbine into the shipping container the fuel system must be drained
and purged according to the procedure in WP 3010 00.
• Prior to installation of gas turbine into the shipping container, make sure appropriate shipping
container is being used. Refer to paragraph 3 for a list of applicable shipping container part
numbers.

/03) *(.
:3
Figure 8. Turbine Rear Frame Sway Mount

*(. /03)
:3
A. Prepare shipping container (refer to paragraph 3 for applicable part numbers) for gas turbine installation as
follows:
(1) Remove four bolts and lockwashers that secure trunnion mount upper pillow blocks. Remove upper
pillow blocks (figure 3).
(2) Loosen four bolts that secure trunnion mount lower pillow blocks, to provide for lateral adjustment.
(3) Position aft mount links outboard. Loosen right mount link jamnut.
(4) Lower four corner posts.
(5) Position aft mount links to proper position (farthest aft location).
B. Remove gas turbine from changeout dolly, 1C9354, as follows:
(1) Install sway mount straight pin, washers, and cotter pin into turbine rear frame 6:00 o’clock
position. One washer under pinhead, one washer under cotter pin (figure 8).
WARNING

(2) Attach 15 ton (13608 kg) hoist to horizontal lift fixture, 1C9625. Raise fixture to working height.
Level fixture by adjusting trolley. Record CG measurement.
clevis, 1C9625P09, onto rear mounts on turbine rear frame (figure 6).
CAUTION

/03) *(.
:3
WARNING
ENSURE HOIST AND LIFT FIXTURE ARE ALIGNED BEFORE REMOVING

CHANGEOUT DOLLY MOUNT PINS. FAILURE TO COMPLY MAY RESULT IN
GAS TURBINE SHIFTING CAUSING SERIOUS INJURY.
WARNING
ENSURE MOUNT PINS TURN FREELY BEFORE REMOVING.
(6) Apply sufficient lifting force on hoist to allow gas turbine to float in mounts. Mount pins shall turn
freely.
(7) Remove air collector support adapter quick-release pins (figure 5).
(8) Remove quick-release pins that secure mount pins onto turbine rear frame. Remove mount pins.
(9) Remove quick-release pins that secure clevis pins onto support. Pull clevis pins outboard for
maximum clearance.
WARNING

(10) Raise gas turbine clear of changeout dolly, 1C9354.
C. Install gas turbine into shipping container as follows:
CAUTION

COMPONENTS WHILE GAS TURBINE IS BEING LOWERED INTO
CONTAINER, OR GAS TURBINE DAMAGE MAY RESULT.
CAUTION
Prior to installation of gas turbine into the shipping container, make sure appropriate
shipping container is being used. Refer to paragraph 3 for a list of applicable shipping
container part numbers.
(1) Lower gas turbine into shipping container. Align trunnion mounts with lower pillow blocks. Align
aft mount links with turbine rear frame mounts (figure 3).
(2) Install left rear mount pin, washers, and cotter pin. One washer under pinhead, one washer under
cotter pin. Secure pin with cotter pin.
(3) Adjust right rear mount link, as required, until mount pin can be inserted freely. Install mount pin,
washers, and cotter pin. One washer under pinhead, one washer under cotter pin. Secure pin with
cotter pin. Hand-tighten adjustable link jamnut.
(4) Slowly release tension on hoist.

*(. /03)
:3
(5) Using four bolts and lockwashers, install upper pillow blocks. Tighten bolts to 50-70 lb ft
(6) Install flat washers, lockwashers, and nuts onto gas turbine trunnions. Tighten nuts to 200-250 lb ft
(7) Tighten lower pillow block bolts to 50-70 lb ft (68-94 N·m) of torque.
(8) Position horizontal lift fixture, 1C9625, trolley at CG. Slowly apply sufficient lifting force to allow
lift fixture pins to rotate freely.
WARNING
WARNING
(9) Remove two turbine rear frame lift fixture quick-release pins. Remove forward lift point
quick-release pin. Raise lift fixture clear of gas turbine.
(10) Remove five bolts that secure air collector support adapters, 1C9375, onto air collector lower
forward flange. Remove support adapters.
(11) Position No. 1 electrical interface panel support bracket. Secure bracket onto air collector with two
bolts and nuts. Tighten nuts finger-tight. Install eight remaining bolts and nuts onto air collector
forward flange. Tighten eight air collector nuts to 483-567 lb in. (54.6-64.0 N·m) of torque.
(12) Install two bolts that secure No. 1 electrical interface panel onto support bracket. Tighten three bolts
to 57-67 lb in. (6.5-7.5 N·m) of torque. Tighten two nuts that secure bracket onto air collector to
483-567 lb in. (54.6-64.0 N·m) of torque.

/03) *(.
:3
D. Install shipping container cover as follows:
(1) Raise four corner posts.
(2) Fill desiccant container, as required.
(3) Ensure flange and gasket on enclosure base are clean and serviceable.
NOTE
• Ensure tee bolts are aligned in recess and nuts have been loosened prior to installing
the lid on the shipping container.
• Up to two tee bolts per side (eight total) can be missing, provided missing tee bolt
locations are not adjacent and are not at the corners.
(4) Attach 4 ton (3629 kg) hoist and sling to two lifting rings at top of lid. Attach two control lines to
opposite ends of lid.
(5) Lower lid straight down over gas turbine, aligning forward and aft guide pins. Ensure flanges seat.
(6) Remove hoist, sling, and guide ropes.
(7) Rotate tee bolts until long side of bolthead is perpendicular to flange. Tighten tee bolt nuts to
428-502 lb in. (48.4-56.7 N·m) of torque. Re-torque tee bolts to 428-502 lb in. (48.4-56.7 N·m) of
torque. Continue to re-torque until all tee bolts are tightened to 428-502 lb in. (48.4-56.7 N·m) of
torque (figure 2).
%ODQN
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GAS AND DUAL FUEL MANIFOLD SUPPORT FIXTURE
REPLACEMENT
())(&7,9,7</03)*$6785%,1(02'(/6

Page No. Change No.
1 - 12 ................................................................................................................................................................ 0
Alphabetical Index
Subject Page
Dual Fuel System Support Fixture, 1C9621G03, Installation. ................................................................. 10
Dual Fuel System Support Fixture, 1C9621G03, Removal...................................................................... 8
Gas System Support Fixture, 1C9621G01, Installation. ........................................................................... 6
Gas System Support Fixture, 1C9621G01, Removal................................................................................ 3
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1. Introduction.
This work package contains instructions for removing and installing the dual fuel manifold support fixture.
2. Reference Material
Title Number
3. Support Equipment
NOTE
Support fixture, 1C9621G01, can only be used on gas turbines with a gas
fuel system. The support fixture, 1C9621G03, can be used for either gas
turbines with a gas fuel system or a dual fuel system.

Fixture, Support - Dual Fuel Manifold (gas system support fixture) 1C9621G01
(Gas Systems Only)
Fixture, Support - Dual Fuel Manifold (dual fuel system support 1C9621G03
fixture) (Gas Only and Dual Fuel Systems)
None required.
None required.
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6. Gas System Support Fixture, 1C9621G01, Removal.
A. Disassemble gas system support fixture as follows (figure 1):
(1) Remove eight capscrews (25, figure 1, sheet 2), washers (26), and nuts (27) that secure left side rail
(22) and right side rail (14) onto left side valve rack (23) and right side valve rack (24).
(2) Attach hoist to crossover bar (1, figure 1, sheet 1) and take up slack.
(3) Attach hoist to left side rail (22).
(4) Remove capscrew (19), washer (20), and nut (21) that secure left side rail (22) onto crossover bar
(1).
WARNING
USE CORRECT LIFTING EQUIPMENT AND TECHNIQUES. STAY OUT FROM

UNDER SUSPENDED LOADS TO PREVENT INJURY.
(5) Remove capscrew (16), washer (17), and nut (18) that secure left side rail (22) to air collector clevis
(15) and remove left side rail (22).
(6) Attach hoist to right side rail (14).
(7) Remove capscrew (19), washer (20), and nut (21) that secure right side rail (14) to crossover bar (1).
(8) Remove capscrew (16), washer (17), and nut (18) that secure right side rail (14) to air collector
clevis (15) and remove right side rail (14).
(9) Remove three capscrews (7), washers (8), and nuts (9) that secure left support (10), center support
(12), and right support (2) to engine brackets (11), (13), and (6).
(10) Remove capscrew (3), washer (4), and nut (5) that secure left support (10) to crossover bar (1) and
remove left support.
(11) Remove capscrew (3), washer (4), and nut (5) that secure center support (12) to crossover bar (1)
and remove center support.
(12) Remove capscrew (3), washer (4), and nut (5) that secure right support (2) to crossover bar (1) and
remove right support.
(13) Remove crossover bar (1).
B. Install all removed tubing onto compressor rear frame (CRF) per SWP 1913 02.
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Figure 1. Support Fixture, 1C9621 (Sheet 1 of 2)
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Figure 1. Support Fixture, 1C9621 (Sheet 2 of 2)
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7. Gas System Support Fixture, 1C9621G01, Installation.
A. Remove required tubing from compressor rear frame (CRF) per SWP 1913 02, before installing gas system
support fixture.
CAUTION
DO NOT OPERATE ENGINE WITH GAS SYSTEM SUPPORT FIXTURE INSTALLED, OR
SEVERE DAMAGE TO THE MANIFOLD HOSES OR TUBES MAY RESULT.
NOTE
• Orientation of tubes are metal stamped on each tube to assist assembly of fixture.
• Numbers are metal stamped at joints of interfacing supports on crossover bar to assist in assembly
of parts.
B. Assemble gas system support fixture as follows (figure 1):
(1) Install lifteye onto crossover bar (1, figure 1, sheet 1).
WARNING
(2) Position crossover bar (1), per metal stampings on bar, and lift bar over mid-compressor flange.
(3) Position top end of right support (2) with end stamped 6 into clevis plate (with 6 stamped on it) of
crossover bar (1), and install capscrew (3), washer (4), and nut (5). Hand-tighten.
(4) Install bottom end of right support (2) onto aft side of lower hole of engine bracket (6) with
capscrew (7), washer (8), and nut (9). Hand-tighten.
(5) Position top end of left support (10) with end stamped 5 into clevis plate (with 5 stamped on it) of
(6) Install bottom end of left support (10) onto aft side of lower hole of engine bracket (11) with
(7) Position top end of center support (12) with end stamped 7 into clevis plate (with 7 stamped on it) of
crossover bar (1), and install with capscrew (3), washer (4), and nut (5). Hand-tighten.
(8) Install bottom end of center support (12) onto aft side of lower hole of engine bracket (13) with
(9) Tighten bottom capscrews (7) of right support (2), left support (10), and center support (12) to 20 lb
ft (27 N·m) of torque.
(10) Install lifteye onto right side rail (14).
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WARNING

(11) Position right side rail (14, figure 1, sheet 2) onto air collector clevis (15), and install with capscrew
(16), washer (17), and nut (18). Hand-tighten.
(12) Install right side rail (14, figure 1, sheet 1), onto crossover bar (1) with capscrew (19), washer (20),
and nut (21). Hand-tighten.
(13) Install lifteye onto left side rail (22).
(14) Position left side rail (22) onto air collector clevis (15), and install with capscrew (16), washer (17),
and nut (18). Hand-tighten.
(15) Install left side rail (22) onto crossover bar (1) with capscrew (19), washer (20), and nut (21). Hand-
tighten.
(16) Measure rectangle from corner to corner (diagonally) to ensure perpendicularity.
(17) Tighten capscrews (3) to 133-157 lb in. (15.1-17.7 N·m) of torque.
(18) Tighten capscrews (16) to 300-340 lb ft (407-460 N·m) of torque.
NOTE
Thick washers (26) are used between the screwhead and valve rack to distribute load.
(20) Attach left side rail (22) and right side rail (14) onto left side valve rack (23) and right side valve
rack (24) with eight capscrews (25, figure 1, sheet 2) (screwheads down), washers (26) (under
screwhead), and nuts (27). Tighten capscrews to 428-502 lb in. (48.4-56.7 N·m) of torque.
81&21752//(':+(135,17('2575$160,77('(/(&7521,&$//<
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8. Dual Fuel System Support Fixture, 1C9621G03, Removal.
A. Disassemble dual fuel system support fixture hardware as follows:
(1) Remove four capscrews (37, figure 1, sheet 2), washers (4), and nuts (5) that secure manifold frame
braces (36) to bracket (35) and brackets on right and left side frame rails (14 and 22). Remove
manifold frame braces.
(2) Remove four capscrews (29), washers (4), and nuts (5) that secure brackets (35) to right and left
sides of manifold support frame (28). Remove brackets.
(3) Remove four capscrews (34), washers (4), and nuts (5) that secure lateral braces (32 and 33,
figure 1, sheet 1) to brackets (30 and 31) and engine brackets (38 and 39). Remove lateral braces.
(4) Remove four capscrews (29), washers (4), and nuts (5) that secure brackets (30 and 31) to manifold
support frame (28). Remove brackets.
(5) Remove four capscrews (29), washers (4), and nuts (5) that secure manifold support frame (28) to
brackets on right and left side rails (14 and 22). Remove manifold support frame.
(6) Follow step B for dual fuel system support fixture removal.
B. Disassemble dual fuel system support fixture as follows:
(1) Remove eight capscrews (25, figure 1, sheet 2), washers (26), and nuts (27) that secure left side rail
(22) and right side rail (14) onto left side valve rack (23) and right side valve rack (24).
(2) Attach hoist to crossover bar (1, figure 1, sheet 2) and take up slack.
(3) Attach hoist to left side rail (22).
(4) Remove capscrew (19), washer (20), and nut (21) that secure left side rail (22) onto crossover bar
(1).
WARNING
(5) Remove capscrew (16), washer (17), and nut (18) that secure left side rail (22) to air collector clevis
(15) and remove left side rail (22).
(6) Attach hoist to right side rail (14).
(7) Remove capscrew (19), washer (20), and nut (21) that secure right side rail (14) to crossover bar (1).
(8) Remove capscrew (16), washer (17), and nut (18) that secure right side rail (14) to air collector
clevis (15) and remove right side rail (14).
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(9) Remove three capscrews (7), washers (8), and nuts (9) that secure left support (10), center support
(12), and right support (2) to engine brackets (11), (13), and (6).
(10) Remove capscrew (3), washer (4), and nut (5) that secure left support (10) to crossover bar (1) and
remove left support.
(11) Remove capscrew (3), washer (4), and nut (5) that secure center support (12) to crossover bar (1)
and remove center support.
(12) Remove capscrew (3), washer (4), and nut (5) that secure right support (2) to crossover bar (1) and
remove right support.
(13) Remove crossover bar (1).
C. Install all removed tubing onto compressor rear frame (CRF) per SWP 1913 02.
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9. Dual Fuel System Support Fixture, 1C9621G03, Installation.
A. Remove required tubing from compressor rear frame (CRF) per SWP 1913 02, before installing dual fuel
system support fixture.
CAUTION
DO NOT OPERATE ENGINE WITH SUPPORT FIXTURE INSTALLED, OR SEVERE
DAMAGE TO THE MANIFOLD HOSES OR TUBES MAY RESULT.
NOTE
• Orientation of tubes are metal stamped on each tube to assist assembly of fixture.
• Numbers are metal stamped at joints of interfacing supports on crossover bar to assist in assembly
of parts.
B. Assemble dual fuel system support fixture as follows:
(1) Install lifteye onto crossover bar (1, figure 1, sheet 1).
WARNING
(2) Using hoist, position crossover bar (1) per metal stampings on bar and lift bar over mid-compressor
flange.
(3) Position top end of right support (2) with end stamped 6 into clevis plate (with 6 stamped on it) of
(4) Install bottom end of right support (2) onto aft side of lower hole of engine bracket (6) with
(5) Position top end of left support (10) with end stamped 5 into clevis plate (with 5 stamped on it) of
(6) Install bottom end of left support (10) onto aft side of lower hole of engine bracket (11) with
(7) Position top end of center support (12) with end stamped 7 into clevis plate (with 7 stamped on it) of
crossover bar (1), and install with capscrew (3), washer (4), and nut (5). Hand-tighten.
(8) Install bottom end of center support (12) onto aft side of lower hole of engine bracket (13) with
(9) Tighten bottom capscrews (7) of right support (2), left support (10), and center support (12) to 20 lb
ft (27 N·m) of torque. Remove hoist.
(10) Install lifteye onto right side rail (14).

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WARNING

(11) Using hoist, position right side rail (14, figure 1, sheet 2) onto air collector clevis (15), and install
with capscrew (16), washer (17), and nut (18). Hand-tighten.
(12) Install right side rail (14, figure 1, sheet 1), onto crossover bar (1) with capscrew (19), washer (20),
and nut (21). Hand-tighten. Remove hoist.
(13) Install lifteye onto left side rail (22).
(14) Using hoist, position left side rail (22) onto air collector clevis (15), and install with capscrew (16),
washer (17), and nut (18). Hand-tighten.
(15) Install left side rail (22) onto crossover bar (1) with capscrew (19), washer (20), and nut (21). Hand-
tighten. Remove hoist.
(16) Measure rectangle from corner to corner (diagonally) to ensure perpendicularity.
(18) Tighten capscrews (16) to 300-340 lb ft (407-460 N·m) of torque.
NOTE
Thick washers (26) are used between the screwhead and valve rack to distribute load.
(20) Attach left side rail (22) and right side rail (14) onto left side valve rack (23) and right side valve
rack (24) with eight capscrews (25, figure 1, sheet 2) (screwheads down), washers (26) (under
screwhead), and nuts (27). Tighten capscrews to 428-502 lb in. (48.4-56.7 N·m) of torque.
C. Assemble dual fuel system support fixture hardware as follows:
(1) Attach manifold support frame (28) to brackets on right and left side rails (14 and 22) with four
capscrews (29), washers (4), and nuts (5). Hand-tighten.
(2) Attach brackets (30 and 31) to manifold support frame (28) with two capscrews (29), washers (4),
and nuts (5). Hand-tighten.
(3) Attach lateral braces (32 and 33) with end marked TO LIQUID MANIFOLD BRACKET to
brackets (30 and 31) and other end of braces to engine brackets (38 and 39) with capscrews (34),
washers (4), and nuts (5). Hand-tighten.
(4) Attach two brackets (35) to right and left sides of support frame (28) with capscrews (29), washers
(4), and nuts (5). Hand-tighten.
(5) Attach two manifold frame braces (36) to brackets (35) and brackets on right and left side rails (14
and 22) with capscrews (37), washers (4), and nuts (5). Hand-tighten.

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(6) Inspect manifold support frame (28) to ensure correct position.
(7) Tighten capscrews (29) to 428-502 lb in. (48.4-56.7 N·m) of torque in the following sequence:
(a) Capscrews (29) attaching brackets (35) to manifold support frame (28).
(b) Capscrews (29) attaching manifold support frame (28) to brackets on side rails (14 and 22).
(c) Capscrews (37) attaching frame braces (36) to brackets (35) and brackets on right and left side
rails (14 and 22).
(d) Capscrews (29) attaching bracket (31) to manifold support frame (28).
(e) Capscrews (34) attaching right lateral brace (32) to bracket (31) and engine bracket (39).
(f) Capscrews (34) attaching left lateral brace (33) to bracket (30) and engine bracket (38).
(g) Capscrews (29) attaching bracket (30) to manifold support frame (28).

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GAS TURBINE INLET INSPECTION
())(&7,9,7</03)*$6785%,1(02'(/6

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10 Blank ................................................................................................................................................... 0
Alphabetical Index
Subject Page
Gas Turbine Inlet Inspection. ................................................................................................................... 3
*(. /03)
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1. Introduction.
This work package contains instructions for inspecting the gas turbine inlet.
Title Number
Borescope Inspection WP 4015 00
None required.
None required.
None required.
/03) *(.
:3
6. Gas Turbine Inlet Inspection.
WARNING
• GAS TURBINE SHALL NOT BE OPERATING AND SHALL BE VERIFIED AS

INOPERABLE. IF POSSIBLE, LOCK OUT SYSTEM SO IT CANNOT BE ROTATED.
• A SAFETY OBSERVER SHALL BE STATIONED ADJACENT TO THE INLET ACCESS.
CAUTION
EMPTY POCKETS BEFORE ENTERING INLET TO ENSURE NO LOOSE OBJECTS ARE

LEFT IN THE INLET.
A. Before accessing inlet, do the following:
(1) Verify gas turbine will be inoperable during inspection.
(2) Shut off main fuel inlet valve per packager’s manual.
(3) Deactivate fire extinguishing system per packager’s manual.
(4) Station safety observer adjacent to inlet access.
(5) Secure enclosure door so that it will remain open. Enclosure door shall remain open.
B. Access inlet plenum through access hatch or inlet duct access per packager’s manual.
NOTE
Some items in table 1 can be inspected only if the gas turbine is removed. If the gas turbine is installed,
inspection will be limited to accessible items only.
C. Using bright light, visually inspect gas turbine inlet per table 1 figure 1, and figure 2.
D. If evidence of foreign object damage (FOD) is found, perform borescope inspection of low pressure
compressor (LPC) and high pressure compressor (HPC) sections per WP 4015 00.
CAUTION

E. Before exiting the enclosure, perform a thorough, final inspection for possible foreign objects.
F. Secure inlet duct access per packager’s manual.
G. Activate the fire extinguishing system per packager's manual and close enclosure door.
*(. /03)
:3
Figure 1. Gas Turbine Inlet Inspection
/03) *(.
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Figure 2. LPC Rotor Blade Inspection Criteria
*(. /03)
:3
Table 1. Gas Turbine Inlet Inspection

On-Site On-Site
Max Serviceable Max Repairable On-Site
Inspect Limits Limits Corrective Action
NOTE
Some of the following items can be inspected only if the gas turbine is removed. If the gas turbine is
installed, inspection will be limited to accessible items only.
1. Inlet Duct or Bellmouth Assembly for:

a. Damage – – Refer to packager’s
manual for limits
and corrective action
b. Plugged water-wash None allowed Any amount Remove
discharge holes contamination per
packager’s manual
c. Dirty airflow path None allowed Any amount Wipe clean if inlet
surfaces screen has been
removed
d. Loose installation None allowed Any amount Tighten fasteners per
fasteners packager’s manual
2. Centerbody Assembly for:
a. Cracks None allowed Not repairable Replace centerbody
b. Nicks and scratches Any number, any Any number, Blend to remove
length, 0.030 in. 0.060 in. (1.52 mm) high metal
(0.76 mm) deep, deep, 0.060 in.
0.030 in. (0.76 mm) (1.52 mm) wide, and
wide, 1.00 in. 0.050 in. (1.27 mm)
(25.4 mm) separation long, provided none
extend into boltholes
c. Missing paint Any amount, if no Any amount Touch up paint
exposed parent metal
d. Dirty airflow path None allowed Any amount Wipe clean if inlet
surfaces screen has been
removed
e. Loose bolts None allowed Any amount Tighten bolts
3. Inlet FOD Sock for:
a. Tears and holes None allowed Any amount Replace sock per
packager’s manual
b. Build up of debris and None allowed Any amount Clean
deposits
/03) *(.
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Table 1. Gas Turbine Inlet Inspection (Continued)

On-Site On-Site
c. Coverage and security of No missing coverage Any amount Cover and secure
sock across entire screen allowed, no non- sock across entire
secure areas allowed screen per
packager’s manual
4. Inlet FOD Screen for:
a. Damage and corrosion - - Refer to packager’s
manual for limits
b. Cracked, broken, or None allowed Any amount Replace screen per
missing pieces packager’s manual
c. Coverage and security of No missing coverage Any amount Cover and secure
screen across entire inlet allowed, no non- screen across entire
area secure areas allowed inlet area per
packager’s manual
5. Baffles for:
a. Cracks, tears, and – – Refer to packager’s
damage manual for limits
b. Loose fasteners None allowed Any amount Tighten fasteners
c. Contact with variable None allowed Any amount Reposition baffles to
inlet guide vane (VIGV) provide proper
case clearance per
packager’s manual
6. Seals for:
a. Cracks, tears, and – – Refer to packager's
damage manual for limits
b. Loose fasteners None allowed Any amount Tighten fasteners
7. LPC Inlet Temperature/Pressure (T2/P2) Sensor for:
a. Damage None allowed Not repairable Replace sensor
b. Security No looseness allowed Any amount Tighten connections/
fasteners
c. Obstructions None allowed Any amount Clear obstructions
d. Buildup of deposits None allowed Any amount Wipe clean
*(. /03)
:3

On-Site On-Site
NOTE
If VIGV installed, inspect per step 7. If inlet frame assembly installed, inspect per step 8.
8. VIGV and Flaps for:

a. Cracks None allowed Not repairable Replace VIGV
assembly
b. Dents and nicks TBP TBP –
c. Deleted
d. Dirt, salt, or industrial None allowed Any amount Wipe clean if
deposits accessible
8A. VIGV Flaps for:
a. Radial movement (1) All flaps with (a) Any single flap (a) Inspect inner
movement of with movement and outer cases for
0.030 in. (0.76 mm) greater than case rub per
or less 0.030 in. (0.76 mm) step 8B.
but less than
0.050 in. (1.27 mm)
(b) Any single flap (b) Replace VIGV
with movement assembly or return
greater than to Depot
0.050 in. (1.27 mm),
not repairable
8B. Inner and Outer Cases for:
a. Inner case rub due to 0.015 in. (0.38 mm) Greater than Replace VIGV
loose flaps or less deep 0.015 in. assembly or return
(0.38 mm), not to Depot
repairable
b. Outer case rub due to 0.030 in. (0.76 mm) Greater than Replace VIGV
loose flaps or less deep 0.030 in. assembly or return
(0.76 mm), not to Depot
repairable
9. Inlet Frame Assembly for:
assembly
c. Loose flap TBP TBP –
deposits accessible
/03) *(.
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On-Site On-Site
10.Inlet Frame Assembly for:
assembly
c. Loose flap TBP TBP –
deposits accessible
11.LPC Stage 0 Rotor Blades for (figure 2):
a. Cracks None allowed Not repairable Replace blade
b. Chips, crush, nicks, None allowed Not repairable Replace blade
dents, and scratches in
root area
c. Chips and crush in Any number, Not repairable Replace blade
leading and trailing 0.025 in. (0.64 mm)
edges, except root area deep
d. Scratches on leading and Any number, Not repairable Replace blade
trailing edges, except root 0.005 in. (0.13 mm)
area deep, 0.050 in.
(1.27 mm) long
e. Nicks and dents on Any number, Not repairable Replace blade
leading and trailing 0.005 in. (0.13 mm)
edges, except root area deep, 0.125 in.
(3.18 mm) diameter
f. Tip curl Not more than Not repairable Replace blade
0.250 in. (6.35 mm)
of original blade tip
width
g. Pits and erosion, except Any number, Not repairable Replace blade
in root area 0.005 in. (0.13 mm)
deep, any diameter,
any spacing
h. Dirt, salt, or industrial None allowed Any amount Wipe clean if
deposits accessible
%ODQN
/03) *(.
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EXTERNAL ENGINE CLEANING
())(&7,9,7</03)*$6785%,1(02'(/6

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Alphabetical Index
Subject Page
External Engine Cleaning. ....................................................................................................................... 3
*(. /03)
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1. Introduction.
This work package contains instructions for cleaning the external engine surfaces.
Title Number
Gas Turbine Water-Wash WP 4014 00
None required.
None required.
None required.
/03) *(.
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6. External Engine Cleaning.
WARNING

FITTINGS.
NOTE
If available, portable steam cleaning equipment may be used.
A. Wash external engine and components with 50-60 gallons (190-227 liters) of clean water using a flexible
hose with adjustable spray nozzle. Maintain water pressure of 40-45 psi (276-310 kPa).
B. If water will not remove dirt, apply water-wash solution per WP 4014 00 and allow to soak for 2 hours
minimum. Flush with clean water.
C. Start engine and operate at idle speed 5 minutes to dry excessive water.
%ODQN
/03) *(.
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GAS TURBINE EXTERNAL INSPECTION (VISUAL)
())(&7,9,7</03)*$6785%,1(02'(/6

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Alphabetical Index
Subject Page
Gas Turbine External Inspection (Visual). ............................................................................................... 3
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1. Introduction.
A. This work package contains instructions for performing a visual external inspection of LM6000 gas
turbine.
B. Replace electrical leads and connecting tubes on gas turbine, as required, per SWP 1913 03.
Title Number
Variable Stator Vane (VSV) Stages 3 to 5 Bushing WP 1412 00
Replacement High-Boss HPC Stator Case)
High Pressure Compressor (HPC) Stator Vanes Replacement WP 2412 00

None required.
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6. Gas Turbine External Inspection (Visual).
A. Inspect tubing, hoses, and electrical harnesses per table 1.
Table 1. Tubing, Hoses, and Electrical Harnesses Inspection

1. Tubing for:
a. Cracks or splits None allowed Not repairable Replace tube*
b. Wrinkles or kinks 2 percent of tube OD Not repairable Replace tube*
in bend ID
c. Dents and flat areas Any amount of deviation Not repairable Replace tube*
from contour, within
20 percent of original tube
OD
d. Nicks or scores Any number, 0.005 in. Any amount, Blend to remove high
(0.12 mm) deep 0.010 in. (0.25 mm) metal. Contour smooth
deep and polish
e. Leaking fittings or None allowed Any amount Light polishing of
connectors entire sealing (mating)
surfaces to remove
scratches. Tighten or
replace tube per
SWP 1913 03
f. Loose fittings or None allowed Any amount Tighten per
connectors SWP 1913 03
g. Attaching cushion None allowed Any amount Replace cushion
clamps for inadequate clamps
clamping
2. Right- and Left-Hand Side Stage 8 LPT Cooling Air Tubes for:
a. Open cracks with Determine length of time Less than 100 hours Replace tube and
visible separation, engine has operated with and orifice is continue engine
misalignment of loss of cooling air 1.375 in. operation
adjacent surfaces, or (34.93 mm) or
missing material larger
resulting in loss of
cooling air
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Table 1. Tubing, Hoses, and Electrical Harnesses Inspection (Continued)

NOTE
Depending on situational circumstances, it may be possible to provide an extension to the 100-hour
limit on operation with ruptured LPT cooling tube. Provide to GE hour and cycle data on operation
of HPT stage 2 disk and LPT stage 1 and 2 disks (with and without ruptured tube). GE will use this
data to determine whether engine removal and disk inspection, required as corrective action for
operation with ruptured tube for greater than 100 hours, can be postponed to coincide with
scheduled maintenance on HPT and LPT.
Greater than Remove engine for
100 hours or orifice inspection of HPT
is less than 1.375 in. stage 2 disk and LPT
(34.93 mm) stage 1 and 2 disks
3. Hoses (except special hoses) for:
a. Broken braid wires Three wires per plait (a Not repairable Replace hose
band of interwoven wires)
and no more than six
broken wires per assembly
b. Crimps None allowed Not repairable Replace hose
c. Leaking fittings or None allowed Any amount Light polishing of
connectors entire sealing (mating)
surfaces to remove
scratches. Tighten or
replace assembly per
SWP 1913 03
d. Loose fittings or None allowed Any amount Tighten per
connectors SWP 1913 03
e. Attaching cushion None allowed Any amount Replace cushion
clamps for inadequate clamps
clamping
4. Fuel Hoses (Natural Gas and Primary/Secondary Fuel Supply Hoses) for:
a. Broken braid wires Three wires per plait (a Not repairable Replace hose
band of interwoven wires)
and no more than six
broken wires per assembly
b. Crimps None allowed Not repairable Replace hose
c. Bulges None allowed Any amount Replace hose
5. Electrical Cables for:
a. Broken braid 50 percent of exterior Not repairable Replace assembly*
braid wires may be
broken, provided circuit
continuity is maintained
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/03) *(.
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b. Kinks/crimps Any amount, provided Not repairable Replace assembly*
circuit continuity is
maintained. Insulation
resistance pin-to-pin and
pin-to-shell shall be
1.0 megohm minimum
c. Security/ installation Clamps must be secure Any amount Correct as required
with no evidence of
abrasion. No relative
motion between cable and
supporting hardware
d. Loose VSV, VBV and None allowed Any amount Remove, clean, and
VIGV electrical inspect for damage or
connectors bent pins. After fully
seating serviceable
connector by hand,
tighten coupling ring
to 70-75 lb in.
(7.9-8.5 N·m) of
torque using strap
wrench (preferred
method). If strap
wrench is not avail-
able, tighten connec-
tor with Teflon-jawed
pliers until slippage
occurs. Check for full
seating by wiggling the
mating connector.
There shall be no
movement with respect
to the interfacing com-
ponents
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e. Loose electrical None allowed Any amount Remove, clean, and
connectors, except inspect for damage or
VSV, VBV and bent pins. After fully
VIGV electrical seating connector by
connectors hand, tighten
connector with Teflon-
jawed pliers until
slippage occurs or
tighten connector with
strap wrench (optional
method). Check for
full seating by
wiggling the mating
connector. There shall
be no movement with
respect to the
interfacing
components
f. Seal damaged or None allowed Any amount Replace seal
missing
g. Braid/ connector 50 percent of wires must Not repairable Replace assembly*
separation be secure and circuit
continuity maintained
h. Bent or distorted pins Must assemble to mating Any amount Straighten pins or
connector replace assembly*
i. Cracked or broken None allowed Not repairable Replace assembly*
pins
j. Corroded pins None allowed Not repairable Replace assembly*
k. Cracked inserts Any amount, provided Not repairable Replace assembly*
continuity is maintained.
Insulation resistance pin-
to-pin and pin-to-shell
shall be 1.0 megohm
minimum
l. Distorted inserts Must assemble to mating Not repairable Replace assembly*
connector and seal
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/03) *(.
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6. Right-Hand Side Upper and Lower Stage 11 HPT Cooling Air Tubes and Left-Hand Side Upper and Lower
Stage 11 HPT Cooling Air Tubes for:
a. Open cracks or Determine length of time Less than 100 hours Replace tube and
missing material engine has operated with continue engine
resulting in loss of loss of cooling air operation
cooling air
Greater than Remove engine for
100 hours inspection of stage 1
and stage 2 HPT disks
*Contact GE Marine and Industrial Customer Service for repair data.
B. Inspect variable inlet guide vane (VIGV) assembly per table 2 and figure 1.
Table 2. VIGV Assembly Inspection

1. VIGV Case or Inlet Frame for:
assembly
b. Nicks, gouges, and TBP – –
scratches
c. Dents Any number with a Any amount Replace VIGV
smooth contour, assembly
0.030 in. (0.76 mm)
deep
d. Damaged anodic Any amount, if parent Up to 5 percent of total Touch up anodic coating
coating metal is not showing surface, providing
damage does not extend
into parent metal
e. Flanges for broken, None allowed Any amount Tighten or replace
loose, or missing damaged hardware
attaching hardware
2. VIGV Actuator for:
a. Leakage None allowed Any amount Tighten or replace
fitting or replace
preformed packing
b. Security No looseness allowed Any amount Tighten or replace
attaching hardware
c. Damaged or worn None allowed Not repairable Replace rod-end bearing
rod-end bearing
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Table 2. VIGV Assembly Inspection (Continued)

3. Actuator Support Brackets for:
a. Cracks None allowed Not repairable Replace bracket
b. Distorted or bent None allowed Not repairable Replace bracket
4. Actuation Brackets for:
b. Distorted or bent None allowed Not repairable Replace bracket
c. Loose, damaged, or None allowed Not repairable Replace bushings or
missing bushings bracket
5. Actuation Ring for:
assembly
b. Nicks, gouges, TBP – –
scratches, and dents
c. Distortion None allowed Not repairable Replace VIGV
assembly
d. Loose, damaged, or None allowed Any amount Replace VIGV
missing bushings assembly
e. Damaged anodic 0.50 in. (12.7 mm) by Any length, 0.250 in. Touch up anodic coating
coating 0.020 in. (0.50 mm), if (6.35 mm) wide, not to
damage does not extend exceed 3 percent of
into parent metal total coated surface
6. Actuator Rigging Bracket for:
b. Distortion or bent None allowed Not repairable Replace bracket
c. Security No looseness allowed Any amount Tighten securing
hardware
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Table 2. VIGV Assembly Inspection (Continued)

7. Vane Lever Arms for:
assembly
b. Distorted or bent None allowed Not repairable Replace VIGV
assembly
c. Damaged or bound Bearing shall rotate Not repairable Replace VIGV
bearing freely in all directions assembly
under finger pressure
d. Security No looseness allowed Any amount Replace or tighten
locknut. Replace or
tighten actuation ring
nut and bolt
8. T2/P2 Sensor for No looseness allowed Any amount Tighten attaching
security hardware
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Figure 1. VIGV Assembly

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C. Inspect low pressure compressor (LPC) per table 3 and figure 2.
Table 3. LPC Inspection

1. LPC Stages 0-3 Case for:
a. Cracks other than None allowed Not repairable Replace stages 0-3
boltholes stator case
b. Cracks at boltholes One, every tenth bolthole in Not repairable Replace stages 0-3
each circumferential flange, stator case
0.250 in. (6.35 mm) long. None
allowed on horizontal flanges
c. Nicks, scores, and Any number, 0.050 in. -- Blend to remove high
scratches (1.27 mm) deep, separated by metal. Contour
0.250 in. (6.35 mm), after smooth and polish
d. Dents Any number with a smooth -- Blend to remove high
contour, 0.060 in. (1.52 mm) metal. Contour
deep smooth and polish
e. Missing anodize Any amount -- --
f. Nicks, dents, None allowed Any amount Blend to remove high
scratches, or scores metal. Contour
on mating flanges or smooth and polish
splitline
g. Loose or missing None allowed Any amount Replace bolts and
bolts and nuts nuts
h. Loss of self-locking None allowed Any amount Replace nut
quality of nuts
2. LPC Stage 4 Case for:
a. Cracks other than None allowed Not repairable Replace stage 4
boltholes stator case
b. Cracks at boltholes One, every tenth bolthole in Not repairable Replace stage 4
each circumferential flange, stator case
0.250 in. (6.35 mm) long
c. Nicks and scratches Any number, 0.050 in. -- Blend to remove high
(1.27 mm) deep, after removal metal. Contour
of high metal, with 0.250 in. smooth and polish
(6.35 mm) separation
d. Dents Any number with a smooth -- Blend to remove high
contour, 0.060 in. (1.52 mm) metal. Contour
deep smooth and polish

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Table 3. LPC Inspection (Continued)

3. No. 1 Electrical Interface Panel for:
a. Cracks None allowed Any amount Replace panel
b. Nicks, scratches, and Any amount, 0.0050 in. Defects not Blend to remove high
scores (0.12 mm) deep exceeding metal. Contour
75 percent of smooth and polish
sheet metal
thickness
c. Dents and distortion Any amount, if proper Any amount Re-form using hand
assembly with mating parts can tools. No cracks
be accomplished allowed
d. Security No looseness allowed Any amount Tighten attaching
bolts per
SWP 1913 03
Figure 2. LPC Case and Front Frame

81&21752//(':+(135,17('2575$160,77('(/(&7521,&$//<
/03) *(.
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D. Inspect air collector per table 4.
Table 4. Air Collector Inspection

1. Aft Flange and Mounts for:
a. Cracks None allowed Not repairable Replace air collector*
b. Distortion None allowed Not repairable Replace air collector*
2. All Other Surfaces for:
a. Cracks Any number, 0.120 in. Not repairable Replace air collector*
(3.04 mm) long,
separated by 2.0 in.
(50.8 mm)
b. Distortion Any amount – –
c. Dents Any amount, 0.50 in. Any amount Re-form to original
(12.7 mm) deep, contour
(101.6 mm), provided
there are no parent
cracks
d. Nicks or scratches Any number, 0.030 in. Any number Blend smooth and
(0.76 mm) deep, touch up paint
(25 mm). No sharp
grooves allowed
e. Corrosion None allowed Any amount Blend smooth and
touch up paint
f. Missing, chipped, or None allowed Any amount Blend smooth and
peeling paint touch up paint
3. Frame Seals for:
a. Tears in rubber None allowed Not repairable Replace frame seal
b. Security No looseness allowed Any amount Tighten attaching
screws
4. Brackets for:
b. Loose, damaged, or None allowed Any amount Replace rivet
missing rivets
c. Security No looseness allowed Any amount Tighten attaching
hardware per
SWP 1913 03
* Contact GE Marine and Industrial Customer Service for repair data.

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E. Inspect the front frame assembly per table 5 and figure 3.

Table 5. Front Frame Inspection
1. Mounts and Trunnions for None allowed Not repairable Replace part
cracks
a. Cracks TBP – –
b. Dents TBP – –
c. Nicks, gouges, and TBP – –
scratches
3. Threaded Pads, Ports, and None allowed One full thread Chase threads
Bosses for damaged cumulative or continuous
threads may be removed
OR
Any amount of thread Install Heli-Coil insert
damage
NOTE
Inspection of any VBV system actuation component requires that the access doors be removed from the air
collector assembly.
4. VBV Actuator for:

a. Leakage None allowed Any amount Replace packing, tighten
fitting, or replace actuator
b. Security No looseness allowed Any amount Tighten attaching hardware
5. VBV Actuator and Bypass Door Rod-End Bearings for:
a. Cracks None allowed Not repairable Replace rod-end bearing
b. Distorted or bent None allowed Not repairable Replace rod-end bearing
c. Damaged or bound None allowed Not repairable Replace rod-end bearing
bearing
6. VBV Actuator and Bypass Door Clevis for:
a. Cracks None allowed Not repairable Replace clevis
b. Distorted or bent None allowed Not repairable Replace clevis
7. VBV Actuator and Bypass Door Bellcranks for:
a. Cracks None allowed Not repairable Replace bellcranks
b. Evidence of binding None allowed Any amount Correct as required
c. Security No looseness allowed Any amount Correct as required

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Table 5. Front Frame Inspection (Continued)

8. VBV Actuation Ring for:
a. Cracks None allowed Not repairable Replace ring
b. Nicks, gouges, TBP – –
scratches, and dents
c. Distortion None allowed Not repairable Replace ring
d. Security No looseness allowed Any amount Correct as required
e. Damaged or missing None allowed Any amount Replace insert
insert
9. VBV Bypass Door Hinges for:
a. Cracks None allowed Not repairable Replace hinge
b. Security No looseness allowed Any amount Correct as required
c. Damaged or missing None allowed Any amount Replace bushing
bushings
10.VBV Bypass Valve Doors for:
a. Cracks None allowed Not repairable Replace door
c. Loose, cracked, or Any amount – –
missing seals
d. Evidence of binding or None allowed Any amount Perform VBV system
misalignment check per WP 1312 00 and
correct as required
11.T25 Sensor for security No looseness allowed Any amount Tighten attaching bolts

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Figure 3. HPC Stator Case Inspection Areas

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F. Inspect transfer gearbox (TGB) assembly per table 6.

Table 6. TGB Assembly Inspection
1. Transfer Gearbox for:
a. Cracks None allowed Not repairable Replace transfer gearbox
b. Nicks, scores, or Any number, any length, – –
scratches on 0.030 in. (0.76 mm) deep
nonmachined
surfaces
c. Leaking plugs or None allowed Any amount Tighten loose fittings or
fittings replace damaged seals
d. Missing or broken None allowed Any amount Replace lockwire
lockwire
2. Gearbox-mounted Accessories for:
a. Security No looseness allowed Any amount Tighten attaching hardware
b. Leakage Any amount Not repairable Replace accessory
3. Mount and Sway Links for:
a. Cracks None allowed Not repairable Replace mount or sway
link
c. Bushings for wear None allowed Not repairable Replace bushings
4. Studs for:
a. Thread damage None allowed Total of 3/4 of one Remove damage with fine
full thread may be file
removed
b. Looseness None allowed Any amount Torque stud one turn. If
still not tight, replace
transfer gearbox
a. Cracks Not serviceable Any amount Replace panel
b. Nicks, scratches, Any number, 0.005 in. Defects not Blend to remove high
and scores (0.13 mm) deep exceeding 75 percent metal. Contour smooth and
of sheet metal polish
thickness
c. Dents and distortion Any number, provided Any amount Re-form using hand tools.
proper assembly with No cracks allowed
mating parts can be
accomplished

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Table 6. TGB Assembly Inspection (Continued)

d. Security No looseness allowed Any amount Tighten attaching hardware
per SWP 1913 03
G. Inspect high pressure compressor (HPC) per table 7, figure 3, and figure 4.
Table 7. HPC Inspection

NOTE
Hot spots and bulges indicate internal damage in that area. Assess condition by borescope inspection.
1. Casing Skin for:

a. Nicks, gouges, Any number, 0.0150 in. Not repairable Replace case
scratches, and dents (0.381 mm) deep, after
b. Cracks None allowed Not repairable Replace case
c. Bulges None allowed Not repairable Replace case
d. Hot spots Serviceable, if metal is Not repairable Replace case
(discoloration) not crazed and cracks
are not present
e. Grooves worn by Any length, 0.0250 in. Not repairable Replace case
actuation ring spacers (0.635 mm) deep, after
2. Stages 8 and 11 Manifolds for:
a. Cracks None allowed Not repairable Replace case
b. Dents Any number, 0.250 in. Not repairable Replace case
(6.35 mm) deep,
provided there is a
0.0250 in. (0.635 mm)
minimum radius at
bottom of dent
c. Nicks and scratches Any number, 0.010 in. Not repairable Replace case
(0.25 mm) deep
3. Casing Ribs for:
a. Cracks None allowed Any amount removable Blend maximum depth
by blending flush with flush to case OD,
casing skin minimum radius equal
to depth

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Table 7. HPC Inspection (Continued)

b. Nicks, gouges, and Any number, 0.060 in. Not repairable Replace case
scratches (1.52 mm) deep,
0.50 in. (12.7 mm) long,
with a minimum
separation of 2.0 in.
(51 mm), after removal
of high metal
4. Circumferential Flanges for:
a. Cracks
(1) Radially outward One per hole, maximum Not repairable Replace case
from boltholes 3 holes per flange
(2) Bolthole to skin None allowed Not repairable Replace case
(3) Cracks in fillet None allowed Not repairable Replace case
between aft
circumferential
flange and
horizontal flange
(4) All other areas None allowed Not repairable Replace case
b. Nicks, scratches, and Any number, 0.030 in. Not repairable Replace case
gouges (0.76 mm) deep, after
removal of high metal,
provided defect does not
extend completely
across mating surface
5. Horizontal Flanges for:
a. Cracks None allowed Not repairable Replace case
b. Nicks, scratches, and Any number, 0.030 in. Not repairable Replace case
gouges (0.76 mm) deep, after
provided defect does not
extend completely
across mating surface
6. Horizontal Flange for None allowed Any amount Replace all loose,
bolts and nuts, broken, broken, or missing
loose, or missing bolts and nuts plus
adjacent bolts and nuts

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Table 7. HPC Inspection (Continued)

7. Circumferential Flange None allowed Any amount Replace broken, loose,
for bolts and nuts, or missing bolts and
broken, loose, or nuts
missing

b. Nicks, scratches, and Any number, 0.0050 in. Defects not exceeding Blend to remove high
scores (0.127 mm) deep 75 percent of sheet metal. Contour smooth
metal thickness and polish
c. Dents and distortion Any amount, provided Any amount Re-form using hand
proper assembly with tools. No cracks
mating parts can be allowed
accomplished
d. Security No looseness allowed Any amount Tighten attaching bolts
per SWP 1913 03

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Figure 4. HPC Stator Case Crack Inspection

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H. Inspect variable stator vane (VSV) actuation system per table 8 and figure 5.
Table 8. VSV Actuation System Inspection

1. VSV Actuator for:
a. Leakage None allowed Any amount Tighten fitting or replace
fitting, packing, or actuator
b. Security No looseness allowed Any amount Tighten attaching hardware
or replace parts
2. Actuator Bracket for:
a. Security No looseness allowed Any amount Tighten mounting bolts
b. Cracks None allowed Not repairable Replace bracket
c. Distortion None allowed Not repairable Replace bracket
3. Actuator lever guide for binding None allowed Not repairable Replace guide and bracket,
or looseness as required
4. Actuation Lever Assembly for:
a. Security No looseness allowed Any amount Tighten attaching hardware
b. Cracks None allowed Not repairable Replace lever assembly
c. Worn slot-loaded bearings None allowed Not repairable Replace bearing ball or lever
assembly
d. Seal boots for wear (tears/ None allowed Not repairable Replace seal boot
rips)
5. Actuation Lever Mount for:
a. Cracks None allowed Not repairable Replace mount
b. Bent stud None allowed Not repairable Replace mount
6. Clevis/Push Rod Assembly for:
a. Missing safety wire None allowed Any amount Replace safety wire
b. Cracks None allowed Not repairable Replace part
c. Bending None allowed Not repairable Replace part. Perform VSV
off-schedule inspection per
WP 4028 00
7. Rod-End Bearings for:
a. Cracks None allowed Not repairable Replace rod-end bearing.
Perform VSV off-schedule
inspection per WP 4028 00
b. Bending None allowed Not repairable Replace rod-end bearing.

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Table 8. VSV Actuation System Inspection (Continued)

c. Looseness or surface wear None allowed Not repairable Replace rod-end bearing
8. Connecting Link for:
a. Cracks None allowed Not repairable Replace connecting link.
b. Lever arm hole wear None allowed Not repairable Replace connecting link
c. Loose bolts None allowed Any amount Replace bolt or actuation
ring
d. Broken or distorted None allowed Not repairable Replace connecting link.
9. Actuation Ring for:
a. Cracks None allowed Not repairable Replace actuation ring.
b. Broken or distorted None allowed Not repairable Replace actuation ring.
c. Improperly adjusted spacers None allowed Any amount Adjust spacer clearance per
WP 1411 00
d. Loose spacer nuts (stage 5 None allowed One per ring segment Apply silicone rubber
only) compound around nut, back
off spacer until head is
against ring, tighten locknut
to secure
e. Actuation ring sleeve torn or None allowed Not repairable Replace sleeve
with missing pieces
f. Worn or elongated lever arm None allowed Not repairable Replace actuation ring.
pin hole Perform VSV off-schedule
10.Vane Lever Arms for:
a. Security No looseness allowed. Locknut in place Replace vane or locknut
Locknut shall be tight
with at least one vane
stud thread showing
Locknut missing Replace locknut. Perform
VSV off-schedule inspection
per WP 4028 00

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b. Cracks, distortion, bending, None allowed Not repairable Replace lever arm. Perform
or loose pin VSV off-schedule inspection
per WP 4028 00
c. Rub marks or scratching of None allowed Not repairable Replace lever arm
lever arm from contact with
connecting link
11.Vane Radial Assembly, IGV-Stage 2, for:
a. Radial outward movement Any amount less than -- Continue operation
(pull vane stem out, away 0.020 in. (0.51 mm)
from HPC case, and measure indicating inner bushing
using shim gages or with dial wear. No visible
indicator on top of vane bushings or washers
stem) missing (whole or in
part). No metal-to-metal
contact
b. Radial outward movement Any amount between -- Plan for washer and bushing
(pull vane stem out, away 0.020 in. (0.51 mm) and replacement at next
from HPC case, and measure 0.025 in. (0.64 mm). No maintenance interval per
using shim gages or with dial visible bushings or WP 2412 00
indicator on top of vane washers missing (whole
stem) or in part). No metal-to-
metal contact
c. Radial outward movement Any amount less than Not repairable Replace inner and outer
(pull vane stem out, away 0.025 in. (0.64 mm). No bushings per WP 2412 00
from HPC case, and measure visible bushings or
using shim gages or with dial washers missing (whole
indicator on top of vane or in part). No metal-to-
stem) metal contact
d. Side-to-side movement (vane Any amount, provided Not repairable Replace inner and outer
stem wiggle, side-to-side, bushings or washers are bushings per WP 2412 00
perpendicular to lever arm) not missing (whole or in
contact
e. Misassembled, cocked, bent, None allowed Not repairable Perform VSV off-schedule
or broken lever arms or inspection per WP 4028 00
actuation arm sleeves and resulting maintenance
actions. Replace lever arms
and actuation arm sleeves
per WP 2412 00
f. Lever arm locknuts backed None allowed Not repairable Replace nuts. Ensure proper
off, not clamping lever arm torque value on all other nuts
per WP 2412 00

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12.Vane Assembly, Stages 3 and 4, for:
using shim gages or with dial wear. No visible
indicator on top of vane bushings or washers
stem) missing (whole or in
contact
b. Radial outward movement Any amount between -- Plan for bushing and/or
(pull vane stem out, away 0.030 in. (0.76 mm) and washer replacement at next
from HPC case, and measure 0.040 in. (1.02 mm), no maintenance interval per
using shim gages or with dial visible bushings or WP 1412 00 or WP 2412 00
indicator on top of vane washers missing (whole
stem) or in part). No metal-to-
metal contact
(pull vane stem out, away 0.040 in. (1.02 mm), no bushings and washers per
from HPC case, and measure visible bushings or WP 1412 00 or WP 2412 00
using shim gages or with dial washers missing (whole
indicator on top of vane or in part). No metal-to-
stem) metal contact
d. Bushing for time since Less than 12500 hours Any amount greater Replace bushings and/or
installation than 12500 hours washers per WP 1412 00 or
WP 2412 00
e. Side-to-side movement (vane Any amount, provided Not repairable Replace bushings and/or
stem wiggle, side-to-side, bushings or washers are washers per WP 1412 00 or
perpendicular to lever arm) not missing (whole or in WP 2412 00
contact
f. Misassembled, cocked, bent, None allowed Not repairable Perform VSV off-schedule
per WP 1412 00 or
WP 2412 00
g. Lever arm locknuts backed None allowed Not repairable Replace locknuts. Ensure
off, not clamping lever arm proper torque value on all
other nuts per WP 1412 00
or WP 2412 00
13.Vane Assembly, Stage 5, for:

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using shim gages) wear, no visible
bushings or washers
missing (whole or in
contact
b. Radial outward movement Any amount between -- Plan for bushings and/or
(pull vane stem out, away 0.025 in. (0.64 mm) and washers replacement at next
from HPC case, and measure 0.035 in. (0.89 mm), no maintenance interval per
using shim gages) visible bushings or WP 1412 00 or WP 2412 00
washers missing (whole
or in part). No metal-to-
metal contact
(pull vane stem out, away 0.035 in. (0.89 mm), no bushings and/or washers per
from HPC case, and measure visible bushings or WP 1412 00 or WP 2412 00
using shim gages) washers missing (whole
or in part). No metal-to-
metal contact
d. Side-to-side movement (vane As measured with dial – Continue operation
stem wiggle side-to-side indicator, less than
perpendicular to lever arm 0.020 in. (0.51 mm) in
using dial indicator located either direction
on nut surface touching top
of lever arm)
e. Bushing for time since Less than 12500 hours Any amount greater Replace bushings and/or
installation than 12500 hours washers per WP 1412 00 or
WP 2412 00
f. Side-to-side movement (vane As measured with dial Not repairable Plan for bushing replacement
stem wiggle side-to-side indicator, amount as soon as practical, not to
perpendicular to lever arm between 0.020 in. exceed next periodic
using dial indicator located (0.51 mm) and 0.035 in. inspection
on nut surface touching top (0.89 mm) in either
of lever arm) direction
g. Side-to-side movement (vane As measured with dial Not repairable Replace bushings and/or
stem wiggle side-to-side indicator, amount under washers per WP 1412 00 or
perpendicular to lever arm 0.035 in. (0.89 mm) WP 2412 00 prior to
using dial indicator located continued operation
on nut surface touching top
of lever arm)

/03) *(.
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h. Lever arm inspection at At bushing replacement Not repairable Replace lever arm per
bushing replacement per any condition, look WP 1412 00 or WP 2412 00
for evidence of any
exposed metal when
replacing bushing
i. Misassembled, cocked, bent, None allowed Not repairable Perform VSV off-schedule
per WP 1412 00 or
WP 2412 00
j. Lever arm locknuts backed None allowed Not repairable Replace nuts. Ensure proper
off, not clamping lever arm torque value on all other nuts
per WP 1412 00 or
WP 2412 00
14.Vane Bushings or Housings, Stages 3-5, for:
a. Looseness using finger Bushings must be tightly Any amount Tighten bolt, not to exceed
pressure, and side-to-side or clamped to case torque value specified per
fore and aft wiggle motion, WP 2412 00. Ensure
any amount. Bushing or bolthole and bushing mating
housings bolts not seated surface with case are free of
(clamping bushing). Shim- obstructions
check bushing or bolt if
suspected loose

*(. /03)
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Figure 5. VSV System Inspection

/03) *(.
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I. Inspect fuel manifold per table 9.
Table 9. Fuel Manifold Inspection

1. Fuel Manifold for:
a. Cracks None allowed Not repairable Replace manifold
segment
b. Nicks, scores, and – – –
scratches
c. Leaks between None allowed Any amount Tighten bolts or replace
segments gasket
d. Leaking fuel hose None allowed Any amount Tighten bolts or replace
plate gasket
e. Loose fuel hose None allowed Any amount Tighten bolts
plate
J. Inspect compressor rear frame (CRF) per table 10 and figure 6.
Table 10. CRF Inspection

1. CRF Outer Casing for:
a. Cracks in parent None allowed Not repairable Replace engine
metal
b. Cracks in welds Any number, separated by Not repairable Replace engine
0.50 in. (12.7 mm),
0.10 in. (2.5 mm) long
transverse to the weld, and
0.060 in. (1.52 mm) long
longitudinal to weld

*(. /03)
:3
Table 10. CRF Inspection (Continued)

c. Nicks, scores, and In axial direction, any Any number Blend out over a 0.50 in.
scratches number, 0.0150 in. (12.7 mm) radius
(0.381 mm) deep and
1.0 in. (25 mm) long. In
circumferential direction,
any number, 0.030 in.
(0.76 mm) deep and 1.0 in.
(25 mm) long with a
minimum separation of
1.0 in. (25 mm) after
provided metal is not
reduced to less than
75 percent of original
thickness
d. Dents, distortions, or Any number with a smooth Not repairable Replace engine
waviness contour, deviations within
0.250 in. (6.35 mm) of
normal surface contour,
except on mating (sealing)
surfaces
e. Hot spots Any number, provided Not repairable Replace engine
(discoloration) metal is not crazed
f. Bulges Not serviceable when Not repairable Replace engine
associated with heat
discoloration
2. Fuel Nozzle Pad and Igniter Pad Areas for:
a. Cracks None allowed Not repairable Replace engine
b. Damaged threads None allowed One full thread may be Chase threads or install
removed, if remaining Heli-Coil insert
threads are not damaged
c. Fuel nozzle pad burn None allowed Not repairable Replace engine
through caused by
failed nozzle
3. All Other Pads and Threaded Parts for:
a. Nicks, scores, and Any number, 0.030 in. Not repairable Replace engine
scratches (0.76 mm) deep not
extending across more than
1/2 a sealing surface, after
removal of high metal. No
air leakage allowed

/03) *(.
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b. Thread damage None allowed One full thread may be Chase threads or install
removed, if remaining Heli-Coil insert
threads are not damaged
4. CRF Forward Flange for:
a. Bolthole cracks Not serviceable Not repairable Replace engine
b. Nicks, scores, and Any number, any length, Not repairable Replace engine
scratches 0.030 in. (0.76 mm) deep,
after removal of high metal,
that do not extend across
more than 0.750 in.
(19.05 mm) of flange
sealing lip
5. CRF Rear Flange for:
a. Bolthole radial cracks One per hole, four per Not repairable Replace engine
flange, radially outward
only
b. Wear on forward face Any amount, provided Not repairable Replace engine
around bolthole bolthead completely covers
hole to seal air leakage.
Maximum of two non-
adjacent hole locations
allowed
c. Nicks, scores, and Any number, any length, Not repairable Replace engine
that does not extend across
more than 0.750 in.
sealing lip
6. CRF Aft Case for:
a. Cracks in parent metal None allowed Not repairable Replace engine
b. Cracks in Welds Any number, spaced by Not repairable Replace engine
0.50 in. (12.7 mm), 0.10 in.
(2.5 mm) long transverse to
the weld, and 0.060 in.
(1.52 mm) long
longitudinal to weld

*(. /03)
:3

c. Nicks, scores, and In axial direction, any Any number Blend out over a 0.50 in.
scratches number, 0.015 in. (12.7 mm) radius
(0.38 mm) deep, 1.0 in.
(25 mm) long. In
circumferential direction,
any number, 0.030 in.
(0.76 mm) deep, 1.0 in.
(25 mm) long with a min
separation of 1.0 in.
(25 mm), after removal of
high metal, provided metal
is not reduced to less than
75 percent of original
thickness
d. Dents, distortions, or Any number with a smooth Not repairable Replace engine
waviness contour, deviations within
0.250 in. (6.35 mm) of
normal surface contour,
except on mating (sealing)
surfaces
e. Hot spots Any number, provided Not repairable Replace engine
(discoloration) metal is not crazed. No
cracks allowed
f. Bulges Not serviceable when Not repairable Replace engine
associated with heat
discoloration
7. CRF Aft Case Forward Flange for:
a. Bolthole radial cracks One per hole, four per Not repairable Replace engine
flange, radially outward
only
b. Wear on forward face Any amount, provided Not repairable Replace engine
around bolthole bolthead completely covers
hole to seal air leakage.
Max of two nonadjacent
hole locations allowed
c. Nicks, scores, and Any number, any length, Not repairable Replace engine
more than 0.750 in.
sealing lip

/03) *(.
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8. CRF Aft Case Rear Flange for:
a. Bolthole cracks Not serviceable Not repairable Replace engine
b. Nicks, scores, and Any number, any length, Not repairable Replace engine
more than 0.750 in.
sealing lip
9. Oil Supply, Oil Scavenge, Sump Vent, and Sump Pressurizing Tubes for:
a. Cracks Not serviceable Not repairable Replace engine
b. Nicks, scores, and Any number, 0.0050 in. Not repairable Replace engine
scratches (0.127 mm) deep, after
c. Wear at contact point Not serviceable Not repairable Replace engine
of strut pad
d. Dents Any number with a smooth Not repairable Replace engine
contour, 0.250 in.
(6.35 mm) deep, except on
mating (sealing) surfaces
e. Oil supply tube Any amount, 0.0050 in. Not repairable Replace engine
grooving and wear on (0.127 mm) deep, after
sleeve removal of high metal
f. Scavenge tubes Any amount, 0.0050 in. Not repairable Replace engine
grooving and wear on (0.127 mm) deep, after
sleeves removal of high metal
g. Vent tube grooving Any amount, 0.020 in. Not repairable Replace engine
and wear on sleeves (0.51 mm) deep, after
h. Vent tube coking 50 percent of sump vent Not repairable Replace engine
tube opening may be
blocked off by coking as
determined visually by
looking into outer end of
strut tubes
i. Sump pressurization Any amount, 0.0050 in. Not repairable Replace engine
tube grooving and (0.127 mm) deep, after
wear on sleeves removal of high metal

*(. /03)
:3

10.All Other CRF Tubes for:
a. Cracks None allowed Not repairable Replace engine
b. Nicks and scratches Any number, any length, Not repairable Replace engine
0.010 in. (0.25 mm) deep,
after removal of high metal
c. Dents Any number, 1/5 tube Any number Re-form to original
diameter, provided proper contour. Inspect for
assembly can be obtained cracks
d. Bent (out of Not serviceable Any amount Straighten tube. Inspect
alignment) for cracks
11.CRF CDP customer bleed for:
a. Leakage at flange seal None allowed Any amount Replace gasket per
SWP 1913 02

/03) *(.
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Figure 6. CRF Inspection

*(. /03)
:3
K. Inspect high pressure turbine (HPT) per table 11 and figure 7.
Table 11. HPT Inspection

1. HPT Case (Nozzle Stator Support) for:
a. Cracks Not serviceable Not repairable Replace HPT stage 2
nozzle assembly
b. Nicks and scratches Any number, any length, Any number, any length, Blend to remove high
0.0150 in. (0.381 mm) provided the thickness of metal. Contour smooth
deep, after removal of parent metal is not reduced and polish
high metal more than 0.0150 in.
(0.381 mm), after removal
of high metal and blending
c. Dents or bulges Three dents or bulges, Not repairable Replace HPT stage 2
0.50 in. (12.7 mm) nozzle assembly
diameter, 0.120 in.
(3.05 mm) deep. No high
metal allowed on flange
mating surfaces
2. Flanges for:
a. Cracks from boltholes Four cracks radially Not repairable Replace HPT stage 2
outward, provided nozzle assembly
effected holes are
separated by five
boltholes. None radially
inward
b. Nicks and scratches Any number, any length, Any number, any length, Blend to remove high
0.0150 in. (0.381 mm) provided the thickness of metal. Contour smooth
deep, after removal of parent metal is not reduced and polish
high metal more than 0.0150 in.
(0.381 mm), after removal
of high metal and blending
c. Broken, loose, or None allowed Any amount Tighten or replace
missing attaching damaged hardware
hardware
3. Borescope Ports for None allowed One full thread may be Chase threads or replace
damaged threads removed or missing Heli-Coil insert
4. Air Tubes for:
a. Cracks None allowed Not repairable Replace HPT stage 2
nozzle assembly
b. Dents TBP – –
* Contact GE Marine and Industrial Customer Service for repair data.

/03) *(.
:3
Figure 7. HPT Inspection
L. Inspect low pressure turbine (LPT) per table 12 and figure 8.
Table 12. LPT Inspection

1. LPT Case for:
a. Cracks None allowed Not repairable Replace LPT module
b. Nicks Any number, 0.0150 in. Not repairable Replace LPT module
(0.381 mm) deep, after
c. Scratches and scores Any number, 0.010 in. Not repairable Replace LPT module
(0.25 mm) deep (after
removal of high metal) in
axial direction. Any
number, 0.010 in.
(0.25 mm) deep (after
removal of high metal),
1.0 in. (25 mm) separation,
in circumferential direction

*(. /03)
:3
Table 12. LPT Inspection (Continued)

d. Dents Any number with a smooth Not repairable Replace LPT module
contour, 0.1250 in.
(3.175 mm) deep, provided
assembly can be
accomplished
e. Distortion None allowed Not repairable Replace LPT module
f. Penetration None allowed Not repairable Replace LPT module
g. Cracks in bosses None allowed Not repairable Replace LPT module
h. Damaged threads in None allowed Any number Chase threads or install
bosses Heli-Coil insert
i. Hot spots (distortion) Any amount, provided Not repairable Replace LPT module
metal is not granular and
cracks are not present
j. Heat or other Any amount, provided Not repairable Replace LPT module
discoloration there are no associated
distortion bulges
k. Bulges Any amount not associated Not repairable Replace LPT module
with heat discoloration and
provided proper assembly
can be accomplished
2. Forward and Aft Flanges for:
b. Nicks, scores, and Any number, any length, Not repairable Replace LPT module
after removal of high metal
with 1.0 in. (25 mm)
separation
c. Dents Any number, provided Not repairable Replace LPT module
damage does not extend
across more than 3/4 of
flange face and does not
result in flange distortion
d. Broken, loose, or None allowed Any amount correctable Tighten or replace
missing attaching by replacing or tightening damaged hardware
hardware
3. Borescope Ports for None allowed One full thread may be Chase threads or install
damaged threads removed or missing Heli-Coil insert

/03) *(.
:3

4. Air Manifold for:
a. Security No looseness allowed Any amount Correct as required
b. Cracks None allowed Not repairable Replace manifold
c. Dents and flat areas Any amount within Not repairable Replace manifold
20 percent of original tube
OD
d. Nicks and scores Any amount, 0.0050 in. Any amount, 0.010 in. Blend to remove high
(0.127 mm) deep (0.25 mm) deep metal. Contour smooth
and polish
5. Support Links for:
a. Security No looseness allowed Any amount Correct as required
b. Broken safety wire None allowed Any amount Replace safety wire
c. Cracks None allowed Not repairable Replace link
d. Distortion (bending) Any amount, providing Not repairable Replace link
parts are not under stress or
contacting surrounding
hardware
6. Support Link Brackets for:
a. Security No looseness allowed Any amount Tighten or replace
hardware
b. Cracks None allowed Not repairable Replace bracket
c. Distortion Any amount, providing Not repairable Replace bracket
parts are not under stress or
contacting surrounding
hardware
d. Worn bushings 0.060 in. (1.52 mm) wear Not repairable Replace bracket
permitted
7. T48 Thermocouples for:
a. Security No looseness allowed Any amount Tighten or replace
hardware
b. Loose KN/KP studs No looseness allowed Any amount Replace T48 harness
or thermocouple as
required
8. P48 probe for security No looseness allowed Any amount Tighten bolts

*(. /03)
:3

b. Nicks, scratches, and Any amount, 0.0050 in. Defects not exceeding Blend to remove high
scores (0.127 mm) deep 75 percent of sheet metal metal. Contour smooth
thickness and polish
c. Dents and distortion Any amount, provided Any amount Re-form using hand tools.
proper assembly with No cracks allowed
mating parts can be
accomplished
d. Security No looseness allowed Any amount Tighten attaching bolts per
SWP 1913 03

/03) *(.
:3
Figure 8. LPT and TRF Inspection

*(. /03)
:3
M. Inspect turbine rear frame (TRF) per table 13 and figure 8.
Table 13. TRF Inspection

1. Insulation Blankets for:
a. Tears (wire mesh Any number, 2.0 in. Not repairable Replace blanket
and insulation (51 mm) long with 8.0 in.
material intact) (203 mm) separation
b. Wire mesh or None allowed Not repairable Replace blanket
insulation material
torn
c. Loose fasteners None allowed Any number Tighten or replace safety
wire
d. Reflective material None allowed Not repairable Replace blanket
burnt away or
missing
e. Security No loose blankets allowed Any amount Tighten or replace safety
wire
f. Saturated with fuel None allowed Not repairable Replace blanket
or oil
2. Flanges for:
scratches
c. Broken, loose, or None allowed Any amount Tighten or replace
missing attaching damaged hardware
hardware
3. Mounts for cracks None allowed Not repairable Replace mounts
4. Strut Pads for:
a. Cracks Any amount in strut ends Not repairable Replace LPT module
that do not permit air
leakage. One bolthole per
flange may be cracked
through radially outward
b. Nicks and scratches Any number, any length, Not repairable Replace LPT module
0.060 in. (1.52 mm) deep,
after removal of high
metal, provided metal is
not reduced to less than
75 percent of its original
thickness

/03) *(.
:3
Table 13. TRF Inspection (Continued)

c. Dents Any number with a smooth Not repairable Replace LPT module
contour, 0.250 in.
sealing surfaces
scratches
6. Oil Supply and Scavenge Tubes for:
a. Cracks Not serviceable Not repairable Replace LPT module
b. Nicks, scores, and Any number, 0.0050 in. Not repairable Replace LPT module
scratches (0.127 mm) deep, after
c. Dents Any number with a smooth Not repairable Replace LPT module
contour, 0.250 in.
mating (sealing) surfaces
d. Tube wear sleeve Any amount, 0.0050 in. Not repairable Replace LPT module
for grooving and (0.127 mm) deep, after
wear removal of high metal
%ODQN
/03) *(.
:3
GAS TURBINE EXHAUST SYSTEM INSPECTION
())(&7,9,7</03)*$6785%,1(02'(/6

Page No. Change No.
1 - 5 .......................................................................................................................................................... 0
6 Blank ..................................................................................................................................................... 0
Alphabetical Index
Subject Page
Gas Turbine Exhaust System Inspection.................................................................................................. 3
*(. /03)
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1. Introduction.
This work package contains instructions for inspecting the gas turbine exhaust system.
None required.
None required.
None required.

Piston Ring, Inner L47833P01 1
Piston Ring, Inner L47833P02 ALT
Piston Ring, Outer L45063P13 ALT
Piston Ring, Outer L45063P16 1
/03) *(.
:3
6. Gas Turbine Exhaust System Inspection.
WARNING
• GAS TURBINE SHALL NOT BE OPERATING AND SHALL BE VERIFIED AS

INOPERABLE. IF POSSIBLE, LOCK OUT SYSTEM SO IT CANNOT BE ROTATED.
• THE EXHAUST DUCT TEMPERATURE SHALL BE AT AN ACCEPTABLE WORKING

LEVEL, BELOW 120°F (49°C). IF EXHAUST PARTS ARE HOT, ALLOW THEM TO COOL
BEFORE INSPECTION.
• A SAFETY OBSERVER SHALL BE STATIONED ADJACENT TO THE EXHAUST DUCT

ACCESS.
CAUTION
TO ENSURE THAT NO LOOSE OBJECTS ARE LEFT IN THE EXHAUST, EMPTY

POCKETS BEFORE ENTERING EXHAUST ACCESS.
A. Before accessing exhaust, do the following (figure 1):
(3) Station safety observer adjacent to exhaust duct access.
B. Access exhaust duct per packager’s manual.
NOTE
Some items can only be inspected if the gas turbine and exhaust duct are separated. If the gas turbine
and exhaust duct are not separated, inspection will be limited to accessible items only.
C. Using bright light, visually inspect turbine rear frame and inner and outer seal carriers for cracks, security,
metal deposits, and damage. Contact General Electric Marine and Industrial Customer Service if
discrepancies are found.
D. Using bright light, visually inspect exhaust duct, inner and outer diffuser walls, and housings for cracks,
security, metal deposits, and damage. If discrepancies are found, refer to the packager’s manual for limits
and corrective action.
E. Using bright light, visually inspect inner and outer piston rings for wear and cracks. If rings are worn or
cracked, replace rings.
F. Perform thorough, final inspection of exhaust duct for possible foreign objects or tools left in exhaust area.
G. Secure exhaust duct access per packager’s manual.
*(. /03)
:3
Figure 1. Gas Turbine Exhaust Duct Interface
/03) *(.
:3
H. Check exhaust system alignment as follows:
NOTE
Exhaust duct alignment should be checked after final full engine alignment is complete.
(1) Measure and record dimension A and dimension B at eight equally spaced locations around
circumference of exhaust duct. Calculate XA as follows:
XA = AMAX - AMIN
(2) Refer to table 1 for the applicable limits. If dimensions exceed the table maximum or minimum
values, then adjust the exhaust diffuser. Refer to packager’s manual.
Table 1. Exhaust System Limits

Minimum Value Maximum Value Maximum XA
Dimension A 2.775 in. (70.49 mm) N/A 0.25 in. (6.3 mm)
(Measured at Outer Piston Ring)
Dimension B 0.14 in. (3.5 mm) N/A N/A
DIM A DIM B
1. 1.
2. 2.
3. 3.
4. 4.
5. 5.
6. 6.
7. 7.
8. 8.
AVG AVG
%ODQN
/03) *(.
:3
GAS TURBINE WATER-WASH
())(&7,9,7</03)*$6785%,1(02'(/6

Page No. Change No.
1 - 7 .......................................................................................................................................................... 0
8 Blank ..................................................................................................................................................... 0
Alphabetical Index
Subject Page
Crank/Soak Cleaning. .............................................................................................................................. 4

On-Line Cleaning..................................................................................................................................... 7
Water and Detergent Requirements.......................................................................................................... 3
Water-Wash Description........................................................................................................................... 3
*(. /03)
:3
1. Introduction.
This work package contains instructions for performing water-wash procedures on the LM6000 gas turbine.
Title Number
Requirements for Water and Steam Purity - Compressor Appendix A3
Cleaning
Water Purity - Compressor Cleaning Appendix A4
Liquid Detergent - Compressor Cleaning Appendix A5
System Descriptions Chapter 5
Engine Operation Chapter 8
None required.
Acetone Fed Spec 0-A-51
ARDROX 6322 (solvent base) Local Purchase
CleanBladeTM GTC1000 Local Purchase
Conntect (water base) Local Purchase
Monopropylene Glycol AMS 1424
PROTOKLENZ-GT-SC Local Purchase
RMC Turbine/Engine Cleaner (solvent base) Local Purchase
Rochem FYREWASH (solvent base) Local Purchase
Techniclean GT (water base) Local Purchase
Turbotect 950 (water base) Local Purchase
Turbo-K Local Purchase
Zok 27 and Zok 27LA (water base) Local Purchase
None required.
/03) *(.
:3
6. Water-Wash Description.
NOTE
The need for gas turbine water-wash and frequency is installation and site specific. In particular,
effectiveness of inlet filtration may have a significant effect on need for washing. Reduced power
output and dirty appearance during borescope are indications that the gas turbine may benefit from off-
line wash.
The following basic water-wash procedures may be applied:
A. Crank/Soak Cleaning: Applied while motoring the high pressure (HP) rotor at greater than 2000 RPM and
low pressure (LP) rotor at greater than 200 RPM. Used for performing a thorough cleaning of engine.
Crank-soak washing removes oily or tarry deposits which bind dirt to blade. The frequency of wash must
be tailored to type of atmospheric contaminants, temperature, operational frequency/profile, gas turbine
health and site economics. In the absence of this information a prudent strategy would be to crank-soak
wash every 2 weeks.
B. On-line Cleaning: Applied while engine is running. Requires special on-line cleaning manifold. It is used
primarily to maintain gas turbine performance between crank-soak washes but rarely is able to make a
significant improvement in performance.
7. Water and Detergent Requirements.
A. Water quality and liquid detergent for crank/soak compressor cleaning must meet requirements specified in
Appendix A4 and Appendix A5 of this manual.
B. The liquid detergents listed below may be used for performing water-wash procedures. Follow liquid
detergent manufacturer's instructions for recommended detergent/water dilution ratios. Ensure that
detergents used, including those listed, meet requirements specified by packager.
• ARDROX 6322 (solvent base)
• CleanBladeTM GTC1000
• Conntect (water base)
• PROTOKLENZ-GT-SC
• RMC Turbine/Engine Cleaner (solvent base)
• Rochem FYREWASH (solvent base)
• Techniclean GT (water base)
• Turbotect 950 (water base)
• Turbo-K
• Zok 27 and Zok 27LA (water base)
*(. /03)
:3
C. In freezing weather, mix one of the antifreeze agents listed below with cleaning solution. Refer to
Appendix A5 for recommended solution mixtures and additional information.
• Acetone
• Isopropyl alcohol
• Monopropylene Glycol
8. Crank/Soak Cleaning.
A. Before initiating crank/soak cleaning sequence, comply with the following requirements:
WARNING
THE ENCLOSURE AREA SHALL BE VENTILATED. THE ENGINE SHALL BE
SHUT DOWN AND COOLED PRIOR TO CRANK/SOAK CLEANING. ALL DRAINS
SHALL BE OPEN.
WARNING
CONCENTRATED B & B 3100 SOLVENT, ACETONE, AND ISOPROPYL

ALCOHOL ARE FLAMMABLE AND TOXIC TO SKIN, EYES, AND RESPIRATORY
TRACT. SKIN, EYE, AND RESPIRATORY PROTECTION IS REQUIRED. AVOID
REPEATED OR PROLONGED CONTACT. USE WITH GOOD VENTILATION.
CAUTION
BE CERTAIN THAT CHECKLISTS HAVE BEEN ESTABLISHED FOR
PACKAGER-FURNISHED EQUIPMENT. CONSULT THE PACKAGER’S
MANUAL FOR MANDATORY PRE-START PROCEDURES, ESPECIALLY
MAKING SURE THAT THE PACKAGER-FURNISHED LUBE SUPPLY SUB-
SYSTEM IS ACTIVATED AND OPERATIONAL PRIOR TO ANY MOTORING
SEQUENCE. FAILURE TO COMPLY MAY RESULT IN PART DAMAGE.
(1) Disconnect pressure sensor lines from PS3 and P48 locations on gas turbine to prevent water
collection in lines and subsequently affecting engine operation.
(2) Cover electronic devices below gas turbine, such as fuel metering valve, to prevent entry of water
that may affect engine operation.
(3) If crank/soak cleaning is not preceded by an extended shutdown period, perform a normal shutdown
(including 5 minutes at core idle for cooling). Refer to Chapter 8 of this manual for engine shutdown
procedures.
(4) Allow gas turbine to cool so that outside surfaces are less than 200°F (93.3°C).
/03) *(.
:3
WARNING
IF NATURAL GAS IS USED TO DRIVE THE STARTER, ADDITIONAL SAFETY

PRECAUTIONS ARE REQUIRED. THESE INCLUDE SAFETY MEASURES FOR
COMBUSTIBLE GASES AND VENTING OF STARTER EXHAUST TO A SAFE
LOCATION.
NOTE
While motoring the engine with the starter, ensure that a minimum lube pressure of 6 psig
(41 kPa) is maintained.
(5) To expedite cooling, motoring starter is permissible. Dry motoring procedures are contained in
Chapter 8 of this manual. Limit starter duty cycles to those defined in Chapter 5.
B. Perform crank/soak cleaning cycle as follows:
(1) Motor HP rotor to 2000 rpm and allow speed to stabilize. LP rotor speed should be 200-300 rpm.
Allow LP rotor speed to stabilize before initiating water flow.
CAUTION
IN BELOW FREEZING CONDITIONS, ANTIFREEZE AGENTS SHALL BE
ADDED TO THE WATER. THE USE OF NON-ISOPROPYL ALCOHOL,
ETHYLENE GLYCOL, AND ADDITIVES CONTAINING CHLORINE, SODIUM,
OR POTASSIUM ARE NOT PERMITTED SINCE THEY MAY ATTACK
TITANIUM AND OTHER METALS IN THE ENGINE.
NOTE
Total solids in the wash and rinse waters shall be no more than 100 ppm. The ph factor
shall be between 6.5 and 8.5 at 77°F (25.0°C). Potable water will normally meet these
requirements. Water-wash solution should be at room temperature and a flow rate of
approximately 20 gpm (76 liters/minute).
NOTE
Residual waste following water-wash with solvent should be disposed of in accordance
with local environmental regulations for the specific geographic location. Users should
contact the solvent supplier for details relative to the solvent used.
NOTE
Packager-supplied control system will open the variable inlet guide vanes (VIGVs) and
will close the variable bypass valves (VBVs). The variable stator vanes (VSVs) will
remain on schedule.
NOTE
The number of wash cycles required to clean a gas turbine depends on the starting
condition and the effectiveness of the wash solution/process.
*(. /03)
:3
NOTE
In some cases, off-line soak washing may not prove to be effective in restoring
performance of its unit. In these cases, compressor top case hand cleaning of HPC blades
and vanes may be necessary. As compressor fouling also affects stall margin, a heavily
fouled compressor may lead to a stall event.
(2) Inject 20 gallons (76 liters) of water-wash solution through crank/soak water-wash manifold while
motoring HP rotor at approximately 2000 rpm and LP rotor at 200-300 rpm.
CAUTION
PACKAGER-SUPPLIED CONTROL SYSTEM SHALL AUTOMATICALLY

CLOSE THE WATER WASH INJECTION VALVE IF LP ROTOR SPEED DROPS
BELOW 200 RPM OR HP ROTOR SPEED DROPS BELOW 2000 RPM. WATER
INJECTION AT LOWER SPEEDS MAY RESULT IN WATER ENTERING LP OR
HP COMPRESSOR ROTORS, WHICH MAY RESULT IN MAJOR ENGINE
DAMAGE.
(3) After completion of wash solution injection, close the VIGVs and maintain VBVs in closed
position. Allow rotors to coast to a stop and the solution to soak for a minimum of 10 minutes.
Operator experience will determine soak time.
NOTE
For systems with driven equipment having large rotational inertia, it may not be practical to allow the
rotors to coast to a stop. The soak will be a rolling soak.
NOTE
During wash cycle, approximately 10 percent of the water and cleaning solution will leak through the
engine casings and openings to the exterior of the engine.
NOTE
The number of rinses required depends on the condition of the engine prior to wash, the quantity of
wash solution used, and the effectiveness of the rinse.
C. Complete rinse cycles as follows:
(1) Open inlet drain, bleed air collector drain, exhaust collector drains, and module drains to remove
any wash solution and rinse water after washing is complete.
(2) Use a minimum of 25 gallons (95 liters) of 160 to 180°F (72 to 82°C) water, while motoring HP
rotor at approximately 2000 rpm and LP rotor at 200-300 rpm.
NOTE
Rinsing performed using unheated water will require more water to achieve the same
rinsing effectiveness as heated water.
(3) Repeat rinse until water sample at turbine exhaust is clear. If conductivity checking is possible,
conductivity should be similar to that of clean rinse water.
/03) *(.
:3
(4) After rinsing, shut off water supply.
(5) Regulate pneumatic starter air supply for normal operation.
(6) Open low pressure compressor (LPC) variable bleed valves.
D. As an option, operator may inspect gas turbine to determine if cleaning process was adequate as follows:
(1) After completion of the rinse cycles, allow rotors to coast to a complete stop.
(2) Borescope inspect LPC and high pressure compressor (HPC) rotors per WP 4015 00, paying
particular attention to stator/blade airfoils.
(3) If excessive contaminants are still present, rewash as required.
E. Make a normal engine start and allow engine to run at synchronous idle for 2-3 minutes to dry engine.
9. On-Line Cleaning.
CAUTION
ANTIFREEZE MIXTURES FOR ON-LINE WATER-WASH AND RINSE SHOULD BE USED

WHEN AMBIENT TEMPERATURES ARE 50°F (10.0°C) OR LESS. FORMATION OF ICE
MAY RESULT IN MAJOR ENGINE DAMAGE.
NOTE
On-line cleaning does not typically eliminate the need for off-line cleaning and it is not effective in
cleaning a significantly fouled compressor. However, on-line cleaning will typically extend the
required intervals for off-line cleaning to maintain the gas turbine performance.
A. Conduct on-line wash with water only. Use of detergent is not recommended. Use of water to NOx
suppression standards per specification MID-TD-0000-3 (Appendix A3) is required.
B. Limit total amount of water to 100 gal/day (379 liters/day) maximum.
C. Refer to packager’s manual for specific amount of water and frequency of on-line wash.
%ODQN
/03) *(.
:3
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Alphabetical Index
Subject Page
Lube Oil Test............................................................................................................................................ 3
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1. Introduction.
This work package contains instructions for lube oil sampling and test analysis.
Title Number
Oil Analysis, Acid ASTM D664-58
Oil Analysis, Color ASTM D1500
Oil Analysis, Particle Count SAE ARP598
Oil Analysis, SOAP NAVA1R 31-1-37
Oil Analysis, Viscosity ASTM D445-65
Oil Analysis, Water ASTM D1744
Lube and Scavenge Pump Chip Detector Inspection WP 4017 00
Lube and Scavenge Pump Screen Check WP 4020 00
None required.
None required.
None required.
/03) *(.
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6. Lube Oil Test.
A. Obtain lube oil sample as follows:
WARNING

RESPIRATORY TRACT. DO NOT INHALE, INGEST, OR LET THIS MATERIAL
TOUCH YOU. SKIN AND EYE PROTECTION IS REQUIRED. AVOID REPEATED
OR PROLONGED CONTACT. USE IN A WELL-VENTILATED AREA.
WARNING
CAUTION
DO NOT TAKE OIL SAMPLE FROM LOW DRAIN POINT. LOW DRAIN POINT MAY
CONTAIN HEAVY SEDIMENTS AND PROVIDE INCORRECT INDICATIONS.
(1) Shut down engine.
NOTE
All oil samples shall be taken from the same location.
(2) Obtain oil sample as follows:
(a) Obtain oil sample within 30 minutes after engine shutdown.
(b) Take oil sample from oil tank filler. Ensure oil extraction equipment and container are clean
and free of contaminates.
(c) If oil sample is obtained from a low drain point, such as the scavenge oil discharge line, flow
approximately l pint (0.5 liter) into a waste container and then, without interrupting the flow,
obtain oil sample.
B. Label the sample with the following information:
Sample Location
Gas Turbine S/N
Oil Type
Date
Total Operating Hours
C. Deliver oil sample to laboratory for analysis. The oil sample shall be tested per table 1.
*(. /03)
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D. If limits of table 1 are exceeded, perform the following corrective action:
WARNING

RESPIRATORY TRACT. DO NOT INHALE, INGEST, OR LET THIS MATERIAL
TOUCH YOU. SKIN AND EYE PROTECTION IS REQUIRED. AVOID REPEATED
OR PROLONGED CONTACT. USE IN A WELL-VENTILATED AREA.
(1) Inspect lube and scavenge pump chip detectors and screens per WP 4017 00 and WP 4020 00.
(2) Flush oil from lube and hydraulic systems as follows:
(a) Shut down engine and completely drain oil tank and as many service lines as possible.
(b) Service oil tank with new lubricating oil. Always use oil from same manufacturer.
(c) Operate engine for 5 minutes.
(d) Shut down engine and drain oil tank and service lines.
(e) Service oil tank with new lubricating oil.
E. If spectrographic oil analysis program (SOAP) analysis indicates an increasing trend in wear, monitor oil
contamination through increased sampling intervals. If maximum limits are reached, change out engine
and flush oil system per step 6.D.(2).
/03) *(.
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Table 1. Lube Oil Sample Testing

Step Test for Procedure Limit
1. Total Acid Number (TAN) Test per ASTM D664-58 1.0
2. Viscosity (Kinematic) Test per ASTM D445-65 Maximum change at 100°F (38°C)
from new oil reading +25% to -10%
3. Color Test per ASTM D1500 4
4. Particle Count Test per SAE ARP598 For Lube NAS 7 Class
For HYD NAS 6 Class
5. SOAP Analysis: Atomic Absorption Method
Element Normal On Watch Shutdown Procedure
Iron (Fe) 0-3 4-7 8+ NAVAIR 31-1-37
Silver (Ag) 0-1 2-4 5+
Aluminum (Al) 0-1 2-4 5+
Chromium (Cr) 0-4 5-7 8+
Copper (Cu) 0-5 6-10 11+
Magnesium (Mg) 0-1 2-4 5+
Nickel (Ni) 0-3 4-6 7+
Silicon (Si) 0-20 21-36 37+
Titanium (Ti) 0-3 4-6 7+
Molybdenum (Mo) 0-3 4-6 7+
Lead (Pb) 0-3 4-6 7+
Tin (Sn) 0-15 16-22 23+
Zinc (Zn) 0-10 11-17 18+
SOAP Analysis: Atomic Emission Method
Element Normal On Watch Shutdown Procedure
Iron (Fe) 0-8 9-13 14+ NAVAIR 31-1-37
Silver (Ag) 0-3 4-6 7+
Aluminum (Al) 0-3 4-6 7+
Chromium (Cr) 0-6 7-9 10+
Copper (Cu) 0-12 13-19 20+
Magnesium (Mg) 0-6 7-9 10+
Nickel (Ni) 0-5 6-8 9+
Silicon (Si) 0-25 26-64 65+
Titanium (Ti) 0-5 6-8 9+
Molybdenum (Mo) 0-5 6-8 9+
Lead (Pb) 0-2 3-4 5+
Tin (Sn) 0-20 21-39 40+
Zinc (Zn) 0-15 16-22 23+
6. Water Test per ASTM D1744 1000 PPM
%ODQN
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LUBE AND SCAVENGE PUMP CHIP DETECTOR CHECK
())(&7,9,7</03)*$6785%,1(02'(/6

Page No. Change No.
1 - 8 .......................................................................................................................................................... 0
Alphabetical Index
Subject Page
Chip Detector and Screen Inspection. ...................................................................................................... 3

Chip Detector Installation. ....................................................................................................................... 7
Chip Detector Removal............................................................................................................................ 3

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1. Introduction.
This work package contains instructions for inspection of the lube and scavenge pump chip detectors.
Title Number
Magnetic Chip Detector Replacement WP 1910 00
Lube and Scavenge Pump Screen Check WP 4020 00
Field Guide for Lubrication System Debris GEK 117488
None required.
Dry Cleaning Solvent Fed Spec P-D-680, Type II

Packing, Preformed J221P905 AR
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6. Chip Detector Removal.
A. Before removing the chip detectors, do the following:
(3) Deactivate fire extinguishing system per packager's manual.
(4) Shut off oil supply to gas turbine.
B. Enter enclosure access per packager's manual. Enclosure door must remain open.
NOTE
Standard chip detector configuration is common scavenge, B-scavenge, and transfer gearbox (TGB)
scavenge. Optional chip detectors may be installed in C-scavenge, D-scavenge, and E-scavenge ports.
C. Remove chip detectors from locations shown in figure 1. Remove chip detector from housing bayonet
mount by pushing knurled ring inward and rotating counterclockwise (figure 2).
7. Chip Detector and Screen Inspection.
CAUTION
OPERATING ENGINE WITHOUT ISOLATING SOURCE OF CHIP DETECTOR MATERIAL

OR WITHOUT INTRODUCING A CORRECTIVE ACTION CREATES RISK OF
SECONDARY DAMAGE.
A. Visually inspect chip detectors and screens for foreign material. Refer to GEK 117488 for help in
communicating chip detector debris quantity and material identification. If any foreign material is found,
analyze and perform corrective action as follows:
(1) Isolate source of foreign material by identifying area from which material was scavenged. Check
lube and scavenge pump screens per WP 4020 00.
(2) Visually examine suspect material for identification of source.
• Bearing races, rollers, and balls are magnetic; therefore, separating out any magnetic materials
will help identification.
• Material composition analysis may be required to identify material.
(a) If material can be visually identified as bearing material, such as roller, ball, and/or race
fragments:
1 Component replacement is required. See table 1 for possible corrective action details.
• Main engine bearings cannot be replaced on site. Main engine bearings must be
replaced at depot level.

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Figure 1. Chip Detector Locations
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Figure 2. Chip Detector Components

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Figure 3. Deleted
Table 1. Component Failure Corrective Action

Chip Detector Possible Cause Corrective Action
1. TGB a. TGB failure a. Replace TGB
b. Inlet gearbox failure b. Replace gas turbine
c. 1B or 2R bearing failure c. Replace gas turbine
d. 3R bearing failure d. Replace gas turbine
2. B-Sump 4R/4B bearing failure Replace gas turbine
3. C-Sump 5R bearing failure Replace gas turbine
4. D- and E-Sump 6R/7R bearing failure Replace LPT module
5. Common Scavenge - Inspect chip detectors/screens
for source
2 Review gas turbine log sheets for significant changes in gas turbine logged parameters
because main gas turbine bearing distress normally increases lube scavenge temperatures
and gas turbine vibration.
(b) If suspect material is found on TGB chip detector or in TGB screen, source must be further
identified. Remove lower drain plug and inspect TGB/A-sump area for any distress.
(c) If suspect material is identified as bolt or rivet fragments, replace component as indicated by
screen identity.
• Bearing cage rivets indicate a radial drive shaft failure.
(d) If suspect material is identified as pieces of preformed packing, gasket, safety wire, coke,
machining chip, seal rub strip material, or the source cannot be identified by available
instructions, place gas turbine on watch as follows:
1 Inspect and clean lube and scavenge pump screens and monitor lube system parameters
daily until source of contamination is located.
2 Shut engine down immediately if chip detector alarm is received, followed by GE contact
for instructions.
3 Remove engine from watch status and return to normal inspection schedule if screens are
free of debris for two consecutive days.
(e) If uncertain on classifying debris source, or if more information is required, contact customer
support manager for clarification.
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/03) *(.
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B. If chip detector is suspected of malfunctioning, check continuity as follows:

(1) Remove electrical connector per WP 1910 00.
(2) Check for open continuity of pins to housing and all pins to each other.
(3) Check continuity across chip detector tip control surfaces. Continuity shall not exceed 10 ohms.
(4) If chip detector fails any of these checks, replace chip detector. Refer to Chapter 10 for electrical
lead and chip detector wiring schematics and troubleshooting tables.
(5) Install electrical connector per WP 1910 00.
8. Chip Detector Installation.

WARNING
DRY CLEANING SOLVENT, P-D-680, TYPE II: COMBUSTIBLE. ELECTRICALLY GROUND
CONTAINERS AND EQUIPMENT. DO NOT INHALE, INGEST, OR LET THIS MATERIAL
TOUCH YOU. EXTREME EXPOSURE OR ASPIRATION INTO THE LUNGS MAY CAUSE
LUNG DAMAGE OR DEATH. CENTRAL NERVOUS SYSTEM DAMAGE/ADVERSE EFFECTS.
IRRITANT. PERSONAL PROTECTIVE EQUIPMENT REQUIRED. USE MECHANICAL
EXHAUST VENTILATION - IF NOT AVAILABLE, USE AN APPROVED RESPIRATOR. USE
EXPLOSION PROOF EQUIPMENT.
WARNING
WHEN USING COMPRESSED AIR FOR CLEANING, COOLING, OR DRYING, DO NOT
EXCEED 30 PSIG (207 KPA). WEAR EYE PROTECTION AND DO NOT DIRECT
A. Clean chip detectors with dry cleaning solvent. Dry with shop air at 29 psig (200 kPa).
B. Inspect preformed packings (figure 2) for damage. If required, replace preformed packings.
WARNING
C. Lubricate preformed packings with lubricating oil.

D. Install chip detectors in chip detector housing by pushing knurled ring inward and rotating clockwise.
Check for proper seating by twisting knurled ring back and forth without pressing inward.

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E. Leak-check chip detectors as follows:

WARNING
A SAFETY OBSERVER SHALL BE STATIONED ADJACENT TO THE

ENCLOSURE ACCESS.
(1) Open fuel supply valve and make a gas turbine start.
(2) Ensure gas turbine will not be operated above idle. Put on protective ear and hand equipment.
Deactivate fire extinguishing system per packager’s manual.
(3) Station a safety observer adjacent to the enclosure access.

(4) Enter enclosure. Check for leaks. Make corrections as required.
(5) Exit enclosure, close enclosure access, and activate fire extinguishing system per packager’s
manual.
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LUBE AND SCAVENGE PUMP SCREEN CHECK
())(&7,9,7</03)*$6785%,1(02'(/6

Page No. Change No.
1 - 8 .......................................................................................................................................................... 0
Alphabetical Index
Subject Page
Chip Detector and Screen Inspection. ...................................................................................................... 3

Lube and Scavenge Pump Inlet Screens Installation. .............................................................................. 7
Lube and Scavenge Pump Inlet Screens Removal. .................................................................................. 3

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1. Introduction.
This work package contains instructions for inspection of the lube and scavenge pump inlet screens.
Title Number
Lube and Scavenge Pump Chip Detector Inspection WP 4017 00
Field Guide for Lubrication System Debris GEK 117488
None required.
Plug:

Packing, Preformed NAS1595-5 7
Chip Detector:

Screens:


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6. Lube and Scavenge Pump Inlet Screens Removal.
WARNING
GAS TURBINE SHALL NOT BE OPERATING AND SHALL BE VERIFIED AS INOPERABLE

DURING INSPECTION PERIOD. IF POSSIBLE, LOCK OUT SYSTEM SO IT CANNOT BE
ROTATED.
A. Before removing lube and scavenge pump inlet screens, perform following:
(4) Enter enclosure access per packager’s manual. Enclosure door shall remain open.
(5) Shut off lube oil supply to gas turbine per packager’s manual.
B. Remove lube and scavenge pump inlet screens (figure 1) as follows:
WARNING

(1) Remove drain plugs or chip detectors from transfer gearbox (TGB), accessory gearbox (AGB),
B-sump, C-sump, D-sump, and E-sump inlet screens. Remove and discard preformed packings.
Examine chip detectors per WP 4017 00. Drain residual oil into approved waste container.
(2) Remove lube inlet screen and six lube scavenge inlet screens from lube and scavenge pump, and
identify by location using tags or vibropeen etch. Remove and discard preformed packings.
7. Chip Detector and Screen Inspection.
CAUTION
OPERATING ENGINE WITHOUT ISOLATING SOURCE OF CHIP DETECTOR MATERIAL OR

WITHOUT INTRODUCING A CORRECTIVE ACTION CREATES RISK OF SECONDARY DAMAGE.
A. Visually inspect chip detectors and screens for foreign material. Refer to GEK 117488 for help in
communicating chip detector debris quantity and material identification. If any foreign material is found,
analyze and perform corrective action as follows:
(1) Isolate source of foreign material by identifying area from which material was scavenged.

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*(. /03)
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(2) Visually examine suspect material for identification of source.
• Bearing races, rollers, and balls are magnetic; therefore, separating out any magnetic materials
will help identification.
• Material composition analysis may be required to identify material.
(a) If material can be visually identified as bearing material, such as roller, ball, and/or race
fragments:
1 Component replacement is required. See table 1 for possible corrective action details.
• Main engine bearings cannot be replaced on site. Main engine bearings must be
replaced at depot level.
2 Review gas turbine log sheets for significant changes in gas turbine logged parameters
because main gas turbine bearing distress normally increases lube scavenge temperatures
and gas turbine vibration.
(b) If suspect material is found on TGB chip detector or in TGB screen, source must be further
identified. Remove lower drain plug and inspect TGB/A-sump area for any distress.
(c) If suspect material is identified as bolt or rivet fragments, replace component as indicated by
screen identity.
• Bearing cage rivets indicate a radial drive shaft failure.
(d) If suspect material is identified as pieces of preformed packing, gasket, safety wire, coke,
machining chip, seal rub strip material, or the source cannot be identified by available
instructions, place gas turbine on watch as follows:
1 Inspect and clean lube and scavenge pump screens and monitor lube system parameters
daily until source of contamination is located.
2 Shut engine down immediately if chip detector alarm is received, followed by GE contact
for instructions.
3 Remove engine from watch status and return to normal inspection schedule if screens are
free of debris for two consecutive days.
(e) If uncertain on classifying debris source, or if more information is required, contact customer
support manager for clarification.
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Figure 1. Lube and Scavenge Pump Screens Check

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Table 1. Component Failure Corrective Action

Filter Screen Possible Cause Possible Corrective Action
A. TGB 1. TGB failure 1. Replace TGB
2. Inlet gearbox failure 2. Replace gas turbine
3. 1B or 2R bearing failure 3. Replace gas turbine
4. 3R bearing failure 4. Replace gas turbine
B. B-Sump 4R/4B bearing failure Replace gas turbine
C. C-Sump 5R bearing failure Replace gas turbine
D. D- and E-Sump 6R/7R bearing failure Replace LPT module
E. AGB Scavenge AGB failure Replace AGB (see NOTE)
NOTE
Some packager and GE supplied components use gas turbine lube oil and are scavenged through the AGB.
Material in the AGB could be indicative of failure of the gearbox mounted components and not failure of the
AGB itself.
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8. Lube and Scavenge Pump Inlet Screens Installation.
WARNING

WARNING
WHEN USING COMPRESSED AIR FOR CLEANING, COOLING, OR DRYING, DO NOT

EXCEED 30 PSIG (207 KPA). WEAR EYE PROTECTION AND DO NOT DIRECT
A. Clean screens with isopropyl alcohol and soft bristle brush. Dry with shop air at 30 psig (207 kPa)
maximum pressure. Replace any damaged screens.
WARNING
B. Lubricate new preformed packings, PN M83248/1-912, with lubricating oil, and install onto TGB, B-, and
C-sump inlet screens. Install inlet screens into same ports from which they were removed and tighten to
57-67 lb in. (6.5-7.5 N·m) of torque.
C. Lubricate new preformed packings, PN M83248/1-908, with lubricating oil, and install onto AGB, D-, and
E-sump inlet screens. Install inlet screens into same ports from which they were removed and tighten to
57-67 lb in. (6.5-7.5 N·m) of torque.
D. Lubricate new preformed packing, PN NAS1593-121, with lubricating oil, and install on lube inlet screen.
Install lube inlet screen into same port from which it was removed and tighten to 57-67 lb in. (6.5-7.5 N·m)
of torque.
E. Lubricate new preformed packings, PN M83248/1-905 or PN J221P905, if chip detectors are used, with
lubricating oil. Install packings onto drain plugs or chip detectors and install in AGB, TGB, B-, C-, D-, and
E-sump inlet screens. Tighten drain plugs or chip detectors to 57-67 lb in. (6.5-7.5 N·m) of torque. Safety-
wire plugs or chip detectors.
F. Turn on lube oil supply to gas turbine.
G. Leak-check main lube and scavenge pump inlet screens as follows:
WARNING
ENCLOSURE ACCESS.
(1) Open fuel supply valve and make a gas turbine start per packager's manual.

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(2) Ensure gas turbine will not be operated above idle.
(3) Put on protective ear and hand equipment.
(5) Station safety observer adjacent to enclosure access.
WARNING
INLET AND EXHAUST AREAS OF RUNNING ENGINES ARE EXTREMELY

DANGEROUS. STAY CLEAR AND WEAR EAR PROTECTION.
WARNING

(6) Enter enclosure. Check for leaks in lube system, and correct leaks as required.
(7) Exit enclosure, close enclosure access, and activate fire extinguishing system per packager’s
manual.
(8) Shut down engine.
81&21752//(':+(135,17('2575$160,77('(/(&7521,&$//<
LM6000 PF+ GEK 119319
WP 4021 00
VARIABLE GEOMETRY PUMP/HYDRAULIC
CONTROL UNIT FILTER CHECK
EFFECTIVITY: LM6000 PF+ GAS TURBINE MODELS

Page No. Change No.
1 - 6 ..........................................................................................................................................................1
Alphabetical Index
Subject Page
VG Pump/HCU Filter Inspection.............................................................................................................3
Change 1 1
81&21752//(':+(135,17('2575$160,77('(/(&7521,&$//<
GEK 119319 LM6000 PF+
WP 4021 00
1. Introduction.
This work package contains instructions for inspection of the variable geometry (VG) pump/hydraulic control
unit (HCU) filter.
Title Number
None required.
Corrosion Preventive Oil MIL-L-6085
Dry Cleaning Solvent Fed Spec P-D-680, Type II

Element, Filter AC-B244F-2440Y1 1
2 Change 1
81&21752//(':+(135,17('2575$160,77('(/(&7521,&$//<
LM6000 PF+ GEK 119319
WP 4021 00
6. VG Pump/HCU Filter Inspection.
WARNING

ROTATED.
A. Before removing VG pump/HCU filter, perform the following:
(5) Shut off oil supply to gas turbine per packager’s manual.
B. Remove VG pump/HCU filter as follows (figure 1):
WARNING

(1) Remove filter bowl drain plug. Drain fluid into a suitable container. Remove and discard preformed
packing.
(2) Using strap wrench, remove filter bowl.
(3) Remove and discard filter element.
(4) Visually inspect filter bowl for large particles.
(5) Remove and discard preformed packing from filter bowl.
Change 1 3
81&21752//(':+(135,17('2575$160,77('(/(&7521,&$//<
GEK 119319 LM6000 PF+
WP 4021 00
Figure 1. VG Pump/HCU Filter Inspection
4 Change 1
81&21752//(':+(135,17('2575$160,77('(/(&7521,&$//<
LM6000 PF+ GEK 119319
WP 4021 00
C. Install VG pump/HCU filter as follows (figure 1):
WARNING
DRY CLEANING SOLVENT, P-D-680. TYPE II: COMBUSTIBLE. ELECTRICALLY

GROUND CONTAINERS AND EQUIPMENT. DO NOT INHALE, INGEST, OR LET
THIS MATERIAL TOUCH YOU. EXTREME EXPOSURE OR ASPIRATION INTO
THE LUNGS. MAY CAUSE LUNG DAMAGE OR DEATH. CENTRAL NERVOUS
SYSTEM DAMAGE/ADVERSE EFFECTS. IRRITANT. PERSONAL PROTECTIVE
EQUIPMENT REQUIRED. USE MECHANICAL EXHAUST VENTILATION - IF
NOT AVAILABLE, USE AN APPROVED RESPIRATOR. USE EXPLOSION PROOF
EQUIPMENT.
WARNING
WHEN USING COMPRESSED AIR FOR CLEANING, COOLING, OR DRYING, DO

NOT EXCEED 30 PSIG (207 KPA). WEAR EYE PROTECTION AND DO NOT
DIRECT COMPRESSED AIR AT SELF OR OTHERS.
(1) Clean filter bowl with dry cleaning solvent. Blow dry with compressed air.
WARNING

(2) Lubricate new preformed packings with corrosion preventive oil.
(3) Install new preformed packing, PN M83248/1-243, into filter bowl.
(4) Push new filter element, PN AC-B244F-2440Y1, into filter bowl.
(5) Install filter bowl onto filter head and hand-tighten until filter bowl bottoms. Tighten filter bowl to
maximum of 50 lb ft. (68 N·m) of torque.
(6) Install new preformed packing, PN M83248/1-110, onto drain plug and install plug. Tighten plug to
49-57 lb in. (5.6-6.4 N·m) of torque.
(7) Safety-wire drain plug to filter bowl and filter bowl to filter head.
(8) Turn on oil supply to gas turbine per packager’s manual.
D. Leak-check VG pump/HCU filter as follows:
WARNING

ENCLOSURE ACCESS.
(1) Open fuel supply valve and make a gas turbine start per packager’s manual.
Change 1 5
81&21752//(':+(135,17('2575$160,77('(/(&7521,&$//<
GEK 119319 LM6000 PF+
WP 4021 00
(2) Ensure gas turbine will not be operated above idle.
(3) Put on protective ear and hand equipment.
(5) Station a safety observer adjacent to the enclosure access.
WARNING
INLET AND EXHAUST AREAS OF RUNNING ENGINES ARE EXTREMELY

DANGEROUS. STAY CLEAR AND WEAR EAR PROTECTION.
WARNING

(6) Enter enclosure. Check for leaks in lube system. Correct leaks as required.
(7) Exit enclosure, secure enclosure access, and activate fire extinguishing system per packager’s
manual.
6 Change 1
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PNEUMATIC STARTER SERVICING
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4 Blank ..................................................................................................................................................... 0
Alphabetical Index
Subject Page
Pneumatic Starter Servicing. .................................................................................................................... 3
*(. /03)
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1. Introduction.
This work package contains instructions for servicing the pneumatic starter before installation.
Title Number
None required.

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6. Pneumatic Starter Servicing.
NOTE
This procedure is to be accomplished before the pneumatic starter is installed.
A. Remove reducer from air supply port. Remove and discard preformed packing (figure 1).
WARNING
B. Pour 12-15 fl oz (355-443 cc) of lubricating oil, MIL-PRF-23699F (C/I), into air supply port.
C. Lubricate new preformed packing, PN J221P906, with lubricating oil, MIL-PRF-23699F (C/I), and install
onto reducer.
D. Install reducer into air supply port. Tighten reducer to 175-205 lb in. (19.8-23.1 N·m) of torque.
Figure 1. Pneumatic Starter Servicing
%ODQN
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IGNITION SYSTEM FUNCTIONAL CHECK
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4 Blank ..................................................................................................................................................... 0
Alphabetical Index
Subject Page
Ignition System Functional Check. .......................................................................................................... 3
*(. /03)
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1. Introduction.
This work package contains instructions for a functional check of the ignition system.
Title Number
None required.
None required.
/03) *(.
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6. Ignition System Functional Check.
A. Before inspecting ignition system, perform the following:
(2) Shut off electrical power to ignition system per packager’s manual.
(3) To clear combustor of any residual fuel, motor gas turbine per packager’s manual for 1 minute and
allow gas turbine to coast down and stop.
WARNING
BEFORE YOU DISCONNECT THE IGNITION LEADS, MAKE SURE THE IGNITION SYSTEM
WAS OFF FOR MORE THAN 2 MINUTES. THE IGNITION SYSTEM COULD BE CHARGED
WITH HIGH VOLTAGE THAT CAN CAUSE DEATH.
B. Disconnect No. 1 ignition exciter input lead at exciter. Temporarily secure input lead away from exciter.
C. Turn on electrical power to ignition system (No. 2 ignition exciter energized) per packager’s manual. An
audible cracking should be heard when the No. 2 igniter plug fires.
D. Turn off electrical power to ignition system. Reconnect input lead to exciter and safety-wire connector.
E. Disconnect No. 2 ignition exciter input lead at exciter. Temporarily secure input lead away from exciter.
F. Turn on electrical power to ignition system (No. 1 ignition exciter energized) per packager’s manual. An
audible cracking should be heard when the No. 1 igniter plug fires.
G. Turn off electrical power to ignition system. Reconnect input lead to exciter and safety-wire connector.
H. If an audible noise or cracking is not heard on No. 1 and/or No. 2 igniters, check out system to isolate
problem, and take appropriate corrective action per Chapter 10.
I. Exit enclosure, close enclosure access, turn on electrical power to ignition system, open main fuel supply
valve, and activate fire extinguishing system per packager's manual.
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VIBRATION MONITORING SYSTEM FUNCTIONAL CHECK
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4 Blank ..................................................................................................................................................... 0
Alphabetical Index
Subject Page
Vibration Monitoring System Functional Check. .................................................................................... 3
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1. Introduction.
This work package contains instructions for a functional check of the vibration monitoring system.
Title Number
Accelerometer Replacement WP 1911 00

Megohmmeter Local Purchase
None required.
None required.
/03) *(.
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6. Vibration Monitoring System Functional Check.
WARNING

ROTATED.
A. Before vibration monitoring system functional check, do the following:

(4) Enter enclosure access per packager’s manual. Enclosure door must remain open.
(5) Turn on power to purchaser control panel.
CAUTION
USE A SMALL OBJECT AND LIGHT TAPS WHEN CHECKING ACCELEROMETER.

EXCESSIVE, HARD TAPPING MAY DAMAGE ACCELEROMETER.
B. Check accelerometer by tapping it lightly with a small object (screwdriver handle). Accelerometer is good
if control panel shows an indication of tapping.
NOTE
Control panel must have power turned on or indications will be incorrect.
C. If accelerometer does not show an indication of tapping, inspect accelerometer for loose or missing cable
clamps, loose mount brackets, and/or loose electrical connections. Make corrections as required and repeat
step 6.B.
D. If accelerometer does not show an indication of tapping after completion of step 6.C., perform electrical
test of accelerometer as follows:
NOTE
Electrical problems are evident by erratic or no output from the accelerometer and are
indicative of shorted or broken coil windings, contaminated connector contacts, loose
connector, or damaged leads at the connector backshell.
(1) Using a megohmmeter, or equivalent, verify insulation resistance of accelerometer by performing

resistance check of each connector pin to backshell.
(2) Resistance shall be 100 megohms minimum at 100 Vdc at an ambient temperature of 60 to 90°F
(15.6 to 32.2°C). If not, replace accelerometer per WP 1911 00.
E. If accelerometer fails electrical test or fails to operate, replace per WP 1911 00 and repeat step 6.B,
step 6.C, and step 6.D.
F. Exit enclosure, close enclosure access, open fuel supply valve, and activate fire extinguishing system per
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OVERSPEED INSPECTION
())(&7,9,7</03)*$6785%,1(02'(/6

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Alphabetical Index
Subject Page
Overspeed Conditions Inspection. ........................................................................................................... 3
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1. Introduction.
This work package contains instructions for overspeed inspection including disposition of the gas turbine.
Title Number
Gas Turbine Inlet Inspection WP 4010 00
External Engine Cleaning WP 4011 00
None required.
None required.
None required.
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6. Overspeed Conditions Inspection.
CAUTION
IF A QUESTIONABLE CONDITION EXISTS, DO NOT ATTEMPT TO MOTOR OR

OPERATE THE ENGINE UNTIL A THOROUGH INVESTIGATION OF THE CONDITION
HAS BEEN MADE. DO NOT REPEAT HOT STARTS, COMPRESSOR STALLS, LOAD-
SHEDDING, OR OTHER PROBLEMS THAT INITIATE EMERGENCY SHUTDOWNS OR
ABORTED OPERATIONS WITHOUT THOROUGH INVESTIGATION. FAILURE TO DO SO
MAY RESULT IN UNDUE STRESS ON ENGINE COMPONENTS THAT MAY RESULT IN
DAMAGE AND ULTIMATE FAILURE.
NOTE
• The electronic control system low pressure rotor trip point is 4650 rpm, while the high pressure
trip point is 10,900 rpm. During overspeed events, the rotor speeds can exceed the control system
trip point.
• Following an overspeed trip, the control system transient data shall be retrieved from the gas
turbine electronic control system. Do not reset the control or attempt another start before retrieving
the data and noting the maximum low pressure rotor and high pressure rotor speeds during the
overspeed event.
A. Following an emergency shutdown for overspeed, retrieve maximum obtained low pressure rotor and high
pressure rotor speeds from electronic control transient data. See appropriate packager’s manual for
instructions.
B. Perform overspeed inspection per table 1 (low pressure rotor) and table 2 (high pressure rotor).
C. Perform gas turbine control system check per appropriate packager’s manual.
D. Perform inlet and exhaust inspection per WP 4010 00 and WP 4011 00 or packager’s manual.
E. If LPC and LPT or HPC and HPT require teardown, remove gas turbine per WP 3010 00 and return to an
authorized depot for teardown and inspection.
F. If required, borescope HPC per WP 4015 00.
Table 1. Low Pressure Rotor Overspeed Inspection and Corrective Action Requirements
Requirements
Control System Inlet and Exhaust LPC & LPT
Condition Check Inspection Teardown
d4650 RPM X – –
>4650 and d5000 RPM X X –
>5000 RPM X – X
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Table 2. High Pressure Rotor Overspeed Inspection and Corrective Action Requirement
Requirements
Control System Inlet and Exhaust Borescope HPC HPC & HPT
Condition Check Inspection Teardown
<10,900 RPM X – – –
t11,055 and <11,202 RPM X X X –
t11,202 RPM X – – X
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OVERTEMPERATURE INSPECTION
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Alphabetical Index
Subject Page
Overtemperature Conditions Inspection. ................................................................................................. 3
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1. Introduction.
This work package contains instructions for overtemperature inspection.
Title Number
LM6000 System Descriptions Chapter 5
Gas Turbine in Enclosure Removal/Installation WP 3010 00
External Engine Inspection WP 4012 00
None required.
None required.
None required.
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6. Overtemperature Conditions Inspection.

CAUTION
IF A QUESTIONABLE CONDITION EXISTS, DO NOT ATTEMPT TO MOTOR OR

OPERATE THE ENGINE UNTIL A THOROUGH INVESTIGATION OF THE CONDITION
HAS BEEN MADE. DO NOT REPEAT HOT STARTS, COMPRESSOR STALLS, LOAD-
SHEDDING, OR OTHER PROBLEMS THAT INITIATE EMERGENCY SHUTDOWNS OR
ABORTED OPERATIONS WITHOUT THOROUGH INVESTIGATION. FAILURE TO DO SO
MAY RESULT IN UNDUE STRESS ON ENGINE COMPONENTS THAT MAY RESULT IN
DAMAGE AND ULTIMATE FAILURE.
A. Perform overtemperature inspection per table 1.
B. Perform sensor and fuel flow system inspection as follows:

(1) Check P0 and PS3 sensor systems. See appropriate packager’s manual (SPAM) to confirm correct
interface location and proper transducer calibration, and check for sensor line leakage. Correct any
abnormal conditions.
(2) Check functionality of XN25 sensors per Chapter 10, TS-27. Check functionality of T2 and T25
sensors per Chapter 10, TS-26.
(3) Check fuel flow calibration for high fuel flow condition. See appropriate packager’s manual.
(4) Confirm A-ring staging valves are closed on start, C-ring staging valves open, then close transiently
near core idle, and B-ring staging valves are always open during start. Refer to Chapter 5, figure 5-4
for fuel system schematic. Check staging valves per Chapter 10, TS-7.
C. Perform variable geometry inspection as follows (Chapter 10, TS-22):

(1) Check variable inlet guide vane (VIGV), variable bypass valve (VBV), variable stator vane (VSV),
and torque motor customer interface cables at electrical panel No. 1 for security. Correct, as
required, before restarting engine.
(2) Check electrical connectors, VIGV A, VBV A, and VSV A for security at hydraulic control unit
(HCU). If installed, check VIGV B, VBV B, and VSV B connectors also. Correct, as required,
before restarting engine.
(3) Ensure VSV position indicator (LVDT) indicated 0-42 percent during start. See appropriate
packager’s manual to verify correct schedule and proper functioning of engine control unit (ECU).
Perform the following and correct before restarting engine:
(a) Inspect VSV system mechanical components for damaged, loose, or missing hardware per
WP 4012 00.
WARNING

(b) Ensure electrical connectors at VSV actuators are secure.

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Table 1. Overtemperature Inspection and Corrective Action Requirements

T4.8 During Start-up (Note 2) T4.8 During Operation
Inspection 1301 to 1301 to 1510 to 1600°F 1702 to 1761 to 1683 to Reference
(Note 1) 1509°F 1509°F 1599°F (871°C) 1760°F (928 1787°F (961 1760°F (918
(705 to (705 to (822 to or more to 960°C) to 975°C) to 960°C)
820°C) 820°C) 870°C) For more For less than For more
For less than For more than 5 but 5 minutes than
40 seconds than less than 7 minutes or
40 seconds 7 minutes >1761°F
(961°C) for
more than
5 minutes
Engine X X X X X X X SPAM
Control
System
Check
(Note 3)
HPC Stages X X X WP 4015 00
1, 7, and 12
Borescope
Inspection
Combustor X X X X WP 4015 00
and HPT
Borescope
Inspection
LPT X X WP 4015 00
Borescope
Inspection
Sensor X X X X X step 6.B.
Inspection
Fuel System X X X X X step 6.B.
Inspection
Variable X X X X X step 6.C.
Geometry
Inspection
Replace X X WP 3010 00
Engine
Note 1. • Record time and temperature in engine log book.
• If maintenance has been performed on the engine, inspect those areas for loose, disconnected,
or improperly inspected connections.
• Borescope engine first to determine engine serviceability.
Note 2. Ensure starter operation meets packager’s requirement. Correct as required before restarting engine.
Note 3. • Check ECU for proper schedules and operation.
• If T4.8 indication system malfunction is found, correct malfunction, restart engine,
and check if T4.8 remains within limits.
• If T4.8 remains within limits, additional inspections are not required.
• If T4.8 exceeds limits, shut down engine and perform additional inspections as indicated above.
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(c) Ensure customer interface cables for VBV/VSV left and right LVDTs, are secure at electrical
panel No. 2.
(d) Perform electrical system wiring check as follows and replace cables as required:
1 Ensure continuity of VSV LVDT electrical cable, left and right, from appropriate actuator
to electrical panel No. 2 per wiring schematics in Chapter 10.
2 Ensure continuity of VBV/VSV LVDT left and right customer interface electrical cables
from electrical panel No. 2 to ECU interface panel per wiring schematics in Chapter 10.
3 Ensure continuity of VIGV, VBV, VSV, torque motor A/B, and, if installed, VIGV, VBV,
VSV, and torque motor B/C customer interface electrical cables from electrical panel No. 1
to ECU interface panel per wiring schematics in Chapter 10.
4 Ensure continuity of VSV portion of the VIGV, VBV, VSV, torque motor A/B, and, if
installed, VIGV, VBV, VSV, and torque motor B/C electrical cables from electrical panel
No. 1 to HCU per wiring schematics in Chapter 10.
5 Verify ohmic value of VSV torque motor A/B, and, if installed, torque motor B/C, at HCU
connectors No. 4 per troubleshooting tables and wiring schematics in Chapter 10.
6 Verify ohmic value of VSV actuator LVDTs per troubleshooting tables and wiring
schematics in Chapter 10.
(e) If VSV LVDT indicator is still in error, perform VSV rig check per WP 1411 00.
(4) Ensure VBV LVDT indicated 83-100 percent during start. See appropriate packager’s manual to
verify correct schedule and proper functioning of ECU. Perform the following and correct before
restarting engine:
(a) Inspect VBV system mechanical components for damaged, loose, or missing hardware per
WP 4012 00.
(b) Ensure electrical connectors at VBV actuators are secure.
(c) Perform electrical system wiring check as follows and replace cables as required:
1 Ensure continuity of VBV LVDT electrical cables, left and right, from appropriate actuator
to electrical panel No. 2 per wiring schematics in Chapter 10.
2 Verify ohmic value of the VBV torque motor A/B, and, if installed, torque motor B/C, at
the HCU connectors No. 3 per troubleshooting tables and wiring schematics in Chapter 10.
3 Verify ohmic value of VBV actuator LVDTs per Chapter 10, troubleshooting tables and
wiring schematics.
(d) If VBV position indicator is still in error, perform VBV rig check per WP 1312 00.
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(5) Ensure VIGV LVDT indicated 27-29 percent during start. See appropriate packager’s manual to
verify correct schedule and proper functioning of ECU. Perform the following and correct before
restarting engine:
(a) Inspect VIGV system mechanical components for damaged, loose, or missing hardware per
WP 4012 00.
(b) Ensure electrical connectors at VIGV actuators are secure.
(c) Ensure customer interface cables, VIGV LVDT, left and right, are secure at electrical panel No.
1.
(d) Perform electrical system wiring check as follows and replace cables as required:
1 Ensure continuity of VIGV electrical cable, left and right, from appropriate actuator to
electrical panel No. 1 per wiring schematics in Chapter 10.
2 Ensure continuity of VIGV LVDT left and right customer interface electrical cables from
electrical panel No. 1 to ECU interface panel per wiring schematics in Chapter 10.
3 Verify ohmic value of the VIGV torque motor A/B, and, if installed, torque motor B/C, at
the HCU connectors No. 2 per troubleshooting tables and wiring schematics in Chapter 10.
4 Verify ohmic value of VIGV actuator LVDTs per troubleshooting tables and wiring
schematics in Chapter 10.
(e) If VIGV position indicator is still in error, perform VIGV rig check per WP 1113 00.
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BEARING SUMP FLOW TESTS
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Alphabetical Index
Subject Page
Bearing Sump Flow Tests. ....................................................................................................................... 3
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1. Introduction.
This work package contains instructions for air flow testing of the lubrication system.
None required.

Air Flow Tester, Portable - Lube System 9453M62P01
CAUTION
THE LUBE SYSTEM PORTABLE AIR FLOW TESTER, 9453M62P01, MUST BE CALIBRATED
ANNUALLY. FAILURE TO DO SO MAY RESULT IN ERRONEOUS READINGS AND DAMAGE
TO ENGINE BEARINGS.
NOTE
Tool will require electrical power to heat air/nitrogen to 70.5 to 74.0°F (21.4 to 23.3°C). Tool is equipped with
a power adapter to convert supply voltage/frequency.
Nitrogen (Optional) BB-N-411
None required.
/03) *(.
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6. Bearing Sump Flow Tests.
CAUTION
DO NOT DEFORM HOSES IF LOWERING MANIFOLD LOWER SECTION TO GAIN CLEARANCE

FOR INSTALLATION OF MANIFOLD UPPER SECTION. FAILURE TO COMPLY MAY RESULT
IN HOSE OR FUEL NOZZLE DAMAGE.
A. Before performing bearing sump flow tests, perform the following:
(1) Verify gas turbine will be inoperable during test.
(3) Deactivate fire extinguishing system per packager’s manual. Enclosure door must remain open.
(4) Shut off lube oil supply to gas turbine.
WARNING
NITROGEN, BB-N-411, CAN DISPLACE OXYGEN IN ENCLOSED AREAS. USE IN A

WARNING
SERIOUS INJURY CAN OCCUR WHEN APPLYING COMPRESSED AIR/NITROGEN
PRESSURE. EYE PROTECTION IS REQUIRED. RELIEVE PRESSURE BEFORE
B. Connect lube flow tester, 9453M62, to a source of clean, dry compressed air or nitrogen and to connection
area to be flow-tested (figure 1, figure 2, and table 1). Connect lube flow tool to electrical supply source.
C. Flow test engine frames and gearboxes with clean, dry air at 70.5 to 74°F (21.4 to 23.3°C) at the tool gage
supply pressure of 20 psig (138 kPa). Allow air/nitrogen temperature to stabilize before recording flow
data (2-3 minutes). Compare measurements with limits specified in table 1. Contact CSE or CSM for
engine disposition if sump exceeds flow limits.
*(. /03)
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Table 1. Bearing Sump Flow Test Requirements

Flow Limits Est.
Area Connection (figure 1) Min Avg Max
A-sump and IGB Front frame aft looking forward (ALF) at 8:00 o’clock - 14.2 scfm* -
position. #-8 to -4 AN reducer required
B-, C-sump Compressor rear frame forward of fuel nozzles at 18.0 scfm* - 20.0 scfm*
8:00 o’clock position, ALF. #-10 to -4 AN reducer
required (PN ANJ919)
D-, E-sump Turbine rear frame at 5:00 o’clock position, ALF. #-8 to - 4.4 scfm* -
-4 AN reducer required
AGB Gearbox front face. Cap lower line to TGB disconnected - 3.1 scfm* -
at 5:00 o’clock position, ALF, right side. #-6F to-4M
reducer required
TGB Right side of TGB - 4.1 scfm* -
*scfm: square cubic foot per minute
/03) *(.
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Figure 1. Engine Connections for Lube Flow Tester, 9453M62 (Sheet 1 of 2)
*(. /03)
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Figure 1. Engine Connections for Lube Flow Tester, 9453M62 (Sheet 2 of 2)
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Figure 2. Lube Flow Tester, 9453M62
%ODQN
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ACOUSTIC SIGNAL CONDITIONER CALIBRATION AND
CHECKOUT PROCEDURE
())(&7,9,7</03)*$6785%,1(02'(/6

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Alphabetical Index
Subject Page
Acoustics Signal Conditioner Calibration and Checkout......................................................................... 3
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1. Introduction.
This work package contains instructions for calibration and checkout for acoustics signal conditioners using a
TSU 109 Charge Generator. The charge generator outputs a sinusoidal picoCoulomb (pC) charge, using
magnitudes dialed on the potentiometer and frequency dialed on the counter. The input magnitude is in peak
levels (not peak-to-peak). All calibration check values are in units to be set on the TSU 109, and the expected
output is read at the control monitor as peak-to-peak.
Title Number
Acoustic Sensor Replacement WP 1611 00

Generator, Charge Cable with Mating Vibrometer Lemo Connector TSU 109
None required.
None required.
/03) *(.
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6. Acoustics Signal Conditioner Calibration and Checkout
A. Check TSU 109 charge generator as follows (figure 1):
(1) Ensure CHECK BAT/OPERATION toggle switch (1) is centered in OFF position.
(2) Check battery as follows:
(a) Push CHECK BAT/OPERATION toggle switch (1) up. If batteries are charged, both +9V and
-9V LED (3) will light.
(b) If LEDs (3) do not light, replace batteries.
(c) Return switch (1) to center (OFF) position.
NOTE
The off-engine cable would normally mate to the acoustic sensor.
(3) Install cable (2) with mating Vibrometer Lemo connector, between TSU 109 charge generator and
off-engine cable.
B. Operate TSU 109 charge generator as follows:
(1) Push CHECK BAT/OPERATION toggle switch (1) down to operate TSU 109 charge generator.
(2) Set output power (O/P) switch (4) in SYM position and set output to 16 pC peak.
(3) Set frequency adjustment (5) at 600 Hz.
(4) Set multiplier switch (6) to nx1.
NOTE
There is a locking mechanism on the potentiometer which must be moved
counterclockwise to allow potentiometer to turn freely.
(5) Unlock potentiometer and turn knob (7) to adjust AMPLITUDE until digit in window corresponds
to first digit (tens) of set point charge value, table 1, and hundred scaled button of potentiometer to
number corresponding to second digit (units) of set point charge value. Lock potentiometer.
(6) Record signal conditioner output value. Peak-to-peak should equal 2.0 psia (13.8 kPa).
(7) Repeat step 6.B.(1) through step 6.B.(7) until all values in table 1 are checked. If values do not meet
expected signal conditioner output value of table 1, replace acoustic signal conditioner per
WP 1611 00.
*(. /03)
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Figure 1. TSU 109 Charge Generator Operation
/03) *(.
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Table 1. Acoustic Sensor Calibration Points

TSU 109 Equivalent Expected Signal Recorded Signal Recorded Signal
TSU 109 Input Amplitude Output Conditioner Output Conditioner Output Conditioner Output
(pC peak) (psi peak-peak) (mA) (mA) (psi peak-peak)
[1]6 2 7.2
[3]2 4 10.4
[4]8 6 13.6
[6]4 8 16.8
[8]0 10 20.0
NOTE
• Information in bracket is the digit shown in amplitude window.
• The Vibrometer RSI signal conditioner should have been calibrated at the factory for a sensor with an
output of 16 pC/psi peak and a range of 0 to 10 psi peak-peak. This range has been used to determine
the expected milliAmp level in the table above.
• Typically, OEMs use 4-20 mA outputs to their control system. The above expected mA output levels
have been provided for your convenience. If there is a better way at the control system of determining
the output level, feel free to use it.
%ODQN
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FUEL SYSTEM PRESSURE CHECK
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Subject Page
Fuel System Pressure Check. ................................................................................................................... 3
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1. Introduction.
This work package provides instructions for pressure-checking the fuel system.
Title Number
Fuel System Replacement WP 1510 00
Dual Fuel System Replacement WP 1511 00

Set, Closure 1C9450G01
Detector, Gas, Hand-Held Local Purchase

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6. Fuel System Pressure Check.
CAUTION
MINIMIZE BENDING OF HOSES DURING THIS OPERATION OR DAMAGE MAY

RESULT.
A. Remove 30 fuel hose assemblies and fuel nozzle seals from fuel nozzles per WP 1510 00 or WP 1511 00.
NOTE
The blank-off plates have a gasket glued to them. Ensure gasket faces fuel hose.
B. Install 30 blank-off plates, P02, from closure set, 1C9450, between fuel hose flanges and fuel nozzles
(figure 1).
NOTE
Capscrews and washers supplied with blank-off plates are installed through hose flanges, blank-off
plates, and into fuel nozzle tapped holes.
C. Lightly coat capscrew threads and contact faces with thread lubricant.
Figure 1. Installation of Closure Set, 1C9450
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CAUTION
• EXCESSIVE TORQUE ON ONE CAPSCREW WILL RESULT IN FUEL HOSE

ASSEMBLY PAD IMPROPERLY SEATING ONTO FUEL NOZZLE.
• IMPROPER SEALING OF FUEL HOSE ASSEMBLY WILL RESULT IN FUEL

LEAKAGE.
• DO NOT EXCEED 15 LB IN. (1.7 N·M) OF TORQUE DURING INITIAL SEATING OF

HOSE ASSEMBLY PLATE ONTO FUEL NOZZLE, OR DISTORTION MAY OCCUR.
D. Using crisscross pattern, install four capscrews and washers to seat fuel hose assembly onto fuel nozzle.
Ensure capscrews are lightly tightened.
E. Final tighten capscrews securing fuel hose assembly and blank-off plate to fuel nozzle as follows:
(1) Using crisscross pattern, tighten four capscrews to 92-108 lb in. (10.4-12.2 N·m) of torque.
(2) Using crisscross pattern, tighten four capscrews to 18-22 lb ft (24.4-29.8 N·m) of torque.
(3) Using crisscross pattern, tighten four capscrews to 30-36 lb ft (40.7-48.8 N·m) of torque.
(4) Using clockwise sequence, verify final torque of 30-36 lb ft (40.7-48.8 N·m) has been applied to
four capscrews.
F. Prepare package as follows:
(1) Ventilate package to eliminate any residual vapors.
(2) Ensure package ventilation fans are off. Check package detectors for presence of gas.
(3) Follow site safety requirements.
(4) Using hand-held gas detector, take a vapor reading at package door before entering. If gas vapors are
too strong, turn on vent fans to purge package.
(5) Post a person at package door.
NOTE
If at any time system pressure drops below 350 psia (2,413 kPa), repressurize to 500 psia (3,447 kPa).
G. Pressure-test fuel system as follows:
(1) Close vent valve between block valves.
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WARNING
FUEL SYSTEM IS PRESSURIZED. USE CARE TO PREVENT INJURY WHEN

DISCONNECTING LINE.
(2) Pressurize fuel system to 500 psia (3,447 kPa) by opening block valves. If necessary in order to
achieve pressure in manifold, open metering valves.
(3) Close block valves to trap pressure in system, and open vent valve.
(4) Monitor GP1, GP2I, GP2P, and GP2O manifold pressures for pressure decay.
(5) Using hand-held gas detector, check all joins up to staging valves.
H. After successful pressure-testing per above, check B2-ring fittings and hoses. B2-ring hose is forward-
most hose on odd number fuel nozzles. Check entire length of hose, particularly where flex portion meets
rigid section. Tag any hose which is leaking for later replacement.
NOTE
Continuing pressure decay may indicate a leak in that portion of system and requires close inspection
of the portion of system that is fed by staging valve that was opened.
I. Open staging valves and check appropriate hoses and fittings as they are opened (table 1). Continue to
monitor manifold pressure for 5 minutes. Note how much system pressure drops immediately after
opening valve. After initial drop, there should be no further drop in system pressure.
J. After all hoses and fittings have been checked (and repaired/replaced as necessary), open block valve
nearest metering valves to vent system.
CAUTION
MINIMIZE BENDING HOSES DURING THIS OPERATION OR DAMAGE MAY RESULT.
K. Remove blank-off plates, P02, and attach fuel hose assemblies to fuel nozzles using new seals per
WP 1510 00 or WP 1511 00.
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Table 1. Flow Test Requirements

Staging Valve No. Ring Hose Check Fuel Nozzles GP1 Results
2 A Middle 2/3/4/5/6/7 - OK/Leak
4 A Middle 8/9/10/11/12/13 - OK/Leak
7 A Middle 14/15/16/17/18/19 - OK/Leak
9 A Middle 20/21/22/23/24/25 - OK/Leak
11 A Middle 26/27/28/29/30/1 - OK/Leak
1 C Aft 2/4/30 - OK/Leak
3 C Aft 6/8/10 - OK/Leak
5 C Aft 12/16/24 - OK/Leak
8 C Aft 18/20/22 - OK/Leak
10 C Aft 24/26/28 - OK/Leak
12 ELBO Aft All 2-cup (odd nos.) - OK/Leak
6 B3 Forward 30/2/4/6/8/10/12 - OK/Leak
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MFG Project No.: 7277395, 7280414, 7280415
GEK 119320 - Illustrated Parts Breakdown
GEK 119320 LM6000 PF+ Model Gas Turbines

GEK119320_FM.0001
Cover Page . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C00
GEK119320_FM.0002
GEK119320_FM.0003
GEK119320_FM.0004
GEK 119320 Section I
GEK119320_INT.000
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.C00
Table I. How to Use This Illustrated Parts GEK119320_INT.000
Breakdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.C00
GEK119320_INT.000
Table II. Glossary of Terms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.C00
GEK119320_INT.000
Table III. Abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.C00
GEK119320_INT.000
Table IV. Publication Change Request . . . . . . . . . . . . . . . . . . . . . . . . 5.C00
GEK 119320 Section II / Group Assembly Parts List
GEK119320_FIG.0001
Figure 1. Major Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C02
Figure 2. Variable Inlet Guide Vane Assembly - GEK119320_FIG.0002
Breakdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C00
Figure 3. Kit, 682L265, Variable Inlet Guide Vane GEK119320_FIG.0003
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C00
GEK119320_FIG.0004
Figure 4. Front Frame Assembly Breakdown . . . . . . . . . . . . . . . . . . . .C02
Figure 5. Front Frame and Associated Parts GEK119320_FIG.0005
(Internal) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C00
Figure 6. Front Frame and Associated Parts GEK119320_FIG.0006
(Lube/Sump) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C00
GEK119320_FIG.0007
Figure 7. Lube System, Front Frame Module . . . . . . . . . . . . . . . . . . . .C02
GEK119320_FIG.0008
Figure 8. Front Frame Module Electrical . . . . . . . . . . . . . . . . . . . . . . . .C02
Figure 9. Air Collector Assembly and Associated GEK119320_FIG.0009
Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C02
GEK119320_FIG.0010
Figure 10. Air Collector Assembly - Cover Plates . . . . . . . . . . . . . . . .C02
GEK119320_FIG.0011
Figure 11. Air Collector Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . .C02

MFG Project No.: 7277395, 7280414, 7280415
Figure 12. Low Pressure Compressor Rotor GEK119320_FIG.0012

Breakdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C00
Figure 13. Low Pressure Compressor Stator GEK119320_FIG.0013
Assembly Breakdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C00
GEK119320_FIG.0014
Figure 14. Inlet Gearbox Assembly Breakdown . . . . . . . . . . . . . . . . . .C00
GEK119320_FIG.0015
Figure 15. Inlet Gearbox Housing Hardware . . . . . . . . . . . . . . . . . . . . .C00
GEK119320_FIG.0016
Figure 16. Radial Adapter Assembly Breakdown . . . . . . . . . . . . . . . . .C00
Figure 17. Transfer and Accessory Gearbox GEK119320_FIG.0017
Figure 18. Transfer Gearbox Housing Studs and GEK119320_FIG.0018
Bushings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C02
Figure 19. Transfer Gearbox Housing Inserts and GEK119320_FIG.0019
Lock Rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C01
GEK119320_FIG.0020
Figure 20. Fan Mid Shaft Breakdown . . . . . . . . . . . . . . . . . . . . . . . . . .C02
Figure 21. High Pressure Compressor Rotor GEK119320_FIG.0021
Figure 22. High Pressure Compressor Stator GEK119320_FIG.0022
Figure 23. High Pressure Compressor Variable GEK119320_FIG.0023
Stator Actuation Rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C00
Figure 24. High Pressure Compressor VSV GEK119320_FIG.0024
Actuation System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C02
GEK119320_FIG.0025
Figure 25. Accelerometer, Core Module . . . . . . . . . . . . . . . . . . . . . . . .C02
Figure 26. Compressor Rear Frame Assembly GEK119320_FIG.0026
Breakdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C01
Figure 27. Compressor Rear Frame Sump GEK119320_FIG.0027
Breakdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C02
Figure 28. High Pressure Turbine Stage 1 Nozzle GEK119320_FIG.0028
Figure 29. High Pressure Turbine Stage 2 Nozzle GEK119320_FIG.0029
Figure 30. High Pressure Turbine Rotor Assembly GEK119320_FIG.0030
Breakdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C02
Figure 31. Low Pressure Turbine Rotor/Stator GEK119320_FIG.0031
Assembly - Rotor Breakdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C02
Figure 32. Low Pressure Turbine Rotor/Stator GEK119320_FIG.0032
Assembly – Stator Breakdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C02
GEK119320_FIG.0033
Figure 33. Gearbox Hangers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C00
Figure 34. Turbine Rear Frame and Sump Assembly GEK119320_FIG.0034
Breakdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C02
GEK119320_FIG.0035
Figure 35. Turbine Rear Frame Assembly . . . . . . . . . . . . . . . . . . . . . . .C02

MFG Project No.: 7277395, 7280414, 7280415
GEK119320_FIG.0036
Figure 36. Turbine Rear Frame – Bearings and Seals . . . . . . . . . . . . . .C02
Figure 37. Turbine Rear Frame – No. 7 Bearing GEK119320_FIG.0037
Figure 38. Turbine Rear Frame – Two Tube Balance GEK119320_FIG.0038
Piston Assembly Breakdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C02
Figure 39. Compressor Stator Case Boss Bracket GEK119320_FIG.0039
Hardware . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C02
Figure 40. Flange Brackets – VIGV Case Aft Flange GEK119320_FIG.0040
to Low Pressure Compressor Case Forward Flange . . . . . . . . . . . . . . .C02
Figure 41. Flange Brackets – Front Frame Aft GEK119320_FIG.0041
Flange to HP Compressor Stator Forward Flange . . . . . . . . . . . . . . . . .C00
Figure 42. Flange Brackets – HP Compressor Aft GEK119320_FIG.0042
Flange to Compressor Rear Frame Forward Flange . . . . . . . . . . . . . . .C02
Figure 43. Flange Brackets – HP Compressor Aft GEK119320_FIG.0043
Flange to Forward Flange Aft Combustor Case . . . . . . . . . . . . . . . . . .C02
Figure 44. Flange Brackets – Compressor Rear GEK119320_FIG.0044
Frame Aft Flange to HP Turbine Fwd Flange . . . . . . . . . . . . . . . . . . . .C02
Figure 45. Flange Brackets – HP Turbine Aft Flange GEK119320_FIG.0045
to Low Pressure Turbine Forward Flange . . . . . . . . . . . . . . . . . . . . . . .C02
Figure 46. Flange Brackets - Low Pressure Turbine GEK119320_FIG.0046
Aft Flange to Turbine Rear Frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C02
GEK119320_FIG.0047
Figure 47. Kit, 738L677, Gas Fuel System . . . . . . . . . . . . . . . . . . . . . .C02
GEK119320_FIG.0048
Figure 48. Kit, 738L298, Spray Injected Turbine . . . . . . . . . . . . . . . . .C01
GEK119320_FIG.0049
Figure 49. Piping - Left Side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C02
GEK119320_FIG.0050
Figure 50. Air System - Right Side . . . . . . . . . . . . . . . . . . . . . . . . . . . .C02
Figure 51. Air System - Low Pressure Turbine 8th GEK119320_FIG.0051
Stage Cooling Air . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C02
GEK119320_FIG.0052
Figure 52. Electrical Leads - VIGV . . . . . . . . . . . . . . . . . . . . . . . . . . . .C00
GEK119320_FIG.0053
Figure 53. Kit, 682L255, UV Flame Detector . . . . . . . . . . . . . . . . . . . .C02
GEK119320_FIG.0054
Figure 54. Pressure Transducer Sensors . . . . . . . . . . . . . . . . . . . . . . . .C02
GEK119320_FIG.0055
Figure 55. Oil System - VIGV . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C02
GEK119320_FIG.0056
Figure 56. Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C02
GEK119320_FIG.0057
Figure 57. Kit, 738L217, LPT Case Cooling . . . . . . . . . . . . . . . . . . . . .C01
GEK119320_FIG.0058
Figure 58. Oil System - Bottom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C02
GEK119320_FIG.0059
Figure 59. Gearbox, Lube System . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C02

MFG Project No.: 7277395, 7280414, 7280415
Figure 60. Lube and Scavenge Pump and Associated GEK119320_FIG.0060

Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C00
GEK119320_FIG.0061
Figure 61. Kit, 537L305, Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C00
GEK119320_FIG.0062
Figure 62. Kit, 682L264, Exhaust Interface . . . . . . . . . . . . . . . . . . . . . .C00
Figure 63. Low Pressure Turbine – External GEK119320_FIG.0063
Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C02
GEK119320_FIG.0064
Figure 64. Kit, 682L207, Chip Detector Cable . . . . . . . . . . . . . . . . . . .C00
GEK119320_FIG.0065
Figure 65. Kit, 682L187G05, Ignition System . . . . . . . . . . . . . . . . . . .C02
Figure 66. Kit, 682L190, Chip Detector Assembly GEK119320_FIG.0066
and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C00
Figure 67. Compressor Discharge Temperature GEK119320_FIG.0067
Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C02
GEK119320_FIG.0068
Figure 68. CDP and Stage 8 Bleed Valves . . . . . . . . . . . . . . . . . . . . . .C00
GEK119320_FIG.0069
Figure 69. Kit, 738L681, Dual Fuel System . . . . . . . . . . . . . . . . . . . . .C02
GEK119320_FIG.0071
Figure 71. Kit, 682L188, Oil Temperature Sensors . . . . . . . . . . . . . . . .C02
GEK119320_FIG.0072
Figure 72. Kit, 682L194, Vibration Sensor . . . . . . . . . . . . . . . . . . . . . .C02
Figure 73. Kit, 738L749, Sump Pressurization GEK119320_FIG.0073
Adapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C02
GEK119320_FIG.0074
Figure 74. Kit, 682L292, Air Collector Cover Plate . . . . . . . . . . . . . . .C02
GEK 119320 Section III

GEK119320_NUI.000
Numerical Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.C02

GE Industrial AeroDerivative
Gas Turbines
GEK 119320
ILLUSTRATED PARTS BREAKDOWN

GE FOR
7LM6000® PF+ MODEL
GAS TURBINES
INDUSTRIAL AERODERIVATIVE
GAS TURBINES

Mail Drop S-133
One Neumann Way
P.O. Box 156301
81&21752//(':+(135,17('2575$160,77('(/(&7521,&$//<
GE Industrial AeroDerivative
Gas Turbines
GEK 119320
ILLUSTRATED PARTS BREAKDOWN

GE FOR
7LM6000® PF+ MODEL
GAS TURBINES
INDUSTRIAL AERODERIVATIVE
GAS TURBINES
The information contained in this document is GE proprietary information and is disclosed in confidence. It is the property of
GE and shall not be used, disclosed to others, or reproduced without the express written consent of GE, including, but without
limitation, it is not to be used in the creation, manufacture, development, or derivation of any repairs, modifications, spare
parts, designs, or configuration changes or to obtain FAA or any other government or regulatory approval to do so. If consent is
given for reproduction in whole or in part, this notice and the notice set forth on each page of this document shall appear in any
such reproduction in whole or in part.
This technical data is considered ITAR and/or EAR controlled pursuant to 22 CFR Part 120-130 and 15 CFR Parts 730-774,
respectively. This technical data is authorized for export with classification: US NLR; ECCN 9E991.
All technical documentation and information contained herein have been developed and approved for use with GE engines and
parts that have been operated and maintained in accordance with GE technical documentation and recommendations. GE has
no technical knowledge of, nor obligation for, non GE-approved parts and repairs. Accordingly, this document is not intended to
apply to non GE-approved parts and repairs, nor to any parts that may be directly or indirectly affected by non GE-approved
parts and repairs.
This document contains trade secrets and confidential commercial or financial information exempt from disclosure under the
FREEDOM OF INFORMATION ACT (FOIA) 5 USC §552(b)(4).
NOTE: THIS CHANGE SUPPLEMENTS GEK 119320 DATED 28 FEBRUARY 2017 AND CHANGE 1 DATED 30 AUGUST
2017.

Mail Drop S-133
One Neumann Way
P.O. Box 156301
28 FEBRUARY 2017
CHANGE 2 - 30 MARCH 2018
81&21752//(':+(135,17('2575$160,77('(/(&7521,&$//<
GEK 119320
LIST OF EFFECTIVE PAGES
This Illustrated Parts Breakdown is part of an LM6000 manual set which

includes:
GEK 119319 On-Site Operation and Maintenance Manual (LM6000 PF+ Series)
GEK 119349 CD – LM6000 PF+ Series Gas Turbine (Standard Edition)
Insert latest changed pages; dispose of superseded pages in accordance with

applicable regulations.
NOTE: On a changed page, the portion of the text affected by the latest change
is indicated by a vertical line, or other change symbol, in the outer margin of
the page. Changes to wiring diagrams are indicated by shaded areas.
Dates of issue for original and changed pages are:
Original .. 0 .... 28 Feb 2017 Change .... 2 .... 30 Mar 2018

Change .... 1 .... 30 Aug 2017
Total number pages in this manual is 682 consisting of the following:
Page #Change Page #Change Page #Change

No. No. No. No. No. No.
Title ............ 2 23-1 - 23-5 ...... 0 50-1 - 50-21 ..... 2

A ................ 2 24-1 - 24-5 ...... 2 51-1 - 51-2 ...... 2
i - ix .......... 2 25-1 - 25-3 ...... 2 52-1 - 52-3 ...... 0
INTRO-1 - 26-1 - 26-7 ...... 1 53-1 - 53-6 ...... 2
INTRO-10 ....... 0 27-1 - 27-10 ..... 2 54-1 - 54-6 ...... 2
1-1 - 1-10 ....... 2 28-1 - 28-5 ...... 1 55-1 - 55-6 ...... 2
2-1 - 2-5 ........ 0 29-1 - 29-5 ...... 2 56-1 - 56-10 ..... 2
3-1 - 3-3 ........ 0 30-1 - 30-5 ...... 2 57-1 - 57-11 ..... 1
4-1 - 4-7 ........ 2 31-1 - 31-6 ...... 2 58-1 - 58-10 ..... 2
5-1 - 5-7 ........ 0 32-1 - 32-9 ...... 2 59-1 - 59-19 ..... 2
6-1 - 6-6 ........ 0 33-1 - 33-2 ...... 0 60-1 - 60-2 ...... 0
7-1 - 7-11 ....... 2 34-1 - 34-3 ...... 2 61-1 - 61-2 ...... 0
8-1 - 8-14 ....... 2 35-1 - 35-6 ...... 2 62-1 - 62-2 ...... 0
9-1 - 9-7 ........ 2 36-1 - 36-2 ...... 2 63-1 - 63-16 ..... 2
10-1 - 10-3 ...... 2 37-1 - 37-2 ...... 0 64-1 - 64-2 ...... 0
11-1 - 11-4 ...... 2 38-1 - 38-7 ...... 2 65-1 - 65-4 ...... 2
12-1 - 12-5 ...... 0 39-1 - 39-7 ...... 2 66-1 - 66-2 ...... 0
13-1 - 13-7 ...... 0 40-1 - 40-5 ...... 2 67-1 - 67-4 ...... 2
14-1 - 14-3 ...... 0 41-1 - 41-3 ...... 0 68-1 - 68-3 ...... 0
15-1 - 15-2 ...... 0 42-1 - 42-7 ...... 2 69-1 - 69-72 ..... 2
16-1 - 16-2 ...... 0 43-1 - 43-14 ..... 2 71-1 - 71-7 ...... 2
17-1 - 17-12 ..... 2 44-1 - 44-4 ...... 2 72-1 - 72-8 ...... 2
18-1 - 18-6 ...... 2 45-1 - 45-9 ...... 2 73-1 - 73-2 ...... 2
19-1 - 19-2 ...... 1 46-1 - 46-5 ...... 2 74-1 - 74-2 ...... 2
20-1 - 20-3 ...... 2 47-1 - 47-42 ..... 2 INDEX-1 -
21-1 - 21-7 ...... 2 48-1 - 48-5 ...... 1 INDEX-52 ....... 2
22-1 - 22-13 ..... 2 49-1 - 49-27 ..... 2
# Zero in this column indicates an original page.
A CHANGE 2
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GEK 119320
TABLE OF CONTENTS
Page
Section Number
I INTRODUCTION
CONTENTS, ARRANGEMENT AND EXPLANATIONS
1. General .............................................. INTRO-1

2. Purpose .............................................. INTRO-1
3. Scope ................................................ INTRO-1
4. Explanation of Parts Breakdown ....................... INTRO-1
5. Part Number Column and Description ................... INTRO-1
6. Attaching Parts ...................................... INTRO-3
7. Quantity Column ...................................... INTRO-3
8. Selective Fit Item ................................... INTRO-3
9. Usable On Assembly Code .............................. INTRO-3
10. Numerical Index ...................................... INTRO-3
11. Changed Data ......................................... INTRO-3
12. Publication Change Request ........................... INTRO-3
Table I. How to Use This Illustrated Parts Breakdown .. INTRO-4

Table II. Glossary of Terms ............................ INTRO-5
Table III. Abbreviations ................................ INTRO-8
Table IV. Publication Change Request ................... INTRO-10
II GROUP ASSEMBLY PARTS LIST
Figure 1. Major Assemblies

(View 1 of 6) ............................. 1-1
(View 2 of 6) ............................. 1-2
(View 3 of 6) ............................. 1-3
(View 4 of 6) ............................. 1-4
(View 5 of 6) ............................. 1-5
(View 6 of 6) ............................. 1-6
Figure 2. Variable Inlet Guide Vane Assembly -
Breakdown
(View 1 of 2) ............................. 2-1
(View 2 of 2) ............................. 2-2
Figure 3. Kit, 682L265, Variable Inlet Guide Vane
Assembly .................................. 3-1
Figure 4. Front Frame Assembly Breakdown
(View 1 of 3) ............................. 4-1
(View 2 of 3) ............................. 4-2
(View 3 of 3) ............................. 4-3
Figure 5. Front Frame and Associated Parts (Internal)
(View 1 of 4) ............................. 5-1
(View 2 of 4) ............................. 5-2
(View 3 of 4) ............................. 5-3
(View 4 of 4) ............................. 5-4
Figure 6. Front Frame and Associated Parts (Lube/Sump)
(View 1 of 3) ............................. 6-1
(View 2 of 3) ............................. 6-2
(View 3 of 3) ............................. 6-3
CHANGE 2 i
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GEK 119320
TABLE OF CONTENTS (Continued)
Page
Section Number
II GROUP ASSEMBLY PARTS LIST (Continued)
Figure 7. Lube System, Front Frame Module

(View 1 of 6) ............................ 7-1
(View 2 of 6) ............................ 7-2
(View 3 of 6) ............................ 7-3
(View 4 of 6) ............................ 7-4
(View 5 of 6) ............................ 7-5
(View 6 of 6) ............................ 7-6
Figure 8. Front Frame Module Electrical
(View 1 of 10) ........................... 8-1
(View 2 of 10) ........................... 8-2
(View 3 of 10) ........................... 8-3
(View 4 of 10) ........................... 8-4
(View 5 of 10) ........................... 8-5
(View 6 of 10) ........................... 8-6
(View 7 of 10) ........................... 8-7
(View 8 of 10) ........................... 8-8
(View 9 of 10) ........................... 8-9
(View 10 of 10) .......................... 8-10
Figure 9. Air Collector Assembly and Associated Parts
(View 1 of 5) ............................ 9-1
(View 2 of 5) ............................ 9-2
(View 3 of 5) ............................ 9-3
(View 4 of 5) ............................ 9-4
(View 5 of 5) ............................ 9-5
Figure 10. Air Collector Assembly - Cover Plates ....... 10-1
Figure 11. Air Collector Assembly
(View 1 of 3) ............................ 11-1
(View 2 of 3) ............................ 11-2
(View 3 of 3) ............................ 11-3
Figure 12. Low Pressure Compressor Rotor Breakdown
(View 1 of 2) ............................ 12-1
(View 2 of 2) ............................ 12-2
Figure 13. Low Pressure Compressor Stator Assembly
Breakdown
(View 1 of 2) ............................ 13-1
(View 2 of 2) ............................ 13-2
Figure 14. Inlet Gearbox Assembly Breakdown ............ 14-1
Figure 15. Inlet Gearbox Housing Hardware .............. 15-1
Figure 16. Radial Adapter Assembly Breakdown ........... 16-1
Figure 17. Transfer and Accessory Gearbox Assembly
Breakdown
(View 1 of 5) ............................ 17-1
(View 2 of 5) ............................ 17-2
(View 3 of 5) ............................ 17-3
(View 4 of 5) ............................ 17-4
(View 5 of 5) ............................ 17-5
Figure 18. Transfer Gearbox Housing Studs and
Bushings ................................. 18-1
Figure 19. Transfer Gearbox Housing Inserts and Lock
Rings .................................... 19-1
ii CHANGE 2
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GEK 119320
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Section Number
Figure 20. Fan Mid Shaft Breakdown

(View 1 of 2) ............................. 20-1
(View 2 of 2) ............................. 20-2
Figure 21. High Pressure Compressor Rotor Assembly
Breakdown
(View 1 of 2) ............................. 21-1
(View 2 of 2) ............................. 21-2
Figure 22. High Pressure Compressor Stator Assembly
Breakdown
(View 1 of 6) ............................. 22-1
(View 2 of 6) ............................. 22-2
(View 3 of 6) ............................. 22-3
(View 4 of 6) ............................. 22-4
(View 5 of 6) ............................. 22-5
(View 6 of 6) ............................. 22-6
Figure 23. High Pressure Compressor Variable Stator
Actuation Rings ........................... 23-1
Figure 24. High Pressure Compressor VSV Actuation
System
(View 1 of 2) ............................. 24-1
(View 2 of 2) ............................. 24-2
Figure 25. Accelerometer, Core Module
(View 1 of 2) ............................. 25-1
(View 2 of 2) ............................. 25-2
Figure 26. Compressor Rear Frame Assembly Breakdown
(View 1 of 4) ............................. 26-1
(View 2 of 4) ............................. 26-2
(View 3 of 4) ............................. 26-3
(View 4 of 4) ............................. 26-4
Figure 27. Compressor Rear Frame Sump Breakdown
(View 1 of 6) ............................. 27-1
(View 2 of 6) ............................. 27-2
(View 3 of 6) ............................. 27-3
(View 4 of 6) ............................. 27-4
(View 5 of 6) ............................. 27-5
(View 6 of 6) ............................. 27-6
Figure 28. High Pressure Turbine Stage 1 Nozzle
Assembly Breakdown
(View 1 of 2) ............................. 28-1
(View 2 of 2) ............................. 28-2
Figure 29. High Pressure Turbine Stage 2 Nozzle
Assembly Breakdown
(View 1 of 2) ............................. 29-1
(View 2 of 2) ............................. 29-2
Figure 30. High Pressure Turbine Rotor Assembly
Breakdown
(View 1 of 3) ............................. 30-1
(View 2 of 3) ............................. 30-2
(View 3 of 3) ............................. 30-3
Figure 31. Low Pressure Turbine Rotor/Stator Assembly -
Rotor Breakdown
(View 1 of 3) ............................. 31-1
(View 2 of 3) ............................. 31-2
(View 3 of 3) ............................. 31-3
CHANGE 2 iii
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GEK 119320
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Section Number
Figure 32. Low Pressure Turbine Rotor/Stator

Assembly – Stator Breakdown
(View 1 of 6) ............................ 32-1
(View 2 of 6) ............................ 32-2
(View 3 of 6) ............................ 32-3
(View 4 of 6) ............................ 32-4
(View 5 of 6) ............................ 32-5
(View 6 of 6) ............................ 32-6
Figure 33. Gearbox Hangers ............................. 33-1
Figure 34. Turbine Rear Frame and Sump Assembly
Breakdown ................................ 34-1
Figure 35. Turbine Rear Frame Assembly
(View 1 of 4) ............................ 35-1
(View 2 of 4) ............................ 35-2
(View 3 of 4) ............................ 35-3
(View 4 of 4) ............................ 35-4
Figure 36. Turbine Rear Frame – Bearings and Seals ..... 36-1
Figure 37. Turbine Rear Frame – No. 7 Bearing Assembly
Breakdown ................................ 37-1
Figure 38. Turbine Rear Frame – Two Tube Balance
Piston Assembly Breakdown
(View 1 of 4) ............................ 38-1
(View 2 of 4) ............................ 38-2
(View 3 of 4) ............................ 38-3
(View 4 of 4) ............................ 38-4
Figure 39. Compressor Stator Case Boss Bracket
Hardware
(View 1 of 5) ............................ 39-1
(View 2 of 5) ............................ 39-2
(View 3 of 5) ............................ 39-3
(View 4 of 5) ............................ 39-4
(View 5 of 5) ............................ 39-5
Figure 40. Flange Brackets – VIGV Case Aft Flange to
Low Pressure Compressor Case Forward
Flange
(View 1 of 3) ............................ 40-1
(View 2 of 3) ............................ 40-2
(View 3 of 3) ............................ 40-3
Figure 41. Flange Brackets – Front Frame Aft Flange
to HP Compressor Stator Forward Flange
(View 1 of 2) ............................ 41-1
(View 2 of 2) ............................ 41-2
Figure 42. Flange Brackets – HP Compressor Aft Flange
to Compressor Rear Frame Forward Flange
(View 1 of 5) ............................ 42-1
(View 2 of 5) ............................ 42-2
(View 3 of 5) ............................ 42-3
(View 4 of 5) ............................ 42-4
(View 5 of 5) ............................ 42-5
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GEK 119320
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Section Number
Figure 43. Flange Brackets – HP Compressor Aft Flange

to Forward Flange Aft Combustor Case
(View 1 of 11) ............................ 43-1
(View 2 of 11) ............................ 43-2
(View 3 of 11) ............................ 43-3
(View 4 of 11) ............................ 43-4
(View 5 of 11) ............................ 43-5
(View 6 of 11) ............................ 43-6
(View 7 of 11) ............................ 43-7
(View 8 of 11) ............................ 43-8
(View 9 of 11) ............................ 43-9
(View 10 of 11) ........................... 43-10
(View 11 of 11) ........................... 43-11
Figure 44. Flange Brackets – Compressor Rear Frame
Aft Flange to HP Turbine Fwd Flange
(View 1 of 3) ............................. 44-1
(View 2 of 3) ............................. 44-2
(View 3 of 3) ............................. 44-3
Figure 45. Flange Brackets – HP Turbine Aft Flange to
Low Pressure Turbine Forward Flange
(View 1 of 6) ............................. 45-1
(View 2 of 6) ............................. 45-2
(View 3 of 6) ............................. 45-3
(View 4 of 6) ............................. 45-4
(View 5 of 6) ............................. 45-5
(View 6 of 6) ............................. 45-6
Figure 46. Flange Brackets - Low Pressure Turbine
Aft Flange to Turbine Rear Frame
(View 1 of 3) ............................. 46-1
(View 2 of 3) ............................. 46-2
(View 3 of 3) ............................. 46-3
Figure 47. Kit, 738L677, Gas Fuel System
(View 1 of 31) ............................ 47-1
(View 2 of 31) ............................ 47-2
(View 3 of 31) ............................ 47-3
(View 4 of 31) ............................ 47-4
(View 5 of 31) ............................ 47-5
(View 6 of 31) ............................ 47-6
(View 7 of 31) ............................ 47-7
(View 8 of 31) ............................ 47-8
(View 9 of 31) ............................ 47-9
(View 10 of 31) ........................... 47-10
(View 11 of 31) ........................... 47-11
(View 12 of 31) ........................... 47-12
(View 13 of 31) ........................... 47-13
(View 14 of 31) ........................... 47-14
(View 15 of 31) ........................... 47-15
(View 16 of 31) ........................... 47-16
(View 17 of 31) ........................... 47-17
(View 18 of 31) ........................... 47-18
(View 19 of 31) ........................... 47-19
(View 20 of 31) ........................... 47-20
(View 21 of 31) ........................... 47-21
(View 22 of 31) ........................... 47-22
(View 23 of 31) ........................... 47-23
CHANGE 2 v
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GEK 119320
Page
Section Number
Figure 47. Continued

(View 24 of 31) .......................... 47-24
(View 25 of 31) .......................... 47-25
(View 26 of 31) .......................... 47-26
(View 27 of 31) .......................... 47-27
(View 28 of 31) .......................... 47-28
(View 29 of 31) .......................... 47-29
(View 30 of 31) .......................... 47-30
(View 31 of 31) .......................... 47-31
Figure 48. Kit, 738L298, Spray Injected Turbine
(View 1 of 3) ............................ 48-1
(View 2 of 3) ............................ 48-2
(View 3 of 3) ............................ 48-3
Figure 49. Piping - Left Side
(View 1 of 19) ........................... 49-1
(View 2 of 19) ........................... 49-2
(View 3 of 19) ........................... 49-3
(View 4 of 19) ........................... 49-4
(View 5 of 19) ........................... 49-5
(View 6 of 19) ........................... 49-6
(View 7 of 19) ........................... 49-7
(View 8 of 19) ........................... 49-8
(View 9 of 19) ........................... 49-9
(View 10 of 19) .......................... 49-10
(View 11 of 19) .......................... 49-11
(View 12 of 19) .......................... 49-12
(View 13 of 19) .......................... 49-13
(View 14 of 19) .......................... 49-14
(View 15 of 19) .......................... 49-15
(View 16 of 19) .......................... 49-16
(View 17 of 19) .......................... 49-17
(View 18 of 19) .......................... 49-18
(View 19 of 19) .......................... 49-19
Figure 50. Air System - Right Side
(View 1 of 14) ........................... 50-1
(View 2 of 14) ........................... 50-2
(View 3 of 14) ........................... 50-3
(View 4 of 14) ........................... 50-4
(View 5 of 14) ........................... 50-5
(View 6 of 14) ........................... 50-6
(View 7 of 14) ........................... 50-7
(View 8 of 14) ........................... 50-8
(View 9 of 14) ........................... 50-9
(View 10 of 14) .......................... 50-10
(View 11 of 14) .......................... 50-11
(View 12 of 14) .......................... 50-12
(View 13 of 14) .......................... 50-13
(View 14 of 14) .......................... 50-14
Figure 51. Air System - Low Pressure Turbine 8th Stage
Cooling Air .............................. 51-1
Figure 52. Electrical Leads - VIGV
(View 1 of 2) ............................ 52-1
(View 2 of 2) ............................ 52-2
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GEK 119320
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Figure 53. Kit, 682L255, UV Flame Detector

(View 1 of 4) ............................. 53-1
(View 2 of 4) ............................. 53-2
(View 3 of 4) ............................. 53-3
(View 4 of 4) ............................. 53-4
Figure 54. Pressure Transducer Sensors
(View 1 of 4) ............................. 54-1
(View 2 of 4) ............................. 54-2
(View 3 of 4) ............................. 54-3
(View 4 of 4) ............................. 54-4
Figure 55. Oil System - VIGV
(View 1 of 3) ............................. 55-1
(View 2 of 3) ............................. 55-2
(View 3 of 3) ............................. 55-3
Figure 56. Hydraulic System
(View 1 of 5) ............................. 56-1
(View 2 of 5) ............................. 56-2
(View 3 of 5) ............................. 56-3
(View 4 of 5) ............................. 56-4
(View 5 of 5) ............................. 56-5
Figure 57. Kit, 738L217, LPT Case Cooling
(View 1 of 8) ............................. 57-1
(View 2 of 8) ............................. 57-2
(View 3 of 8) ............................. 57-3
(View 4 of 8) ............................. 57-4
(View 5 of 8) ............................. 57-5
(View 6 of 8) ............................. 57-6
(View 7 of 8) ............................. 57-7
(View 8 of 8) ............................. 57-8
Figure 58. Oil System - Bottom
(View 1 of 6) ............................. 58-1
(View 2 of 6) ............................. 58-2
(View 3 of 6) ............................. 58-3
(View 4 of 6) ............................. 58-4
(View 5 of 6) ............................. 58-5
(View 6 of 6) ............................. 58-6
Figure 59. Gearbox, Lube System
(View 1 of 9) ............................. 59-1
(View 2 of 9) ............................. 59-2
(View 3 of 9) ............................. 59-3
(View 4 of 9) ............................. 59-4
(View 5 of 9) ............................. 59-5
(View 6 of 9) ............................. 59-6
(View 7 of 9) ............................. 59-7
(View 8 of 9) ............................. 59-8
(View 9 of 9) ............................. 59-9
Figure 60. Lube and Scavenge Pump and Associated
Parts ..................................... 60-1
Figure 61. Kit, 537L305, Cover.......................... 61-1
Figure 62. Kit, 682L264, Exhaust Interface.............. 62-1
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Section Number
Figure 63. Low Pressure Turbine – External Components

(View 1 of 12) ........................... 63-1
(View 2 of 12) ........................... 63-2
(View 3 of 12) ........................... 63-3
(View 4 of 12) ........................... 63-4
(View 5 of 12) ........................... 63-5
(View 6 of 12) ........................... 63-6
(View 7 of 12) ........................... 63-7
(View 8 of 12) ........................... 63-8
(View 9 of 12) ........................... 63-9
(View 10 of 12) .......................... 63-10
(View 11 of 12) .......................... 63-11
(View 12 of 12) .......................... 63-12
Figure 64. Kit, 682L207, Chip Detector Cable ........... 64-1
Figure 65. Kit, 682L187G05, Ignition System
(View 1 of 3) ............................ 65-1
(View 2 of 3) ............................ 65-2
(View 3 of 3) ............................ 65-3
Figure 66. Kit, 682L190, Chip Detector Assembly and
Installation ............................. 66-1
Figure 67. Compressor Discharge Temperature Sensor
(View 1 of 3) ............................ 67-1
(View 2 of 3) ............................ 67-2
(View 3 of 3) ............................ 67-3
Figure 68. CDP and Stage 8 Bleed Valves
(View 1 of 2) ............................ 68-1
(View 2 of 2) ............................ 68-2
Figure 69. Kit, 738L681, Dual Fuel System
(View 1 of 56) ........................... 69-1
(View 2 of 56) ........................... 69-2
(View 3 of 56) ........................... 69-3
(View 4 of 56) ........................... 69-4
(View 5 of 56) ........................... 69-5
(View 6 of 56) ........................... 69-6
(View 7 of 56) ........................... 69-7
(View 8 of 56) ........................... 69-8
(View 9 of 56) ........................... 69-9
(View 10 of 56) .......................... 69-10
(View 11 of 56) .......................... 69-11
(View 12 of 56) .......................... 69-12
(View 13 of 56) .......................... 69-13
(View 14 of 56) .......................... 69-14
(View 15 of 56) .......................... 69-15
(View 16 of 56) .......................... 69-16
(View 17 of 56) .......................... 69-17
(View 18 of 56) .......................... 69-18
(View 19 of 56) .......................... 69-19
(View 20 of 56) .......................... 69-20
(View 21 of 56) .......................... 69-21
(View 22 of 56) .......................... 69-22
(View 23 of 56) .......................... 69-23
(View 24 of 56) .......................... 69-24
(View 25 of 56) .......................... 69-25
(View 26 of 56) .......................... 69-26
(View 27 of 56) .......................... 69-27
viii CHANGE 2
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Section Number
Figure 69. Continued

(View 28 of 56) ........................... 69-28
(View 29 of 56) ........................... 69-29
(View 30 of 56) ........................... 69-30
(View 31 of 56) ........................... 69-31
(View 32 of 56) ........................... 69-32
(View 33 of 56) ........................... 69-33
(View 34 of 56) ........................... 69-34
(View 35 of 56) ........................... 69-35
(View 36 of 56) ........................... 69-36
(View 37 of 56) ........................... 69-37
(View 38 of 56) ........................... 69-38
(View 39 of 56) ........................... 69-39
(View 40 of 56) ........................... 69-40
(View 41 of 56) ........................... 69-41
(View 42 of 56) ........................... 69-42
(View 43 of 56) ........................... 69-43
(View 44 of 56) ........................... 69-44
(View 45 of 56) ........................... 69-45
(View 46 of 56) ........................... 69-46
(View 47 of 56) ........................... 69-47
(View 48 of 56) ........................... 69-48
(View 49 of 56) ........................... 69-49
(View 50 of 56) ........................... 69-50
(View 51 of 56) ........................... 69-51
(View 52 of 56) ........................... 69-52
(View 53 of 56) ........................... 69-53
(View 54 of 56) ........................... 69-54
(View 55 of 56) ........................... 69-55
(View 56 of 56) ........................... 69-56
Figure 71. Kit, 682L188, Oil Temperature Sensors
(View 1 of 5) ............................. 71-1
(View 2 of 5) ............................. 71-2
(View 3 of 5) ............................. 71-3
(View 4 of 5) ............................. 71-4
(View 5 of 5) ............................. 71-5
Figure 72. Kit, 682L194, Vibration Sensor
(View 1 of 5) ............................. 72-1
(View 2 of 5) ............................. 72-2
(View 3 of 5) ............................. 72-3
(View 4 of 5) ............................. 72-4
(View 5 of 5) ............................. 72-5
Figure 73. Kit, 738L749, Sump Pressurization Adapter.... 73-1
Figure 74. Kit, 682L292, Air Collector Cover Plate...... 74-1
III NUMERICAL INDEX ............................................. INDEX-1
CHANGE 2 ix
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INTRODUCTION
INTRODUCTION. The critical parts life limitations

have been substantiated based on
1. GENERAL. This Illustrated Parts engineering analysis that assumes
Breakdown is an illustrated listing this product will be operated and
of the parts of the 7LM6000 PF+ maintained using the procedures
Series Gas Turbine Models designed, and inspections provided in the
developed, and manufactured by the instructions for continued operation
GE AeroDerivative Gas Turbines, supplied with this product by GE, or
Cincinnati, Ohio 45215. its licensees. For Life Limited Parts
and parts that influence Life Limited
Parts, any repair, modification, or
WARNING maintenance procedures not approved
by GE, or its licensees, or any
ANY PART PREVIOUSLY USED substitution of such parts not
IN AN AIRCRAFT APPLICATION supplied by GE, or its licensees,
IS FORBIDDEN FOR USE IN LM may materially affect these limits.
ENGINES. ONLY PARTS LISTED
IN THE IPB ARE AUTHORIZED 4. EXPLANATION OF PARTS BREAKDOWN.
FOR USE ON LM PRODUCTS. Figure and Index column: This column
contains the Figure Number in which
2. PURPOSE. The Illustrated Parts the part or assembly is shown, and
Breakdown is intended to be used for the Index Number common to the
requisitioning, storing, issuing, and illustration and to the listing.
identifying parts. The Figure Number is separated from
the Index Number by a hyphen. Both
CAUTION Figure Numbers and Index Numbers
are in numerical sequence. When an
IF SHIPPING DOCUMENTATION illustration is changed, additional
OR PART NUMBER DOES NOT MATCH indexes are added between existing
PART IDENTIFICATION AS SHOWN indexes by adding the preceding Index
IN IPB, CONTACT YOUR CSM Number plus a letter of the alphabet
TO VERIFY/VALIDATE PART such as –22A, -22B, etc.
NUMBER APPLICABILITY BEFORE
INSTALLATION OR DAMAGE TO 5. PART NUMBER COLUMN AND
GAS GENERATOR/GAS TURBINE DESCRIPTION. The Part Number column
COMPONENTS MAY OCCUR. contains the part number assigned
to each part in accordance with the
3. SCOPE. Major sections, Contract Drawing Specification.
assemblies, subassemblies, and
attaching parts are presented in an THE PART NUMBER COLUMN CONTAINS:
orderly sequence to provide both
the detailed parts information and (A) COM’L ITEMS: Commercial Items
relationship of parts to assemblies. use the word COM’L in the Part Number
The listing shows Part Number, column. Identifying information
Description, Quantity. Items in the such as dimensions, size, material
listings are keyed to those in the type, special features and commercial
illustrations by common Index catalog numbers is listed in the
Numbers. Additional descriptive Description column.
identifying data, references to
higher and lower assemblies, (B) NO NUMBER: Articles without
specialized part and marking part numbers are listed as “No Number”
information, references to other parts in the Part Number column. The
publications, and GE Control Drawing Model Number (if any) and other
Numbers are furnished within the descriptive data are given in the
nomenclature of the specified item. Description.
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(C) GENERAL ELECTRIC PART (D) HAZARDOUS MATERIAL:

NUMBERS: Parts designed by the
General Electric Company. Required
explanations related to the General WARNING
Electric Company parts are noted in
the Description. Included are the ASBESTOS
following types:
THIS ENGINE MAY CONTAIN SMALL
(1) DECALS, METALCALS, VINYL AMOUNTS OF ASBESTOS. WHEN
FILM MARKINGS: The identifying WORKING WITH THIS ENGINE,
drawing number is listed in the Part THE FOLLOWING PRECAUTIONS
Number column. From the marking MUST BE RIGIDLY ADHERED TO:
(decal) special information is given
to: • BEFORE ANY MAINTENANCE
ACTIVITIES ARE UNDERTAKEN,
(a) Provide instructions REVIEW THE ILLUSTRATED
PARTS BREAKDOWN TO DETERMINE
(b) Identify a reparable assy IF THE HARDWARE TO BE WORKED
ON OR USED CONTAINS ASBESTOS.
(c) Special replacement ALL WARNINGS IN THIS MANUAL
information MUST BE OBSERVED.
(d) Need to be requisitioned • WHENEVER MECHANICAL REMOVAL

separately OF MATERIAL SUCH AS MACHINING,
GRINDING, BUFFING, DRILLING,
(2) PARTS KIT: The part SANDING, OR ANY TYPE OF
number is the number assigned by MATERIAL BUILD-UP ON PARTS
the Contract Drawing Specification. THAT CONTAIN ASBESTOS IS
The Description column will note that NECESSARY, APPROPRIATE
Kits are available. Parts common to PERSONAL, PROTECTIVE EQUIPMENT
those already listed are coded and MUST BE WORN, AND NATIONAL
additional parts are listed. ENVIRONMENTAL CONTROLS REQUIRED
FOR THE HANDLING OF ASBESTOS-
(3) SYMMETRICALLY OPPOSITE CONTAINING MATERIAL MUST BE
PARTS: (Mirror image) Listed in the COMPLIED WITH.
Part Number column on separate lines.
• BEFORE HANDLING, REPLACING,
(4) MATCHED PARTS: Note in the OR DISPOSING OF ASBESTOS-
Description column that the parts are CONTAINING HARDWARE,
matched (machined to fit) and are to APPROPRIATE PERSONAL,
be maintained as a set. PROTECTIVE EQUIPMENT AND
NATIONAL ENVIRONMENTAL
(5) UNDRILLED UNTRIMMED PARTS CONTROLS MUST BE STRICTLY
(SPD): Marked in the Description ADHERED TO FOR HANDLING
column as SPD (Spare Part Drawing) and ASBESTOS-CONTAINING HARDWARE.
noted that such parts require drilling
or trimming at time of installation. (1) Special Hazard Symbol: Part
numbers having this ' symbol (see
example below) following them may
contain hazardous materials. Refer
to referenced assembly parts listings
for specific information identifying
the type or types of hazardous
material contained in an identified
part. Read appropriate warnings in all
operating, maintenance, and repair
manuals and adhere to all site
safety and environmental controls
concerning use, maintenance, and
disposal.
9644M07G01 '
INTRO-2
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GEK 119320
6. ATTACHING PARTS. All parts used to h. SPL: Special. Parts may have
attach parts or assemblies to the restricted usage. See text following
engine or to each other are designated the parts listing.
as Attaching Parts. Attaching Parts
are listed immediately following the i. DEL: Deleted part is no longer
assembly or part that they attach and required in this application.
are preceded by the words (ATTACHING
PARTS). End of Attaching Parts is j. NP: Not Procurable. Part
indicated by the symbol ---*--- and is not procurable in the configuration
is used to denote the end of the represented by the indicated part
Attaching Parts and continuation of number. Reference is normally made
the listing or breakdown. to the next higher assembly (NHA).
7. QUANTITY COLUMN. The number 8. SELECTIVE FIT ITEM. Items

appearing in the Quantity column is selected for fit balance, etc.,
the quantity required at this according to specific instructions
location. Other entries which may on a drawing. The quantity required is
appear in the Quantity column are as listed in the UNITS PER ASSEMBLY
follows: COLUMN: of the first entry. “AR”
is listed in this column for the
a. REF: The letters “REF” second and successive optional items.
indicate that the listing of the
part or assembly is repeated, and 9. USABLE ON ASSEMBLY CODE. The
that reference should be made to breakdown of similar assemblies
its previous listing in the Group combined in the same listing is
Assembly Parts List for the quantity. indicated by the Assembly Code
preceding the listing. This letter
b. AR: The letters “AR” (As in the CODE column indicates that
Required) are used in the Units Per the part is used on a certain higher
Assembly column when the quantity assembly. This Assembly Code applies
or selection cannot be accurately only to the list on which it appears.
specified. For example: Lockwire, For example:
paint, adhesive, second and
successive optional selective fit An assembly table for a rotor will
items, repair parts. appear like this.
c. SUP: SUPERSEDED PART. Old ASSEMBLY TABLE

parts may be used until supply is
exhausted - then use new parts. CODE USE ON
A 9661M81G30
d. RPL: Part to be replaced by B 9661M81G32
later configuration - see change Blank ALL ABOVE ASSYS
document when applicable.
e. RWK: Part reworked (or 10. NUMERICAL INDEX. The Numerical

modified) and reidentified to new part Index is an alpha-numerical listing of
number. all part numbers in the Group Assembly
Parts List.
f. DSC: Discontinued, old part
should no longer be used for this 11. CHANGED DATA. A bar in the left
application. hand or right hand margin indicates a
line changed in the latest issue of
g. ALT: Alternate part, may be the IPB.
used interchangeably with other
current parts. 12. PUBLICATION CHANGE REQUEST. The
Publication Change Request (PCR),
Table IV, may be used when a suspected
error is found in this manual.
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TABLE I
INTRO-4
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TABLE II
GLOSSARY OF TERMS
ALTERED PART. “Altered part” is a part FRONT (FORWARD) END. The end into
(or parts) that are altered to meet which air is introduced.
the requirements of a design activity.
GROUP. A collection of units or
BASELINE. An approved and defined assemblies, which is a subdivision
point of departure for control of of a set or system.
future changes in system or equipment
performance and design. A baseline is INTERCHANGEABLE ITEMS.
documented by a specification and “Interchangeable items” are items
other documents. which when interchanged or
substituted, any one for another,
BULK MATERIALS. “Bulk materials” are without modification or selection,
those necessary constituents of an will provide the same design,
assembly or subassembly such as oil, engineering, and physical and
wax, solder, cement, ink, damping functional characteristics required
fluid, grease, powdered graphite, of the original items and will require
flux, welding rod, thread, twine and no modification of any system or
chain for which the quantity required assembly in which either may be used.
is not readily predetermined; or if
knowing the quantity, the physical ITEM. “Item” is a document,
nature of the material is such that it material, process, part,
is not adaptable to depiction on a subassembly, assembly, unit, set,
drawing; or which can be cut to system, accessory, attachment, etc.
finished size by the use of such
hand or bench tools as shears, pliers, ITEM IDENTIFICATION AND PART NUMBER.
knives, etc., without any further The complete number required to
machining operations and the identify a part, relate it to its
configuration is such that it can be drawing, and provide a basis for
fully described in writing without the determining the interchangeability or
necessity of pictorial presentation. non-interchangeability of the part.
COMMERCIAL ITEM. “Commercial items” LINEAR. Two or more similar units

means supplies or services which arranged along the engine are
normally are advertised and are or identified by numbers which start at
have been sold or offered to the the forward end and progress toward
public commercially by any supplier. the rear. Bearings and stages of the
compressor rotor are examples of
COMMERCIAL PART. A part of such a linear identification.
class or kind that it is regularly
used for other purposes, and is sold MANUFACTURER. “Manufacturer” is a
or traded in the course of conducting person or firm (a) who owns,
normal business operations. operates, or maintains a factory or
establishment that produces on the
COMPONENT. A part or a subassembly of premises the materials, supplies,
a next higher assembly. articles, or equipment required under
the contract or of the general
DESIGN ACTIVITY. An activity having character described by the
responsibility for the design and specifications, standards, and
the preparation and maintenance of publications; or (b) who, if newly
engineering drawings for a given item entering into a manufacturing
of supply. activity of the type described
INTRO-5
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TABLE II
GLOSSARY OF TERMS (Continued)
above, has made all necessary prior NOTE: The term “reparable” is the
agreements for manufacturing space, logistic status of an item rather
equipment, and personnel, to perform than the “condition” of an item. The
the manufacturing operations term “repairable” is used to describe
required. the condition of a repairable item
which is unserviceable and requires
MATCHED PARTS. “Matched parts” are repair.
those parts, such as special
application parts, which are machine RETROFIT. A modification of equipment
matched, or otherwise mated, and for to include changes made in later
which replacement as a matched set or production models.
pair is mandatory.
RIGHT AND LEFT SIDES. With the
MODIFICATION. Changes to systems/ observer standing aft and engine
equipment and spares approved after forward, the right side of the engine
the updating changes are identified. will correspond to the observer’s
right and the left side of the engine
NOMENCLATURE. Item identification. to observer’s left.
The description of all items appearing
in the Group Assembly Parts List shall ROTATION. The direction of rotation is
consist of the nomenclature placed in established by standing aft,
the drawing title block by the design looking forward. Rotation of the main
activity in accordance with the rotor is generally in a clockwise
drawing specification. direction.
PART. Any single inseparable end item. SELECTED PART. “Selected part”
One or more pieces joined together is a part or parts selected for
which are not normally special requirements or required to
subject to disassembly without conform to special inspection or
destruction of designed use. qualification requirements by the
design activity.
PART NUMBER. A number applied to a
part for identification purposes. SPECIFICATION CONTROL DRAWING. One
which discloses configuration,
PART OF. An item which is required design, and test requirements for the
to enable an equipment to fulfill item, other than military standard
its assigned function is “part of” items, designed and manufactured by
that equipment. An item which is vendors (but which does not specify
physically attached to and essential source).
to the operation of another item is
considered “part of” the item to which SOURCE CONTROL DRAWING. A drawing
it is attached. which specifies configuration,
design, and test requirements for an
POSITION NUMBERING. All numbering item (other than military standard
begins with Number 1 and progresses items), and which further specifies
clockwise, aft looking forward. the sources from which the item shall
be obtained.
REAR (AFT) END. The end from which the
jet or expanding gas is expelled. SYMMETRICALLY OPPOSITE PARTS.
“Symmetrically opposite parts” are
REPARABLE. Items which can be those parts which are mirror images
reconditioned or repaired for reuse of each other.
when they become unserviceable.
INTRO-6
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GEK 119320
TABLE II
GLOSSARY OF TERMS (Continued)
TOP AND BOTTOM. Top and bottom refer together normally capable of
to the upper and lower portions of the independent operations in a variety
engine in a normal installation. Also of situations.
referred to as the 12 o’clock and
6 o’clock positions. VENDOR. “Vendor” is a design
activity, manufacturer, wholesaler,
UNIT. An assembly or any combination or agent from whom parts are acquired.
of parts and assemblies mounted
INTRO-7
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TABLE III
ABBREVIATIONS
ALT Alternate HPC High Pressure

AP Attaching Part Compressor
AR As Required HPT High Pressure Turbine
ASSY, ASSYS Assembly HPTR High Pressure Turbine
Rotor
BAL Balance HPTS High Pressure Turbine
BP Blueprint Stator
BRG Bearing HYD Hydraulic
CFF Compressor Front ID Inside Diameter

Frame IDENT Identification
CCW Counterclockwise IGN Ignition
CDP Compressor Discharge IGV Inlet Guide Vane
Pressure IN Inch
CHG Change INT Internal
CID Change In Design INTCHG Interchangeable
CIP Compressor Inlet
Pressure LG Long
CIT Compressor Inlet LH Left Hand
Temperature LPT Low Pressure Turbine
CL Class
CO. Company MFR Manufacturer
CRES Corrosion Resistant MOD Modification
Steel
CRF Compressor Rear NAS National Aircraft
Frame Standards
CSK Countersink NF National Fine
NHA Next Higher Assembly
DBL Double NO. Number
DC Direct Current NOM Nomenclature, Nominal
DEG Degree NP Non Procurable
DIA Diameter
DLE Dry Low Emission OD Outside Diameter
DSC Discontinued OGV Outlet Guide Vane
DWG Drawing OS Oversize
EA Each PKG Packaging

ELEC Electrical PN Part Number
EQUIV Equivalent PR Pair
EXT External PSI Pounds Per Square
EXH Exhaust, Exhibit Inch
F Fahrenheit QTY Quantity

FIG Figure
FIL Fillister RE Rear
FLEX Flexible REF Reference
FT Foot RH Right Hand
FWD Forward RPL Replace
RWK Rework
GEN Generator
HD Head
HEX Hexagonal
INTRO-8
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TABLE III
ABBREVIATIONS (Continued)
SB Service Bulletin THK Thick

SH Sheet TMF Turbine Mid Frame
SPD Spare Part Drawing
SPEC Specification US Undersize
SPL Special
STIG Steam Injection Gas VBV Variable Bleed Valve
Turbine VIGV Variable Inlet Guide
STG, STGS Stage(s) Vane
SUP Supersede VGP Variable Geometry
Pump
TACH Tachometer VSV Variable Stator Vane
TBD To Be Determined
TEMP Temperature W Wide, Width
THD Thread WT Weight
INTRO-9
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TABLE IV
PUBLICATION CHANGE REQUEST
INTRO-10
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MAJOR ASSEMBLIES

=

=
=
=
=

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=
=

=
=
FIGURE 1 MAJOR ASSEMBLIES (SHEET 1 OF 6)
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GEK 119320

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GEK 119320

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GEK 119320

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GEK 119320

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DESCRIPTION USE
FIG INDEX PART NUMBERS QTY
1234567 ON
MAJOR ASSEMBLIES
1 - 0 WHITE
ASSEMBLY TABLE
CODE USE ON
A L65011G01
B L65011G02
C L65011G03
BLANK ALL ABOVE ASSYS
1 - 0 L65011G01 GAS TURBINE ASSEMBLY, LM6000PF1 . . . . . . . 1

SEE FIGURES 10, 25, 45, 49, 50, 54, 56, AND
58
USE ON LM6000-PF1-NGDG01
SEE FIGURES 10, 25, 45, 49, 50, 54, 56, AND
58
ADDED PER CID 556912
SEE FIGURES 10, 25, 45, 49, 50, 54, 56, AND
58
1 - 1 L65016G01 .SUPER CORE MODULE ASSEMBLY, LM6000 PF1 . . . 1
SEE FIGURE 41 FOR BREAKDOWN
1 - 1A 102A571P01 .PLATE, IDENTIFICATION-GAS GENERATOR . . . . . 1
SECTION (EU CERTIFIED)
1 - 1B NAS1216-06E-5L .SCREW, PANHEAD, HI-TORQUE RECESS . . . . . . 4
1 - 2 L60043G01 ..FWD, MID SHAFT ASSEMBLY LM6000 PG . . . . . 1
1 - 3 L43903G05 ..MODULE, LOW PRESSURE COMPRESSOR . . . . . . 1
1 - 4 L43053G07 ...ROTOR ASSEMBLY, LOW PRESSURE COMPRESSOR . . 1
1 - 5 L43904G03 ...STATOR ASSEMBLY, LOW PRESSURE COMPRESSOR . 1
1 - 6 L65045G01 ..CORE MODULE - LM6000 . . . . . . . . . . . . 1
SEE FIGURES 24, 26, 39, 42, 43, 44, AND 67
FOR BREAKDOWN
1 - 7 L43784G26 ...ASSY, COMPRESSOR ROTOR - LM6000 . . . . . . 1
1 - 8 L43568G11 ...STATOR ASSEMBLY, COMPRESSOR (HIGH BOSS) . . 1
LM6000
SEE FIGURES 22 AND 23 FOR BREAKDOWN
SEE FIGURES 24-28, 39-1, AND 49-166
1 - 9 L47066G21 ...COMPRESSOR REAR FRAME - DLN . . . . . . . . 1
SEE FIGURES 26-1 AND 27 FOR BREAKDOWN
SEE FIGURES 42-53, 43-91, 49-197, 50-137,
54-29, 58-78, AND 69-575
1 - 10 L47064P05 ...COMPRESSOR REAR FRAME, AFT CASE - DLN . . . 1
SEE FIGURES 26-76, 43-90, AND 44-21
1 - 11 L63650G01 ...COMBUSTION CHAMBER ASSY . . . . . . . . . . 1
1 - 12 L65050G01 ...HPT ASSEMBLY - LM6000 PF1 . . . . . . . . . SUP
SUPERSEDED BY L65050G02 PER CID 556875
1 - 12 L65050G02 ...HPT ASSEMBLY - LM6000 PF1 . . . . . . . . . 1
1 - 13 L65051G01 ....ROTOR ASSEMBLY HIGH PRESSURE TURBINE . . . 1
LM6000 PF1
USE ON L65050G01
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GEK 119320
DESCRIPTION USE
1234567 ON
MAJOR ASSEMBLIES
1 - 13 L65051G02 ....ROTOR ASSEMBLY HIGH PRESSURE TURBINE . . . 1

LM6000 PF1
USE ON L65050G02
1 - 14 L65052G01 ....STAGE 2 NOZZLE HIGH PRESSURE TURBINE . . . 1
LM6000 PF1
USE ON L65050G01
1 - 14 L65052G02 ....STAGE 2 NOZZLE HIGH PRESSURE TURBINE . . . 1
LM6000 PF1
USE ON L65050G02
1 - 15 L65031G01 ...NOZZLE, STG 1 HIGH PRESSURE TURBINE . . . . RPL
LM6000 PF1
USE ON L65045G01
REPLACED BY L65031G02 PER CID 556877
1 - 15 L65031G02 ...NOZZLE, STG 1 HIGH PRESSURE TURBINE . . . . 1
LM6000 PF1
USE ON L65045G01
1 - 16 L43791G16 ..ASSEMBLY, FRONT FRAME MODULE . . . . . . . . 1
SEE FIGURE 8
1 - 17 L43540G05 ...DRIVE, ACCESSORY ASSEMBLY LM6000 . . . . . 1
SEE FIGURES 17, 18, AND 33
1 - 18 L24644G07 ....GEARBOX ASSEMBLY-TRANSFER . . . . . . . . 1
SEE FIGURES 16-18, 17-5, 18-5, 59-203,
AND 61-6
1 - 19 L43792G09 ...ASSEMBLY, COMPRESSOR FRONT FRAME - LM6000 . 1
SEE FIGURES 4-1, 5, 6, AND 9 FOR
BREAKDOWN
SEE FIGURES 7-108, 13-70, AND 16
1 - 20 9185M71G31 ....GEARBOX, ASSY INLET . . . . . . . . . . . 1
SEE FIGURE 5-61
1 - 21 L47316G15 Δ ....AIR COLLECTOR, FRONT FRAME . . . . . . . . 1
CAN CONTAIN HAZARDOUS OR REGULATED
MATERIAL - SODIUM DICHROMATE DIHYDRATE,
CAS #7789-12-0 BELOW THE LIMITS OF EU
REGULATION (EC) NO. 1272/2008 ANNEX VI,
PART 3, TABLE 3.2. NO NOTIFICATION
REQUIRED. MANUFACTURE AND REPAIR OF
THIS SUBSTANCE IN THE EUROPEAN UNION IS
SUBJECT TO AUTHORIZATION UNDER EU
REGULATION (EC) NO. 1907/2006
SEE FIGURES 9-1 AND 11-1 FOR BREAKDOWN
SEE FIGURES 4-67, 8-64, 10-12, 33-18,
AND 48-25
1 - 22 L65060G01 .LOW PRESSURE TURBINE MODULE ASSEMBLY . . . . 1 A
LM6000 PF1
SEE FIGURES 38, 46, 51, AND 63
1 - 22 L65060G02 .LOW PRESSURE TURBINE MODULE ASSEMBLY . . . . 1 B
LM6000 PF1
1 - 22 L65060G03 .LOW PRESSURE TURBINE MODULE ASSEMBLY . . . . 1 C
LM6000 PF1
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GEK 119320
DESCRIPTION USE
1234567 ON
MAJOR ASSEMBLIES
1 - 23 L65061G01 ..ROTOR AND STATOR LOW PRESSURE TURBINE . . . 1

LM6000 PF1
USE ON L65060G01 AND G02
1 - 23 L65061G03 ..ROTOR AND STATOR LOW PRESSURE TURBINE . . . 1
LM6000 PF1
USE ON L65060G03
1 - 24 L60062G01 ..TURBINE REAR FRAME AND SUMP . . . . . . . . 1
SEE FIGURE 38-1
1 - 25 682L265G03 VARIABLE INLET GUIDE VANE ASSEMBLY, SAC . . . AR
SEE FIGURES 3, 40, 52, AND 55 FOR BREAKDOWN
1 - 26 L43918G01 .VARIABLE INLET GUIDE VANE ASSY . . . . . . . 1
1 - 27 738L298G02 KIT, SPRINT (NOT ILLUSTRATED) . . . . . . . . RPL
REPLACED BY 738L298G03 PER CID 556880
1 - 27 738L298G03 KIT, SPRINT (NOT ILLUSTRATED) . . . . . . . . AR
1 - 28 537L305G01 COVER, FUEL PUMP - GEARBOX, ASSY AND . . . . . AR
INSTALLATION (NOT ILLUSTRATED)
1 - 29 682L187G05 IGNITION SYSTEM (NOT ILLUSTRATED) . . . . . . AR
1 - 29 682L187G06 IGNITION SYSTEM (NOT ILLUSTRATED) . . . . . . AR
1 - 30 738L677G02 GAS FUEL SYSTEM, DLE, 15 PPM LM6000 PF1 . . . AR
(NOT ILLUSTRATED)
1 - 30 738L681G02 DUAL FUEL SYSTEM, DLE 15PPM, LM6000 PF ELO . . AR
LONG TERM (NOT ILLUSTRATED)
1 - 31 - INDEX NOT USED . . . . . . . . . . . . . . . .
1 - 32 682L190G02 CHIP DETECTOR ASSY & INSTALLATION (NOT . . . . AR
ILLUSTRATED)
1 - 33 682L255G06 UV FLAME DETECTOR (NOT ILLUSTRATED) . . . . . AR
1 - 34 682L207G01 KIT, CHIP DETECTOR CABLE (NOT ILLUSTRATED) . . AR
1 - 35 738L205G01 VALVE, STAGE 8 BLEED - LM6000 (NOT . . . . . . AR
ILLUSTRATED)
1 - 36 738L204G01 VALVE, CDP BLEED LM6000 (NOT ILLUSTRATED) . . AR
1 - 37 682L264G01 SEAL, EXHAUST ASSY AND INSTALLATION (NOT . . . AR
ILLUSTRATED)
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GEK 119320
DESCRIPTION USE
1234567 ON
MAJOR ASSEMBLIES
1 - 38 682L280G03 HYDRAULIC ACCUMULATOR - OFF ENGINE GAS . . . . AR

TURBINE (NOT ILLUSTRATED)
SEE FIGURE 59-181A FOR BREAKDOWN
1 - 38 682L280G04 HYDRAULIC ACCUMULATOR - OFF ENGINE GAS . . . . AR
TURBINE (NOT ILLUSTRATED)
SEE FIGURE 59-181A FOR BREAKDOWN
ADDED PER CID 556902 AND SB LM6000-IND-0334
1 - 39 682L188G02 KIT, OIL TEMPERATURE SENSORS (NOT . . . . . . AR
ILLUSTRATED)
1 - 40 682L194G05 VIBRATION SENSOR (NOT ILLUSTRATED) . . . . . . AR
1 - 41 738L749G03 ADAPTER, SUMP PRESSURIZATION KIT (NOT . . . . AR
ILLUSTRATED)
1 - 42 682L292G01 KIT, COVER PLATE, AIR COLLECTOR-LM6000 (NOT . 1
ILLUSTRATED)
81&21752//(':+(135,17('2575$160,77('(/(&7521,&$//<
GEK 119320
VARIABLE INLET GUIDE VANE ASSEMBLY - BREAKDOWN

=

= =
=

= =

=
=

= =
=
=

=

=

=
=
=
=

=
=

=

=
B
A-A

=
=
=
=
A-A

=

=

=
=

=
=

=

=
=
FIGURE 2 VARIABLE INLET GUIDE VANE ASSEMBLY - BREAKDOWN (SHEET 1 OF 2)
*(35235,(7$5<,1)250$7,216XEMHFWWRWKHUHVWULFWLRQVRQWKH7LWOHSDJH 2-1
GEK 119320

=
=

=

=
=

=

= =

=

=

=
A-A

= = =

=

=
=

=
=
FIGURE 2 VARIABLE INLET GUIDE VANE ASSEMBLY - BREAKDOWN (SHEET 2 OF 2)
2-2 *(35235,(7$5<,1)250$7,216XEMHFWWRWKHUHVWULFWLRQVRQWKH7LWOHSDJH
GEK 119320
DESCRIPTION USE
1234567 ON
VARIABLE INLET GUIDE VANE ASSEMBLY -

BREAKDOWN
2 - 0 WHITE
2 - 0 L43918G01 VARIABLE INLET GUIDE VANE ASSY . . . . . . . . REF
REFERENCE FROM FIGURE 1-26
2 - 1 L45024P02 ' .CASE - INNER FORWARD VIGV . . . . . . . . . . 1
MATERIAL - SODIUM DICHROMATE, DIHYDRATE,
REQUIRED. MANUFACTURE AND REPAIR OF THIS
SUBSTANCE IN THE EUROPEAN UNION IS SUBJECT
TO AUTHORIZATION UNDER EU REGULATION (EC)
NO. 1907/2006
2 - 2 L45078P01 .PACKING, PREFORMED . . . . . . . . . . . . . 1
2 - 3 L45027G07 ' .CASE, VIGV - OUTER . . . . . . . . . . . . . 1
NO. 1907/2006
2 - 4 J970P08 ..INSERT, SCR THD 0.500-20 . . . . . . . . . . 2
2 - 4 MS51831CA206L ..INSERT . . . . . . . . . . . . . . . . . . . ALT
2 - 5 MS21209F1-25L ..INSERT, SCREW LOCKING HELICAL COIL, . . . . 16
0.190-32 BY 0.475 LG
2 - 6 J970P03 ..INSERT, SCR THD 0.190-32 . . . . . . . . . . 4
2 - 6 J1216P03 ..INSERT, SCREW THREAD . . . . . . . . . . . . ALT
2 - 7 L44652G01 ' .VANE, INLET GUIDE - BODY . . . . . . . . . . 43
NO. 1907/2006
2 - 8 L45139P01 .WASHER . . . . . . . . . . . . . . . . . . . 43
2 - 9 9610M50P03 .NUT, SELF-LOCKING DOUBLE HEXAGON, 0.3125-24 . 43
2 - 10 L44653G01 ' .VANE, INLET GUIDE - FLAP . . . . . . . . . . 43
NO. 1907/2006
2 - 11 L45135P03 .BUSHING . . . . . . . . . . . . . . . . . . . 43
2 - 12 L45135P04 .BUSHING . . . . . . . . . . . . . . . . . . . 43
2 - 13 L45141P01 .LEVER, ACTUATOR . . . . . . . . . . . . . . . 43
2 - 13 L45141P02 .LEVER, ACTUATOR . . . . . . . . . . . . . . . ALT
2 - 14 L45137P01 .WASHER - THRUST . . . . . . . . . . . . . . . 43
2 - 15 L45139P01 .WASHER . . . . . . . . . . . . . . . . . . . 43
GEK 119320
DESCRIPTION USE
1234567 ON

BREAKDOWN

2 - 17 J646P43E .BOLT, MACHINE - DOUBLE HEXAGON HEAD, . . . . 86
0.375-24 BY 4.000 LG
2 - 17 MS9559-40 .BOLT, MACHINE-DOUBLE HEXAGON, EXTENDED . . . ALT
WASHER HEAD, 0.375-24 BY 4.000 LG
2 - 18 MS9321-12 .WASHER, FLAT . . . . . . . . . . . . . . . . 172
2 - 19 9211M36P01 .NUT, SELF-LOCKING, 0.375-24 . . . . . . . . . 86
2 - 20 L43543P05 ' .RING, VIGV ACTUATOR . . . . . . . . . . . . . 1
NO. 1907/2006
2 - 21 L44811P01 .BLOCK, SUPPORT - ACTUATOR RING . . . . . . . 8
2 - 22 L45101P04 .SHIM, ACTUATOR RING, 0.118-0.122 THK . . . . 8
2 - 22 L45101P05 .SHIM, ACTUATOR RING, 0.108-0.112 THK . . . . AR
2 - 23 J643P11A .BOLT, MACHINE - DOUBLE HEXAGON HEAD, . . . . 16
0.190-32 BY 0.875 LG
2 - 24 L47021P02 .BRACKET, ACTUATOR . . . . . . . . . . . . . . 2
2 - 25 L47022P02 .BRACKET, ACTUATOR . . . . . . . . . . . . . . 2
2 - 26 L45071P04 .BUSHING . . . . . . . . . . . . . . . . . . . 43
2 - 27 L45071P10 .BUSHING . . . . . . . . . . . . . . . . . . . 43
2 - 28 L45071P09 .BUSHING . . . . . . . . . . . . . . . . . . . 4
0.375-24 BY 0.688 LG
2 - 30 9628M03P10 .NUT, SELF-LOCKING, DBL HEX, 0.375-24 . . . . 16
2 - 30 9628M03P04 .NUT, SELF-LOCKING, DBL HEX, 0.375-24 . . . . ALT
2 - 30 9628M03P16 .NUT, SELF-LOCKING, DBL HEX, 0.375-24 . . . . ALT
2 - 30 9703M19P16 .NUT, SELF-LOCKING, 0.375-24 . . . . . . . . . ALT
2 - 31 L45076P02 .PIN BOLT, ACTUATOR . . . . . . . . . . . . . 43
2 - 32 J201P02 .NUT, SELF-LOCKING-DOUBLE HEX THIN, 0.250-28 . 43
2 - 33 L45110P01 ' .COVER, PLUG . . . . . . . . . . . . . . . . . 1
NO. 1907/2006
2 - 34 L28124P03 .GASKET . . . . . . . . . . . . . . . . . . . 1
2 - 35 J643P04B .BOLT, MACHINE - DOUBLE HEXAGON HEAD, . . . . 2
0.190-32 BY 0.438 LG
2 - 36 J908P06B .BOLT, MACHINE, HEX HD, 0.500-20 BY 0.875 LG . 2
GEK 119320
DESCRIPTION USE
1234567 ON

BREAKDOWN
2 - 37 L47059P004 .BRACKET, ACTUATOR RIGGING . . . . . . . . . . 1

2 - 38 J455P016A .BOLT, SHOULDER, DBL HEX HD, 0.3125-24 BY . . 2
0.344 LG
2 - 39 J626P05 .NUT, SELF-LOCKING, TEN POINT, 0.3125-24 . . . 2
2 - 40 L47397P01 .PLATE, COVER . . . . . . . . . . . . . . . . 1
0.250-28 BY 0.750 LG
2 - 42 L44628G06 ' .SHROUD, FAN BOOSTER - INLET GUIDE VANE . . . 1
NO. 1907/2006
GEK 119320
KIT, 682L265, VARIABLE INLET GUIDE VANE ASSEMBLY

=
=

= =

= = =

=

=
= =

=

=
=
=

=
=

=

=

=

=

= =

=
=

=

= =
=

=
=
=
=
FIGURE 3 KIT, 682L265, VARIABLE INLET GUIDE VANE ASSEMBLY (SHEET 1 OF 1)
GEK 119320
DESCRIPTION USE
1234567 ON
KIT, 682L265, VARIABLE INLET GUIDE VANE

ASSEMBLY
3 - 0 WHITE
3 - 0 682L265G03 VARIABLE INLET GUIDE VANE ASSEMBLY, SAC . . . REF
3 - 1 L43418P03 ' .ACTUATOR, VARIABLE STATOR VANE/IGV (EU . . . 2
CERTIFIED)
NO. 1907/2006
SEE FIGURE 55-50
3 - 2 L45661P02 .TUBE/HOSE, OIL . . . . . . . . . . . . . . . 1
SEE FIGURE 55-53
3 - 3 L45663P02 .TUBE/HOSE, OIL . . . . . . . . . . . . . . . 1
SEE FIGURE 55-42
3 - 4 L45665G01 .TUBE, OIL - IGV . . . . . . . . . . . . . . . 1
SEE FIGURE 55-47
3 - 5 L45667G01 .TUBE, OIL - IGV . . . . . . . . . . . . . . . 1
SEE FIGURE 55-36
3 - 6 L45983P03 .HOSE, OIL - IGV . . . . . . . . . . . . . . . 1
SEE FIGURE 55-38
3 - 7 L45669P02 .TUBE/HOSE, OIL . . . . . . . . . . . . . . . 1
SEE FIGURE 55-52
3 - 8 L45671P02 .TUBE/HOSE, OIL . . . . . . . . . . . . . . . 1
SEE FIGURE 55-43
3 - 9 L45673G01 .MANIFOLD, OIL . . . . . . . . . . . . . . . . 1
SEE FIGURE 55-45
3 - 10 L45675G01 .TUBE,OIL - IGV . . . . . . . . . . . . . . . 1
SEE FIGURE 55-35
3 - 11 J1276F0185DAB .HOSE, TEFLON . . . . . . . . . . . . . . . . 1
SEE FIGURE 55-37
3 - 12 L45689P02 .TUBE/HOSE, OIL . . . . . . . . . . . . . . . 1
SEE FIGURE 55-56
3 - 13 L45691P02 .TUBE/HOSE, OIL . . . . . . . . . . . . . . . 1
SEE FIGURE 55-44
3 - 14 L45693G01 .MANIFOLD, OIL . . . . . . . . . . . . . . . . 1
SEE FIGURE 55-46
3 - 15 L44745P01 .SENSOR, TEMPERATURE, COMPRESSOR, INLET (EU . 1
CERTIFIED)
SEE FIGURE 52-7
3 - 16 L44715P01 .CABLE, ELECTRICAL - IGV LEFT SIDE . . . . . . 1
SEE FIGURE 52-8
3 - 16 L44715P02 .CABLE, ELECTRICAL - IGV LEFT SIDE . . . . . . ALT
SEE FIGURE 52-8
3 - 17 L44716P01 .CABLE, ELECTRICAL - IGV RIGHT SIDE . . . . . 1
SEE FIGURE 52-6
3 - 17 L44716P02 .CABLE, ELECTRICAL - IGV RIGHT SIDE . . . . . ALT
SEE FIGURE 52-6
GEK 119320
DESCRIPTION USE
1234567 ON
KIT, 682L265, VARIABLE INLET GUIDE VANE

ASSEMBLY
3 - 18 L45130G01 .BEARING BLOCK . . . . . . . . . . . . . . . . 2

SEE FIGURE 55-41
3 - 19 L45906G07 BRACKET, ANGLE-VARIABLE INLET GUIDE VANE . . . REF
3 - 20 L45906G05 BRACKET, ANGLE - VIGV . . . . . . . . . . . . REF
3 - 21 L46048G05 BRACKET, ANGLE-VARIABLE INLET GUIDE VANE . . . REF
3 - 22 L45985G03 BRACKET, ELECTRICAL . . . . . . . . . . . . . REF
3 - 25 L45072P01 BRACKET, FORWARD ACTUATOR MOUNTING . . . . . . REF
3 - 26 L45073P01 BRACKET, AFT ACTUATOR MOUNTING . . . . . . . . REF
3 - 26 L62764P01 BRACKET, ACTUATOR MOUNTING . . . . . . . . . . REF
3 - 27 L45908G01 BRACKET, INLET GUIDE VANE - ELECTRICAL . . . . REF
3 - 28 L45905G01 BRACKET, ELECTRICAL PANEL SUPPORT - FORWARD . REF
GEK 119320
FRONT FRAME ASSEMBLY BREAKDOWN

= B

V-G
=
= A
= V-G

= =

=
=

=
C

=
FIGURE 4 FRONT FRAME ASSEMBLY BREAKDOWN (SHEET 1 OF 3)
81&21752//(':+(135,17('2575$160,77('(/(&7521,&$//<
GEK 119320
A C

=

=

=

= =

=

=

=
=
=

=

=

=
=

=

=
=

=

=
=

=

=

=

=

=
=
=

= F
=
D

=
=

F

=
=
= =

=

=

=

=
= =

=
= =

=

=
=
=

=
81&21752//(':+(135,17('2575$160,77('(/(&7521,&$//<
GEK 119320
F
E

=

= =

= =

=

=
H
V-G

= =

=

=

=

=
81&21752//(':+(135,17('2575$160,77('(/(&7521,&$//<
GEK 119320
DESCRIPTION USE
1234567 ON
4 - 0 WHITE
4 - 1 L43792G09 ASSEMBLY, COMPRESSOR FRONT FRAME - LM6000 . . REF
4 - 2 L47371G10 .COMPRESSOR FRONT FRAME, MACHINING . . . . . . 1
SEE FIGURES 6-57, 50-134, AND 49-168
4 - 3 9107M35G08 ..STUD, EXTENSION, BELLCRANK . . . . . . . . . 18
WELDED TO FRAME AT ASSEMBLY
4 - 4 MS51830-202L Δ ...INSERT, SCREW THREAD-LOCKED IN, KEY . . . . 1
LOCKED, 0.375-16 EXTERNAL THD, 0.250-28
INTERNAL THD
MAY CONTAIN HAZARDOUS MATERIAL -
CADMIUM, CAS #7440-43-9
4 - 5 MS9390-090 ...PIN, STRAIGHT . . . . . . . . . . . . . . . 2
4 - 6 L56212G01 Δ .VALVE, BY-PASS - COMPRESSOR FRONT FRAME . . . 12
NO. 1907/2006
4 - 7 J200P02 .NUT, SELF-LOCKING, REDUCED HEXAGON, . . . . . 24
0.190-32
4 - 8 133A1624P40 .WASHER, FLAT, 0.203 ID, 0.380 OD, 0.063 . . . 24
THICK
4 - 9 9130M96P06 .SCREW, MACHINE, 0.190-32 BY 1.67 LG . . . . . 24
4 - 10 9106M39P04 .BUSHING . . . . . . . . . . . . . . . . . . . 24
4 - 11 L37241G01 Δ .HINGE ASSEMBLY . . . . . . . . . . . . . . . 12
NO. 1907/2006
4 - 12 9022M73P06 ..BUSHING, NYLON . . . . . . . . . . . . . . . 4
0.3125-24 BY 1.250 LG
4 - 14 NAS1149C0532R .WASHER, FLAT, 0.328 ID . . . . . . . . . . . 24
4 - 15 L43395P02 Δ .CLEVIS, BYPASS . . . . . . . . . . . . . . . 12
NO. 1907/2006
4 - 16 9048M33P06 .BEARING, PLAIN, ROD END . . . . . . . . . . . 12
4 - 17 2092M71P01 .NUT, SELF-LOCKING 0.250-28 UNJF-3B . . . . . 12
4 - 18 MS21083C5 .NUT, SELF-LOCKING, 0.3125-24 . . . . . . . . 12
4 - 19 9107M21P06 .BOLT, ROUND HEAD, 0.3125-24 BY 1.50 LG . . . 12
81&21752//(':+(135,17('2575$160,77('(/(&7521,&$//<
GEK 119320
DESCRIPTION USE
1234567 ON
4 - 21 J414P052A .BOLT, SHEAR-DOUBLE HEX HEAD, 0.250-28 BY . . 12

1.551 LG
4 - 22 MS9321-10 .WASHER, FLAT, 0.276 ID BY 0.500 OD BY . . . . 24
0.062 THK
4 - 23 MS21083C4 .NUT, SELF-LOCKING, HEX HD, 0.250-28 . . . . . 12
4 - 24 L47023G04 .RING, ACTUATING-FRONT FRAME (MATCHED . . . . 1
ASSEMBLY)
4 - 25 J970P05 ..INSERT, SCREW THREAD, SELF-LOCKING . . . . . 4
4 - 26 J815P029A .BOLT, SHEAR, DBL HEX HD, 0.3125-24 BY . . . . 4
1.137 LG
4 - 27 L43326G02 Δ .BELLCRANK, VALVE . . . . . . . . . . . . . . 12
NO. 1907/2006
4 - 27 L43326G01 Δ .BELLCRANK, VALVE . . . . . . . . . . . . . . ALT
NO. 1907/2006
4 - 28 L43379P04 ..BEARING, SPHERICAL . . . . . . . . . . . . . 12
4 - 29 MS14103-5 ..BEARING, PLAIN . . . . . . . . . . . . . . . 12
4 - 30 MS9490-09 .BOLT, MACHINE, HEX HD, FULL SHANK, . . . . . 18
0.250-28 BY 0.688 LG
4 - 31 9107M99P01 .WASHER, FLAT . . . . . . . . . . . . . . . . 18
4 - 32 9107M25P04 .WASHER, THRUST . . . . . . . . . . . . . . . 18
4 - 33 9131M44P02 .BUSHING, SLEEVE . . . . . . . . . . . . . . . 18
4 - 34 9131M45P02 .WASHER, FLAT . . . . . . . . . . . . . . . . 18
4 - 35 9108M27P03 .BOLT, EXTERNAL-REL, 0.375-24 BY 1.230 LG . . 18
4 - 36 L43420P07 Δ .ACTUATOR, VARIABLE BYPASS VALVE W/O LVDT . . 4
NO. 1907/2006
SEE FIGURES 7-110 AND 56-75
81&21752//(':+(135,17('2575$160,77('(/(&7521,&$//<
GEK 119320
DESCRIPTION USE
1234567 ON
4 - 37 L43419P07 Δ .ACTUATOR, VARIABLE BYPASS VALVE W/LVDT . . . 2

NO. 1907/2006
NOTE
VBV ACTUATOR L43419 IS LOCATED AT THE 1
AND 7 O'CLOCK POSITIONS (FORWARD LOOKING
AFT). VBV ACTUATOR L43420 IS LOCATED AT
THE REMAINING FOUR POSITIONS.

0.062 THK
4 - 40 J414P034A .BOLT, SHEAR-DOUBLE HEX HEAD, 0.250-28 BY . . 6
1.270 LG
0.062 THK
4 - 42 9049M91P07 .CLEVIS, ACTUATOR . . . . . . . . . . . . . . 6
4 - 43 9048M34P03 .BEARING, PLAIN, ROD END . . . . . . . . . . . 6
4 - 44 2092M71P02 .NUT, SELF-LOCKING 0.3125-24 UNJF-3B . . . . . 6
4 - 46 J415P123A .BOLT, SHEAR - DOUBLE HEX HEAD, 0.3125-24 . . 6
BY 1.125 LG
4 - 48 9107M21P06 .BOLT, ROUND HEAD, 0.3125-24 BY 1.50 LG . . . 6
4 - 50 L43324G03 Δ .BELLCRANK ASSEMBLY, ACTUATOR . . . . . . . . 6
NO. 1907/2006
4 - 51 MS14103-5 ..BEARING, PLAIN . . . . . . . . . . . . . . . 2
4 - 52 L43434P06 .TRUNNION . . . . . . . . . . . . . . . . . . 2
4 - 53 J908P12A .BOLT, MACHINE-HEX HEAD, 0.500-20 BY 1.625 . . 8
LG
4 - 54 L43546P01 .WASHER, FLAT . . . . . . . . . . . . . . . . 2
4 - 55 L43374P03 Δ .PAD, MOUNT . . . . . . . . . . . . . . . . . 1
NO. 1907/2006
81&21752//(':+(135,17('2575$160,77('(/(&7521,&$//<
GEK 119320
DESCRIPTION USE
1234567 ON

0.500-20 BY 1.188 LG
4 - 57 J644P16F .BOLT, MACHINE - DOUBLE HEXAGON HEAD, . . . . 33
0.250-28 BY 1.188 LG
4 - 58 L61883P01 .SPACER . . . . . . . . . . . . . . . . . . . 33
0.250-28 BY 1.312 LG
SEE FIGURE 9-52
4 - 60 J1213P04 .NUT, SELF-LOCKING, DOUBLE HEXAGON . . . . . . 65
INCREASED WRENCHING, 0.250-28
SEE FIGURE 9-53
4 - 61 L47869G01 .BUMPER, LPC STATOR CASE . . . . . . . . . . . 112
4 - 62 J221P904 .PACKING, PREFORMED, 0.346 ID . . . . . . . . 1
4 - 63 MS9902-04 .PLUG . . . . . . . . . . . . . . . . . . . . 1
4 - 64 L43476P01 .PLATE, BLANK-OFF, CIT SENSOR . . . . . . . . 1
0.190-32 BY 0.625 LG
4 - 66 J644P14A BOLT, MACHINE - DOUBLE HEXAGON HEAD, . . . . . 96
0.250-28 BY 1.062 LG
SEE FIGURE 13-69
4 - 66A L47910P01 PLUG, ICAD NOZZLE - FRONT FRAME . . . . . . . 24
USE ON 682L292G01
4 - 66B J904P06A BOLT, MACHINE, HEX HD, 0.250-28 BY 0.875 LG . 48
USE ON 682L292G01
4 - 67 L47316G15 Δ AIR COLLECTOR, FRONT FRAME . . . . . . . . . . REF
NO. 1907/2006
81&21752//(':+(135,17('2575$160,77('(/(&7521,&$//<
GEK 119320
FRONT FRAME AND ASSOCIATED PARTS (INTERNAL)

= =
=
=
B

=

=

= = E
=

=
= =

= C

= =
D
= =

=
=

= =

=
=
=

=
=
V-F
V-F

=
=
=
A
FIGURE 5 FRONT FRAME AND ASSOCIATED PARTS (INTERNAL) (SHEET 1 OF 4)
GEK 119320

B

=
=

= =

=

=

=
=
= = = =

=
=

=

=

=
=

=

=
=
D
C

= = =
= =
=
=

=
=

=
=

=

=

=

=
GEK 119320

=

=

=
=
= =

= =

= =

= =

= =

=

= =

= =

= =

= =
V-F
GEK 119320

=

=

=

= G
=

=

=

=
=

=

=

=
GEK 119320
DESCRIPTION USE
1234567 ON
5 - 0 WHITE
5 - 1 L44853G01 .SLEEVE, FAN FRAME . . . . . . . . . . . . . . 1
5 - 2 9006M23P02 ..INSERT, SCREW THREADED . . . . . . . . . . . 3
0.190-32 BY 0.750 LG
5 - 4 9607M05P39 .PACKING, PREFORMED, 17.800 ID . . . . . . . . 1
5 - 5 9065M62G11 .HOUSING, NO. 1 BRG - FAN FRAME . . . . . . . 1
SEE FIGURE 20-16
5 - 6 9065M31P06 ..HOUSING, AFT, NO. 1 BEARING-FAN FRAME . . . 1
SEE FIGURE 6-66
5 - 7 9065M32P06 ..HOUSING, NO. 1 BEARING-FAN FRAME-FWD . . . . 1
5 - 8 J815P036A ..BOLT, SHEAR, DBL HEX HD, 0.3125-24 BY . . . 20
1.356 LG
5 - 9 9155M50P01 ..WASHER, FLAT . . . . . . . . . . . . . . . . 20
5 - 10 9021M86P01 ..NUT, SELF-LOCKING, DBL HEX HD, . . . . . . . 20
COUNTERBORED 0.3125-24
0.3125-24 BY 0.875 LG
5 - 12 133A1624P56 .WASHER, FLAT, AMS 5510, 0.335 IN ID, 0.495 . 84
IN OD, 0.040 IN THICK
5 - 13 9695M93G01 .NUT ASSY . . . . . . . . . . . . . . . . . . 1
5 - 14 9695M94G01 .NUT ASSY . . . . . . . . . . . . . . . . . . 2
5 - 15 J951P07A .SCREW, MACHINE, FLUSH HD TORX DRIVE, . . . . 8
0.190-32 BY 0.625 LG
5 - 16 9065M66G04 .HOUSING ASSY, NO. 2 BEARING . . . . . . . . . 1
SEE FIGURE 6-67
0.250-28 BY 0.938 LG
5 - 19 9658M51P03 .BEARING, NO. 2 ROLLER . . . . . . . . . . . . 1
5 - 19 9658M51P04 .BEARING, NO. 2 ROLLER . . . . . . . . . . . . ALT
5 - 19 1327M96P01 .BEARING, ROLLER . . . . . . . . . . . . . . . ALT
5 - 19 1471M99P01 .BEARING, ROLLER . . . . . . . . . . . . . . . ALT
5 - 19 1851M45P01 .BEARING, ROLLER, CYLINDRICAL, NO. 2 . . . . . ALT
0.250-28 BY 0.500 LG
5 - 21 1664M36G01 .MANIFOLD, OIL . . . . . . . . . . . . . . . . 1
5 - 22 9629M62P02 .GASKET . . . . . . . . . . . . . . . . . . . 1
0.190-32 BY 1.125 LG
5 - 24 R1394P026 .BOLT, MACHINE, DBL HEX HD, EXTENDED . . . . . 2
WASHER, 0.250-28 BY 1.875 LG
5 - 25 MS122903 .CLAMP, LOOP, 0.312 TUBE DIA . . . . . . . . . 2
5 - 26 9046M52P01 .BRACKET, ANGLE . . . . . . . . . . . . . . . 1
5 - 27 9329M94P001A .BRACKET . . . . . . . . . . . . . . . . . . . 1
0.190-32 BY 0.500 LG
5 - 29 MS21043-3 .NUT, SELF-LOCKING, REDUCED HEX, REDUCED . . . 2
HEIGHT, 0.190-32
5 - 31 L44700G02 .NOZZLE, BEARING OIL . . . . . . . . . . . . . 2
GEK 119320
DESCRIPTION USE
1234567 ON
5 - 33 R1393P012L .BOLT, MACHINE, DBL HEX HD, EXTENDED . . . . . 4

WASHER, 0.190-32 BY 0.938 LG
0.250-28 BY 0.688 LG
NOTE
USE WITH NUT, FIGURE 6-29.

SEE FIGURE 14-29
NOTE
USE WITH BOLTS, FIGURES 6-27 AND 6-28.
5 - 37 J1212P04 .NUT, SELF-LOCKING, DBL HEX, 0.250-28 . . . . 12

SEE FIGURE 14-28
NOTE
USE WITH BOLTS, FIGURES 6-27 AND 6-28.
5 - 38 9047M54G07 ' .SUPPORT ASSY, STAGE 4 . . . . . . . . . . . . 1

NO. 1907/2006
5 - 39 9064M84P04 .VANE, STAGE 4 . . . . . . . . . . . . . . . . 112
0.250-28 BY 0.688 LG
5 - 41 L44713P01 .SEAL, FASTENER . . . . . . . . . . . . . . . 20
5 - 42 L44713P02 .SEAL, FASTENER . . . . . . . . . . . . . . . 31
5 - 43 9006M36P02 .BRACKET . . . . . . . . . . . . . . . . . . . 2
SEE FIGURE 6-64
5 - 44 J198P01 .NUT, SELF-LOCKING, SPLINE DRIVE, 0.190-32 . . 4
5 - 45 MS9321-09 .WASHER, FLAT . . . . . . . . . . . . . . . . 2
0.190-32 BY 1.062 LG
5 - 47 L44713P01 .SEAL, FASTENER . . . . . . . . . . . . . . . 4
5 - 48 9365M41P223 .SEAL, O-RING . . . . . . . . . . . . . . . . 4
5 - 49 NAS1102E3-8 .SCREW, MACHINE, FLAT 100 DEG HD, 0.190-32 . . 4
BY 0.500 LG
5 - 50 L44827G04 ' SEAL, STATIONARY, AIR AND OIL - NO. 1 BRG . . 1
NO. 1907/2006
USE ON L60016G01
SEE FIGURE 6-65
5 - 51 9117M41P04 .STUD, LOCKED IN . . . . . . . . . . . . . . . 20
GEK 119320
DESCRIPTION USE
1234567 ON
5 - 52 MS51990E104P .LOCKRING, SERRATED . . . . . . . . . . . . . 20

5 - 53 J626P03 NUT, SELF-LOCKING, TEN POINT, 0.190-32 . . . . 20
USE ON L60016G01
5 - 54 9607M05P33 PACKING, PREFORMED, 20.360 ID . . . . . . . . 1
USE ON L60016G01
USE ON L60016G01
5 - 56 L44854P01 SEAL, AIR, STATIONARY-BRG NO. 1 . . . . . . . 1
USE ON L60016G01
USE ON L60016G01
0.190-32 BY 0.875 LG
USE ON L60016G01
5 - 59 NAS1149C0332R WASHER, FLAT, 0.203 ID . . . . . . . . . . . . 20
USE ON L60016G01
5 - 60 J628P03 NUT, SELF-LOCKING, TEN POINT - INCREASED . . . 20
WRENCHING, CBORED, DRY FILM, 0.190-32
USE ON L60016G01
5 - 61 9185M71G31 GEARBOX, ASSY INLET . . . . . . . . . . . . . REF
5 - 62 9064M10G01 MANIFOLD ASSEMBLY, LUBE . . . . . . . . . . . REF
GEK 119320
FRONT FRAME AND ASSOCIATED PARTS (LUBE/SUMP)

=
=
=
=
=
=

=
=

=
=
=

=

=

=
=

=
= =
V-A

=
=

=
=
=

=

=
FIGURE 6 FRONT FRAME AND ASSOCIATED PARTS (LUBE/SUMP) (SHEET 1 OF 3)
81&21752//(':+(135,17('2575$160,77('(/(&7521,&$//<
GEK 119320
V-A

=
=
B

=

= =
= = = =

=
=

=

= = =

=
= =
= =
=
=

=
=
= = =

=

=

=

=

=
=
=

= =

=
=
=

=
81&21752//(':+(135,17('2575$160,77('(/(&7521,&$//<
GEK 119320

=
=
=

=
=

=
=

=
=

=

=

= =

=
81&21752//(':+(135,17('2575$160,77('(/(&7521,&$//<
GEK 119320
DESCRIPTION USE
1234567 ON
FRONT FRAME AND ASSOCIATED PARTS

(LUBE/SUMP)
6 - 0 WHITE
6 - 1 9064M10G01 .MANIFOLD ASSEMBLY, LUBE . . . . . . . . . . . 1
SEE FIGURE 5-62
6 - 2 9065M45G02 .MANIFOLD ASSEMBLY, LUBE . . . . . . . . . . . 1
0.250-28 BY 0.938 LG
6 - 4 L43425G03 .TUBE, LUBE-GEARBOX . . . . . . . . . . . . . 1
6 - 8 NAS1102E3-8 .SCREW, MACHINE, FLAT 100 DEG HD, 0.190-32 . . 2
BY 0.500 LG
6 - 9 9111M92G01 .NUT ASSEMBLY . . . . . . . . . . . . . . . . 1
6 - 10 9111M92P01 ..CHANNEL, NUT . . . . . . . . . . . . . . . . 1
6 - 11 J371P04 ..NUT, SELF-LOCKING, GANG CHANNEL, 0.250-28 . 13
6 - 12 9695M44P01 ..NUT, SELF-LOCKING, GANG CHANNEL, 0.190-32 . 3
6 - 13 9006M16G01 .NUT ASSEMBLY . . . . . . . . . . . . . . . . 1
6 - 14 9006M16P01 ..CHANNEL, NUT . . . . . . . . . . . . . . . . 1
6 - 15 9695M44P01 ..NUT, SELF-LOCKING, GANG CHANNEL, 0.190-32 . 3
6 - 16 J371P04 ..NUT, SELF-LOCKING, GANG CHANNEL, 0.250-28 . 18
6 - 17 J951P09A .SCREW, MACHINE, 0.190-32 BY 0.750 LG . . . . 6
QTY 3 PER NUT CHANNEL INDEX 9 AND INDEX 13
6 - 18 L43426P001A .BRACKET . . . . . . . . . . . . . . . . . . . 1
6 - 19 J198P01 .NUT, SELF-LOCKING, SPLINE DRIVE, 0.190-32 . . 4
6 - 20 L44713P02 .SEAL, FASTENER . . . . . . . . . . . . . . . 3
6 - 21 9273M62P04 .PISTON RING . . . . . . . . . . . . . . . . . 2
6 - 22 MS9565-08 .BOLT, MACHINE, DBL HEX HD, EXTENDED . . . . . 3
WASHER, 0.190-32 BY 0.625 LG
6 - 23 MS9321-09 .WASHER, FLAT . . . . . . . . . . . . . . . . 3
0.190-32 BY 0.500 LG
6 - 25 J1432P05 .CLAMP, LOOP, CUSHIONED, 0.312 TUBE DIA . . . 1
6 - 26 9329M84G09 .HOUSING, DAMPER, BEARING NO. 3R . . . . . . . 1
SEE FIGURE 14-30
***PARTIAL BREAKDOWN FOLLOWS***
6 - 27 9329M88P01 ..BOLT, SELF-RETAINING, SLABBED HEAD . . . . . 10
6 - 27 9329M88P05 ..BOLT, SELF-RETAINING, SLABBED HEAD . . . . . ALT
6 - 28 9329M88P03 ..BOLT, SELF-RETAINING, SLABBED HEAD . . . . . 2
6 - 28 9329M88P07 ..BOLT, SELF-RETAINING, SLABBED HEAD . . . . . ALT
***END OF PARTIAL BREAKDOWN***
NOTE
FIGURE 6-27 AND 6-28 BOLTS ARE USED WITH
FIGURE 5-36 WASHERS AND FIGURE 5-37 NUTS.
6 - 29 J1212P04 .NUT, SELF-LOCKING, DBL HEX, 0.250-28 . . . . 15
NOTE
FIGURE 6-29 NUTS ARE USED WITH FIGURE 5-35
BOLTS.
6 - 30 L43427G02 .TUBE, SCAVENGE . . . . . . . . . . . . . . . 1
81&21752//(':+(135,17('2575$160,77('(/(&7521,&$//<
GEK 119320
DESCRIPTION USE
1234567 ON

(LUBE/SUMP)
6 - 31 L43428G03 .TUBE, SCAVENGE . . . . . . . . . . . . . . . 1

6 - 34 9022M34G01 .FLANGE, SNAP ON . . . . . . . . . . . . . . . 2
0.190-32 BY 0.625 LG
0.190-32 BY 0.438 LG
0.190-32 BY 0.562 LG
6 - 41 L44699P01 ' .SEAL, INTEGRAL - OIL LUBE . . . . . . . . . . 1
NO. 1907/2006
6 - 41 L44699P02 .SEAL, INTEGRAL - OIL LUBE . . . . . . . . . . ALT
6 - 42 1539M73G03 ' .SEAL ASSEMBLY, STATIONARY, BEARING NO. 3 . . 1
NO. 1907/2006
6 - 43 9365M41P236 .SEAL, O-RING . . . . . . . . . . . . . . . . 1
6 - 45 L43398G01 ' .PACKING ASSEMBLY WITH RETAINER, BEARING . . . 1
NO. 3
NO. 1907/2006
WASHER, 0.250-28 BY 0.875 LG
6 - 47 9374M29G02 .SEAL, AIR, STATIONARY BEARING NO. 3 . . . . . 1
0.250-28 BY 0.625 LG
6 - 50 9329M86P02 .BEARING, NO. 3 ROLLER . . . . . . . . . . . . 1
81&21752//(':+(135,17('2575$160,77('(/(&7521,&$//<
GEK 119320
DESCRIPTION USE
1234567 ON

(LUBE/SUMP)
6 - 51 9329M87P03 .RETAINER, BRG . . . . . . . . . . . . . . . . 1

6 - 52 J904P33B .BOLT, MACHINE, DBL HEX HD, 0.250-28 BY . . . 11
0.458 LG
6 - 53 9046M14P02 NUT, PLAIN, ROUND-BRG 3 . . . . . . . . . . . 1
USE ON L60016G01
6 - 54 9607M31P02 SPACER, RING-LOCKNUT, BRG 3 . . . . . . . . . 1
USE ON L60016G01
6 - 54 9607M31P04 SPACER, RING-LOCKNUT, BRG 3 . . . . . . . . . ALT
USE ON L60016G01
6 - 55 9607M01P04 RING, RETAINING, KEYED-LOCK NUT, BRG 3 . . . . 1
USE ON L60016G01
6 - 56 9648M79P10 RING, RETAINING . . . . . . . . . . . . . . . 1
USE ON L60016G01
6 - 56 9648M79P42 RING, RETAINING . . . . . . . . . . . . . . . ALT
USE ON L60016G01
6 - 57 L47371G10 COMPRESSOR FRONT FRAME, MACHINING . . . . . . REF
6 - 58 L47317G01 .TUBE, LUBE . . . . . . . . . . . . . . . . . 1
6 - 59 9006M24G03 .TUBE, OIL SUPPLY . . . . . . . . . . . . . . 1
SEE FIGURE 56-70
6 - 60 9006M24P03 ..BUSHING . . . . . . . . . . . . . . . . . . 1
NOTE
TUBES L47317G01, 9006M24G03, AND BUSHING
9006M24P03 ARE WELDED AT ASSY.

WASHER, 0.190-32 BY 0.562 LG
6 - 62 9380M27P08 DISK, COMPRESSOR ROTOR-STAGE 2 . . . . . . . . REF
6 - 63 L46338G01 MANIFOLD, OIL - A SUPPLY . . . . . . . . . . . REF
6 - 64 9006M36P02 BRACKET . . . . . . . . . . . . . . . . . . . REF
6 - 65 L44827G04 ' SEAL, STATIONARY, AIR AND OIL - NO. 1 BRG . . REF
NO. 1907/2006
6 - 66 9065M31P06 HOUSING, AFT, NO. 1 BEARING-FAN FRAME . . . . REF
6 - 67 9065M66G04 HOUSING ASSY, NO. 2 BEARING . . . . . . . . . REF
81&21752//(':+(135,17('2575$160,77('(/(&7521,&$//<
GEK 119320
LUBE SYSTEM, FRONT FRAME MODULE
B
A
FIGURE 7 LUBE SYSTEM, FRONT FRAME MODULE (SHEET 1 OF 6)
81&21752//(':+(135,17('2575$160,77('(/(&7521,&$//<
GEK 119320

A
= =
=

=

= =

=

=
=

=
= =

=
=
=

=
=
=

=
=

=
=
=

=

=
=
=

B
=

=
= C =

=

= =

=

=
=

=

=

=
=
=
=

=
= =
= = =
81&21752//(':+(135,17('2575$160,77('(/(&7521,&$//<
GEK 119320
D E

=

= = =

=

=

=
=
= =

=

=

=

= =

=
= =

=
=

=

= =
=
=
=
=

=

= =

=

=

=
81&21752//(':+(135,17('2575$160,77('(/(&7521,&$//<
GEK 119320
G
F

=

=

=
=
=
=
= =

=

= =

= =

=

=

=
81&21752//(':+(135,17('2575$160,77('(/(&7521,&$//<
GEK 119320

=

=

=

=
= =

=
=

=

=

=

=
81&21752//(':+(135,17('2575$160,77('(/(&7521,&$//<
GEK 119320

N

= =
=

=

=

=

=
=
=

=

= =

=

=
=

=

=

=
=

=

= =
81&21752//(':+(135,17('2575$160,77('(/(&7521,&$//<
GEK 119320
DESCRIPTION USE
1234567 ON
7 - 0 WHITE
7 - 0 L43791G16 ASSEMBLY, FRONT FRAME MODULE . . . . . . . . . REF
7 - 1 133A1624P7 .WASHER, FLAT, 0.281 ID, 0.630 OD, 0.063 THK . 4
7 - 3 L45635G01 .MANIFOLD, FUEL . . . . . . . . . . . . . . . 1
7 - 4 L45649G01 .MANIFOLD, OIL . . . . . . . . . . . . . . . . 1
7 - 5 L45683G01 .TUBE, OIL - DRAIN . . . . . . . . . . . . . . 1
SEE FIGURE 56-77
7 - 6 L45623G01 .TUBE, OIL - VBV HEAD, LOWER-RIGHT SIDE . . . 1
SEE FIGURE 56-57
7 - 7 L45651G01 .TUBE, OIL-VBV ROD, LOWER-RIGHT SIDE . . . . . 1
SEE FIGURE 56-58
7 - 8 L45645G01 .TUBE, OIL - VBV HEAD LOWER-LEFT SIDE . . . . 1
SEE FIGURE 56-59
7 - 9 L45659G01 .TUBE, OIL-VBV ROD, LOWER-LEFT SIDE . . . . . 1
SEE FIGURE 56-60
7 - 10 L45679G01 .TUBE, OIL - VSV/VBV, DRAIN . . . . . . . . . 1
SEE FIGURE 56-64
7 - 11 L45647G01 .MANIFOLD, OIL . . . . . . . . . . . . . . . . 1
7 - 12 L45633G01 .MANIFOLD, OIL - VBV . . . . . . . . . . . . . 1
7 - 13 J180G0440G090 .HOSE, TEFLON . . . . . . . . . . . . . . . . 1
SEE FIGURE 56-62
7 - 14 J180F0480G090 .HOSE, TEFLON . . . . . . . . . . . . . . . . 1
SEE FIGURE 56-61
7 - 15 J193H0360A090 .HOSE, TEFLON . . . . . . . . . . . . . . . . 1
SEE FIGURE 56-72
7 - 15 J193H0360C090 .HOSE, TEFLON . . . . . . . . . . . . . . . . ALT
SEE FIGURE 56-72
7 - 16 J180H0420G090 .HOSE, TEFLON . . . . . . . . . . . . . . . . 1
SEE FIGURE 56-63
7 - 16 AS156K420C090 .HOSE, TEFLON . . . . . . . . . . . . . . . . ALT
SEE FIGURE 56-63
7 - 17 J1092P04 .NUT, SELF-LOCKING, TEN POINT - REDUCED . . . 1
HEIGHT, 0.250-28
7 - 18 MS9557-15 .BOLT, MACHINE-DOUBLE HEXAGON EXTENDED . . . . 1
7 - 19 J1221G18 .CLAMP, LOOP, CUSHIONED, 1.125 TUBE DIA . . . 1
0.190-32 BY 0.625 LG
7 - 22 J219P03 Δ .GASKET, SEAL-FLANGE, FUEL AND OIL . . . . . . 1
NO. 1907/2006
7 - 23 L49328G01 .TUBE, REDUCER . . . . . . . . . . . . . . . . 1
0.190-32 BY 0.625 LG
7 - 26 J219P04 .GASKET, SEAL-FLANGE, FUEL AND OIL . . . . . . 1
81&21752//(':+(135,17('2575$160,77('(/(&7521,&$//<
GEK 119320
DESCRIPTION USE
1234567 ON

SEE FIGURE 9-51
7 - 31 L49327P01 .BRACKET, ANGLE SUPPORT . . . . . . . . . . . 1
SEE FIGURE 9-50
HEIGHT, 0.250-28
7 - 34 L45643G01 .TUBE, OIL -VBV . . . . . . . . . . . . . . . 2
7 - 35 L45810G01 .TUBE, OIL - DRAIN . . . . . . . . . . . . . . 1
7 - 36 L45657G01 .TUBE, OIL . . . . . . . . . . . . . . . . . . 2
7 - 37 L46093P002A .BRACKET, VBV . . . . . . . . . . . . . . . . 1
WASHER, 0.250-28 BY 0.562 LG
HEIGHT, 0.250-28
HEIGHT, 0.250-28
HEIGHT, 0.250-28
7 - 49 L46095G01 .BRACKET, VBV . . . . . . . . . . . . . . . . 1
SEE FIGURE 56-78
WASHER, 0.250-28 BY 0.562 LG
HEIGHT, 0.250-28
HEIGHT, 0.250-28
SEE FIGURE 56-69
SEE FIGURE 56-68
7 - 61 L45812G01 .TUBE, OIL - VBV . . . . . . . . . . . . . . . 1
81&21752//(':+(135,17('2575$160,77('(/(&7521,&$//<
GEK 119320
DESCRIPTION USE
1234567 ON
7 - 63 L46093P001A .BRACKET, VBV . . . . . . . . . . . . . . . . 1

WASHER, 0.250-28 BY 0.562 LG
HEIGHT, 0.250-28
HEIGHT, 0.250-28
HEIGHT, 0.250-28
7 - 75 L46094P001A .BRACKET, VBV . . . . . . . . . . . . . . . . 1
WASHER, 0.250-28 BY 0.562 LG
HEIGHT, 0.250-28
HEIGHT, 0.250-28
7 - 84 9365M41P122 .SEAL, O-RING, 1.051 ID . . . . . . . . . . . 6
7 - 85 9365M41P117 .SEAL, O-RING, 0.739 ID . . . . . . . . . . . 6
7 - 87 L45803G02 .CAN, DRAIN . . . . . . . . . . . . . . . . . 6
7 - 88 9378M31P01 .FITTING-REDUCER . . . . . . . . . . . . . . . 6
7 - 90 9378M31P01 .FITTING-REDUCER . . . . . . . . . . . . . . . 6
7 - 91 1153M64G23 Δ .CLAMP, TUBE . . . . . . . . . . . . . . . . . 1
NO. 1907/2006
WASHER, 0.250-28 BY 1.312 LG
HEIGHT, 0.250-28
81&21752//(':+(135,17('2575$160,77('(/(&7521,&$//<
GEK 119320
DESCRIPTION USE
1234567 ON
7 - 95 1153M64G23 Δ .CLAMP, TUBE . . . . . . . . . . . . . . . . . 1

NO. 1907/2006
WASHER, 0.250-28 BY 1.312 LG
HEIGHT, 0.250-28
7 - 99 L45820G01 Δ .ELBOW, AIR, B SUMP PRESSURIZATION . . . . . . 1
NO. 1907/2006
SEE FIGURE 49-192
7 - 100 9294M61P03 .GASKET, METAL . . . . . . . . . . . . . . . . 1
WASHER, 0.250-28 BY 0.750 LG
7 - 102 L46054G03 .BRACKET, OIL . . . . . . . . . . . . . . . . 1
SEE FIGURES 8-62, 56-65, AND 71-20
SEE FIGURE 8-63
7 - 107 L44571P01 Δ HYDRAULIC CONTROL UNIT (EU CERTIFIED) . . . . REF
NO. 1907/2006
7 - 109 L46042G03 BRACKET, VSV/VBV . . . . . . . . . . . . . . . REF
81&21752//(':+(135,17('2575$160,77('(/(&7521,&$//<
GEK 119320
DESCRIPTION USE
1234567 ON
7 - 110 L43420P07 Δ ACTUATOR, VARIABLE BYPASS VALVE W/O LVDT . . . REF

NO. 1907/2006
7 - 110 L43419P07 Δ ACTUATOR, VARIABLE BYPASS VALVE W/LVDT . . . . REF
NO. 1907/2006
NOTE
VBV ACTUATOR L43419 IS LOCATED AT THE 1
AND 7 O'CLOCK POSITIONS (FORWARD LOOKING
AFT). VBV ACTUATOR L43420 IS LOCATED AT
THE REMAINING FOUR POSITIONS.

81&21752//(':+(135,17('2575$160,77('(/(&7521,&$//<
GEK 119320
FRONT FRAME MODULE ELECTRICAL

=

=

=

A
=
=

=

=
=
= B

=

Y
=
AA

P

=

=
=

=
=

=
FIGURE 8 FRONT FRAME MODULE ELECTRICAL (SHEET 1 OF 10)
81&21752//(':+(135,17('2575$160,77('(/(&7521,&$//<
GEK 119320
B

= D
=
F
V-C

G =

= =

=
=

=
V-C

=
=
V-L
81&21752//(':+(135,17('2575$160,77('(/(&7521,&$//<
GEK 119320

=

=

=

=
=

= =

=

=

=
=
=

E F G
=

=

=
=
=

=
=
=

= =

=

=
= =
81&21752//(':+(135,17('2575$160,77('(/(&7521,&$//<
GEK 119320
J
H

=
=
=

= =

=

=
K V-L

=
=

=

=
=
=

=

= =
=

= =

=

=
=
81&21752//(':+(135,17('2575$160,77('(/(&7521,&$//<
GEK 119320

=

=

=

=
V-N

V-N
=

=

=

=
= =
AE
81&21752//(':+(135,17('2575$160,77('(/(&7521,&$//<
GEK 119320
P
=

T

=
=

=
V-R
V-R
U

=
V-R

=
V

=
81&21752//(':+(135,17('2575$160,77('(/(&7521,&$//<
GEK 119320

T U
=
=

= =
=

=

=

=

=
V
=

=
=

= =

=

=
W X

=

= =

=
=
=

=
81&21752//(':+(135,17('2575$160,77('(/(&7521,&$//<
GEK 119320

=

=

=

=

=

=
Z

= = =

=

=
=

=
=

=
=
81&21752//(':+(135,17('2575$160,77('(/(&7521,&$//<
GEK 119320

AA

= =

= AD

=

=
AC
AB

=
=
AC

AB

=
=

= = =

=
=

=

=
= =

=

=

=
=

=

=
81&21752//(':+(135,17('2575$160,77('(/(&7521,&$//<
GEK 119320
AD

=

= =

=
=

=
=

=
=

=

=

=
=

=
AE

=

=

=
=

=
81&21752//(':+(135,17('2575$160,77('(/(&7521,&$//<
GEK 119320
DESCRIPTION USE
1234567 ON
8 - 0 WHITE
8 - 0 L43791G16 ASSEMBLY, FRONT FRAME MODULE . . . . . . . . . REF
8 - 1 L45760G05 .PANEL, ELECTRIC . . . . . . . . . . . . . . . 1
SEE FIGURES 56-67, 64-4, 66-13, AND 71-10
8 - 2 MS9559-03 .BOLT, MACHINE-DOUBLE HEXAGON, EXTENDED . . . 3
8 - 2 J646P06F .BOLT, MACHINE - DOUBLE HEXAGON HEAD, . . . . ALT
0.375-24 BY 0.562 LG
8 - 4 L45938G01 .BRACKET, ELECTRICAL . . . . . . . . . . . . . 1
WASHER, 0.250-28 BY 0.500 LG
WASHER, 0.250-28 BY 0.500 LG
WASHER, 0.250-28 BY 0.500 LG
8 - 12 L44745P04 .SENSOR, TEMPERATURE, COMPRESSOR, INLET (EU . 1
CERTIFIED)
0.190-32 BY 0.438 LG
8 - 13 MS9565-05 .BOLT, MACHINE, DBL HEX HD, EXTENDED . . . . . ALT
WASHER, 0.190-32 BY 0.438 LG
8 - 14 L47072P01 .CABLE, ELECTRIC . . . . . . . . . . . . . . . 1
8 - 14 L47072P02 .CABLE, ELECTRIC . . . . . . . . . . . . . . . ALT
8 - 24 MS9902-03 .PLUG, MACHINE THREAD-DRILLED, 0.375-24 BY . . 1
0.360 LG
8 - 25 133A1624P2 .WASHER, FLAT . . . . . . . . . . . . . . . . 3
SEE FIGURE 71-23
8 - 27 1540M69P308 .CLAMP, LOOP - CUSHION, 0.50 INCH TUBE DIA . . 2
81&21752//(':+(135,17('2575$160,77('(/(&7521,&$//<
GEK 119320
DESCRIPTION USE
1234567 ON
8 - 27 1540M69P208 .CLAMP, LOOP - CUSHION . . . . . . . . . . . . ALT

8 - 30 1540M69P206 .CLAMP, LOOP - CUSHION, 0.38 INCH TUBE DIA . . ALT
8 - 31 1540M69P304 .CLAMP, LOOP - CUSHION, 0.250 INCH TUBE DIA . 5
8 - 31 1540M69P204 .CLAMP, LOOP - CUSHION, 0.250 INCH TUBE DIA . ALT
HEIGHT, 0.250-28
SEE FIGURE 71-22
HEIGHT, 0.250-28
8 - 38 1540M69P206 .CLAMP, LOOP - CUSHION, 0.38 INCH TUBE DIA . . ALT
USE ON L43540G05
8 - 41 L46154G03 .BRACKET, OIL - ELECTRICAL . . . . . . . . . . 1
USE ON L43540G05
8 - 42 L46146G03 .BRACKET, LUBE . . . . . . . . . . . . . . . . 1
USE ON L43540G05
8 - 43 L46056G01 .BRACKET, TUBE . . . . . . . . . . . . . . . . 1
USE ON L43540G05
USE ON L43540G05
USE ON L43540G05
USE ON L43540G05
USE ON L43540G05
8 - 48 1541M25P01 ..CLIP, SPRING TENSION - ELECTRICAL CABLES . . 4
8 - 49 AN123165 ..RIVET, SOLID . . . . . . . . . . . . . . . . 8
8 - 50 MS21060L4 ..NUT, SELF-LOCKING, PLATE, TWO LUG, . . . . . 1
FLOATING
8 - 51 AN123470 ..RIVET, SOLID, FLUSH HEAD . . . . . . . . . . 2
81&21752//(':+(135,17('2575$160,77('(/(&7521,&$//<
GEK 119320
DESCRIPTION USE
1234567 ON
8 - 52 MS9557-10 BOLT, MACHINE-DOUBLE HEXAGON EXTENDED . . . . 1

USE ON L65011G01, G02, AND G03
8 - 53 J1092P04 NUT, SELF-LOCKING, TEN POINT - REDUCED . . . . 1
HEIGHT, 0.250-28
SEE FIGURE 71-25
8 - 54 1540M69P304 CLAMP, LOOP - CUSHION, 0.250 INCH TUBE DIA . . 1
8 - 55 MS9557-08 BOLT, MACHINE-DOUBLE HEXAGON EXTENDED . . . . 1
8 - 56 1540M69P204 CLAMP, LOOP - CUSHION, 0.250 INCH TUBE DIA . . 1
8 - 56 1540M69P304 CLAMP, LOOP - CUSHION, 0.250 INCH TUBE DIA . . ALT
8 - 57 L63967G01 .BRACKET, SUPPORT - VSV HARNESS . . . . . . . 1
8 - 58 L63968G01 .BRACKET, SUPPORT - VSV HARNESS . . . . . . . 1
WASHER, 0.250-28 BY 0.875 LG
8 - 62 L46054G03 BRACKET, OIL . . . . . . . . . . . . . . . . . REF
8 - 63 MS9557-10 BOLT, MACHINE-DOUBLE HEXAGON EXTENDED . . . . REF
NO. 1907/2006
8 - 66 L35166P01 DETECTOR, RESISTANCE TEMPERATURE, IMMERSION . REF
TYPE (EU CERTIFIED)
TYPE (EU CERTIFIED)
TYPE (EU CERTIFIED)
TYPE (EU CERTIFIED)
8 - 68 J221P904 PACKING, PREFORMED, 0.346 ID . . . . . . . . . REF
81&21752//(':+(135,17('2575$160,77('(/(&7521,&$//<
GEK 119320
DESCRIPTION USE
1234567 ON

8 - 74 L43563P01 CHIP DETECTOR, MAGNETIC - SCAVENGE OIL (EU . . REF
CERTIFIED)
8 - 74 4J7316 CHIP DETECTOR (EU CERTIFIED) . . . . . . . . . REF
81&21752//(':+(135,17('2575$160,77('(/(&7521,&$//<
GEK 119320
AIR COLLECTOR ASSEMBLY AND ASSOCIATED PARTS

= =

=
=
=
=

=
=

=
= =

=

=
=

=

=

=

=
=
=

=

=

=
=

=

= =

=
= =

= G

=
= =

=

=
=
A
=
F
FIGURE 9 AIR COLLECTOR ASSEMBLY AND ASSOCIATED PARTS (SHEET 1 OF 5)
81&21752//(':+(135,17('2575$160,77('(/(&7521,&$//<
GEK 119320
D
=

= =

=

C

=

=
=
=

=

=

=

E
=
=
=

=

= =

=
= =
81&21752//(':+(135,17('2575$160,77('(/(&7521,&$//<
GEK 119320

=

=

=

=
=

=

=

=
81&21752//(':+(135,17('2575$160,77('(/(&7521,&$//<
GEK 119320

=

=
81&21752//(':+(135,17('2575$160,77('(/(&7521,&$//<
GEK 119320

=
J-J

=
=
J-J

=
=
=
=
=
H

=

=
=

=
=
=

= =

=

=

=
J-J
81&21752//(':+(135,17('2575$160,77('(/(&7521,&$//<
GEK 119320
DESCRIPTION USE
1234567 ON
9 - 0 WHITE
9 - 1 L47316G15 Δ .AIR COLLECTOR, FRONT FRAME . . . . . . . . . REF
NO. 1907/2006
9 - 2 L46092G01 ..BRACKET, FUEL . . . . . . . . . . . . . . . 2
9 - 3 MS9321-10 ..WASHER, FLAT, 0.276 ID BY 0.500 OD BY . . . 8
0.062 THK
9 - 4 MS21046C4 ..NUT, HEX . . . . . . . . . . . . . . . . . . 8
9 - 5 L47997G01 ..ASSY - BAFFLE, AIR COLLECTOR . . . . . . . . 1
9 - 6 L47997P02 ...BRACKET . . . . . . . . . . . . . . . . . . 4
9 - 7 L47997P03 ...BRACKET . . . . . . . . . . . . . . . . . . 2
9 - 8 L47997P04 ...BRACKET . . . . . . . . . . . . . . . . . . 2
9 - 9 L47997P05 ...BRACKET . . . . . . . . . . . . . . . . . . 2
9 - 10 L47997P06 ...BRACKET . . . . . . . . . . . . . . . . . . 2
9 - 11 J643P08B ...BOLT, MACHINE - DOUBLE HEXAGON HEAD, . . . 12
0.190-32 BY 0.688 LG
9 - 12 J201P01 ...NUT, SELF-LOCKING-DOUBLE HEX THIN, . . . . 12
0.190-32
9 - 13 J643P08A ..BOLT, MACHINE - DOUBLE HEXAGON HEAD, . . . . 4
0.190-32 BY 0.688 LG
9 - 14 J643P08B ..BOLT, MACHINE - DOUBLE HEXAGON HEAD, . . . . 4
0.190-32 BY 0.688 LG
9 - 15 133A1624P66 ..WASHER, FLAT, 0.203 ID, 0.470 OD, 0.045 . . 6
THK
9 - 16 L47896P01 ..BRACKET . . . . . . . . . . . . . . . . . . 4
9 - 17 MS9321-11 ..WASHER, FLAT . . . . . . . . . . . . . . . . 8
9 - 18 MS21046C5 ..NUT, SELF-LOCKING, HEX . . . . . . . . . . . 8
9 - 19 L46042G03 .BRACKET, VSV/VBV . . . . . . . . . . . . . . 1
SEE FIGURE 8-72
9 - 21 J644P19F .BOLT, MACHINE - DOUBLE HEXAGON HEAD, . . . . 6
0.250-28 BY 1.375 LG
9 - 22 L47009G07 .SEAL, ACTUATOR . . . . . . . . . . . . . . . 1
WASHER, 0.250-28 BY 0.938 LG
9 - 24 L47009G07 .SEAL, ACTUATOR . . . . . . . . . . . . . . . 1
9 - 25 L43502G03 .SEAL, FRAME . . . . . . . . . . . . . . . . . 2
FLOATING
9 - 29 L52085G01 .BRACKET, SUPPORT-ELECTRICAL PANEL . . . . . . 1
SEE FIGURE 55-54
81&21752//(':+(135,17('2575$160,77('(/(&7521,&$//<
GEK 119320
DESCRIPTION USE
1234567 ON
9 - 30 J908P13A .BOLT, MACHINE, HEX HD, 0.500-20 BY 1.750 LG . 39

SEE FIGURE 59-198
9 - 31 J908P11A .BOLT, MACHINE, HEX HD, 0.500-20 BY 1.500 LG . 43
SEE FIGURE 8-65
9 - 34 L46340G01 .TUBE, OIL - A SUPPLY . . . . . . . . . . . . 1
SEE FIGURE 56-80
9 - 35 L45907G03 .BRACKET, PANEL . . . . . . . . . . . . . . . 1
SEE FIGURE 55-55
FLOATING
SEE FIGURE 59-202
9 - 39 L45581G01 .BRACKET, VSV/VBV . . . . . . . . . . . . . . 1
SEE FIGURE 7-111
9 - 40 J648P28A .BOLT, MACHINE - DOUBLE HEXAGON HEAD, . . . . AR
0.500-20 BY 2.125 LG
9 - 41 NAS1149C0863R .WASHER, FLAT, 0.515 ID . . . . . . . . . . . AR
9 - 43 J534P58 .NIPPLE, TUBE, SPHERICAL END, 0.750-16 ROD . . 1
9 - 44 J1315G108 .CAP ASSEMBLY, TUBE (WITHOUT SAFETY WIRE . . . 1
HOLES)
9 - 44 J1315G08 .CAP ASSEMBLY, TUBE . . . . . . . . . . . . . ALT
9 - 45 L46344G01 .TUBE, AIR - STARTER . . . . . . . . . . . . . 1
9 - 46 L61883P01 .SPACER . . . . . . . . . . . . . . . . . . . 6
SEE FIGURE 8-61
0.500-20 BY 2.250 LG
SEE FIGURE 59-201
9 - 49 L49142G01 BRACKET, ELECTRICAL . . . . . . . . . . . . . 1
9 - 50 L49327P01 BRACKET, ANGLE SUPPORT . . . . . . . . . . . . REF
9 - 51 MS9557-10 BOLT, MACHINE-DOUBLE HEXAGON EXTENDED . . . . REF
9 - 52 J644P18A BOLT, MACHINE - DOUBLE HEXAGON HEAD, . . . . . REF
0.250-28 BY 1.312 LG
9 - 53 J1213P04 NUT, SELF-LOCKING, DOUBLE HEXAGON INCREASED . REF
WRENCHING, 0.250-28
81&21752//(':+(135,17('2575$160,77('(/(&7521,&$//<
GEK 119320
AIR COLLECTOR ASSEMBLY - COVER PLATES

=

=

=

=

=

=
=

=

=
=

=

=

=

=

=

=

=

=

=

=

=

=
=

=

=
=
=
=
FIGURE 10 AIR COLLECTOR ASSEMBLY - COVER PLATES (SHEET 1 OF 1)
81&21752//(':+(135,17('2575$160,77('(/(&7521,&$//<
GEK 119320
DESCRIPTION USE
1234567 ON
10 - 0 WHITE
10 - 0 L65011G01 GAS TURBINE ASSEMBLY, LM6000PF1 . . . . . . . REF
REFERENCE FROM FIGURE 1
10 - 1 L47955P01 .COVER PLATE . . . . . . . . . . . . . . . . . 1
10 - 2 L43082G02 Δ .PANEL, COVER . . . . . . . . . . . . . . . . 4
NO. 1907/2006
0.062 THK
0.250-28 BY 0.688 LG
10 - 5 L43083G05 .PLATE, COVER . . . . . . . . . . . . . . . . 1
10 - 6 L43083G04 Δ .PLATE, COVER . . . . . . . . . . . . . . . . 1
NO. 1907/2006
10 - 7 L47351G02 Δ .COVER PLATE, AIR COLLECTOR . . . . . . . . . 2
NO. 1907/2006
10 - 7 L47351G01 Δ .COVER PLATE, AIR COLLECTOR . . . . . . . . . ALT
NO. 1907/2006
81&21752//(':+(135,17('2575$160,77('(/(&7521,&$//<
GEK 119320
DESCRIPTION USE
1234567 ON
10 - 8 L25226G01 Δ .PANEL, ACCESS . . . . . . . . . . . . . . . . 1

NO. 1907/2006
10 - 10 MS35338-139B .WASHER, LOCK . . . . . . . . . . . . . . . . 12
0.250-28 BY 0.875 LG
NO. 1907/2006
81&21752//(':+(135,17('2575$160,77('(/(&7521,&$//<
GEK 119320
AIR COLLECTOR ASSEMBLY

=
V-B
V-A
V-A

=
= =

= = =
FIGURE 11 AIR COLLECTOR ASSEMBLY (SHEET 1 OF 3)
81&21752//(':+(135,17('2575$160,77('(/(&7521,&$//<
GEK 119320
V-B

=
V-D

=
V-C

=

=
V-E V-F
V-C

=

=
81&21752//(':+(135,17('2575$160,77('(/(&7521,&$//<
GEK 119320
V-D

=

=

=
V-E V-F

=

= =
81&21752//(':+(135,17('2575$160,77('(/(&7521,&$//<
GEK 119320
DESCRIPTION USE
1234567 ON
AIR COLLECTOR ASSEMBLY
11 - 0 WHITE
NO. 1907/2006
11 - 2 J970P04 .INSERT, SCREW THREAD, SELF-LOCKING, . . . . . 24
0.250-28
0.250-28
0.250-28
0.250-28
0.250-28
0.250-28
0.250-28
0.250-28
0.250-28
0.250-28
11 - 12 J970P03 .INSERT, SCR THD 0.190-32 . . . . . . . . . . 4
11 - 13 J970P04 .INSERT, SCREW THREAD, SELF-LOCKING, . . . . . AR
0.250-28
11 - 14 L47963P01 .PIN, THREADED . . . . . . . . . . . . . . . . AR
11 - 15 J970P06 .INSERT, SCREW THREAD, SELF-LOCKING LOCKED . . 3
IN, KEY LOCKED, DRY FILM, PLASTIC LOCKING
DEVICE
81&21752//(':+(135,17('2575$160,77('(/(&7521,&$//<
GEK 119320
LOW PRESSURE COMPRESSOR ROTOR BREAKDOWN

=

=
=

=

=

= = B

= =

=

=

=

=

=
=
FIGURE 12 LOW PRESSURE COMPRESSOR ROTOR BREAKDOWN (SHEET 1 OF 2)
GEK 119320

=
=

=

=

= =

=
=
=

=
=
=

=

=

=
=

=

=
=

=

= =

=

= =
=
=

=
=
=

= =
= =

=

=
= = =

= =

=
FIGURE 12 LOW PRESSURE COMPRESSOR ROTOR BREAKDOWN (SHEET 2 OF 2)
GEK 119320
DESCRIPTION USE
1234567 ON
12 - 0 WHITE
12 - 0 L43053G07 ROTOR ASSEMBLY, LOW PRESSURE COMPRESSOR . . . REF
12 - 1 L24546P06 ' .DISK, LOW PRESSURE COMPRESSOR ROTOR - . . . . 1
STAGE 0 (LIFE LIMITED PART)
NO. 1907/2006
12 - 2 L45003P01 ' .RETAINER, BLADE . . . . . . . . . . . . . . . 1
NO. 1907/2006
12 - 3 J626P05 .NUT, SELF-LOCKING, TEN POINT, 0.3125-24 . . . 48
12 - 5 AS3580-5-24 .BOLT, MACHINE, DBL HEX HD, 0.3125-24 BY . . . 48
1.500 LG
12 - 6 J626P04 .NUT, SELF-LOCKING, TEN POINT - INCREASED . . AR
WRENCHING, 0.250-28
12 - 7 133A1624P5 .WASHER, FLAT, 0.265 ID, 0.750 OD, 0.063 THK . AR
12 - 7 NAS1149C0463R .WASHER, FLAT, 0.265 ID . . . . . . . . . . . AR
12 - 8 AS3580-4-24 .BOLT, MACHINE, DBL HEX HD, 0.250-28 BY . . . AR
1.500 LG
12 - 8 J644P21A .BOLT, MACHINE - DOUBLE HEXAGON HEAD, . . . . ALT
0.250-28 BY 1.500 LG
0.250-28 BY 1.375 LG
0.250-28 BY 1.312 LG
12 - 9 L24550P07 ' .BLADE, STAGE 0 . . . . . . . . . . . . . . . 48
NO. 1907/2006
GEK 119320
DESCRIPTION USE
1234567 ON
12 - 10 L44648G03 ' .SHAFT, FORWARD - FAN BOOSTER (LIFE LIMITED . 1

PART)
NO. 1907/2006
12 - 11 J817P088A .BOLT, SHEAR, DBL HEX HD, 0.4375-20 BY . . . . 38
2.372 LG
12 - 12 9653M31P03 .NUT, SELF-LOCKING, 0.4375-20 . . . . . . . . 38
12 - 12 9653M31P04 .NUT, SELF-LOCKING, 0.4375-20 . . . . . . . . ALT
12 - 13 705B734P27 WASHER, FLAT . . . . . . . . . . . . . . . . . 20
USE ON L60016G01
SEE FIGURE 20-2 FOR BOLT
12 - 14 9691M14P14 .NUT, SELF-LOCKING - SPLINE DRIVE, DEEP . . . 20
COUNTERBORE 0.750-16
USE ON L60016G01
SEE FIGURE 20-2 FOR BOLT
USE ON L60016G01
12 - 16 L24547P04 ' .DISK, LOW PRESSURE COMPRESSOR - STAGE 1 . . . 1
(LIFE LIMITED PART)
NO. 1907/2006
12 - 17 L24551P21 .BLADE, LOW PRESSURE COMPRESSOR ROTOR - . . . 54
STAGE 1
12 - 18 L24551P22 .BLADE, LOW PRESSURE COMPRESSOR ROTOR - . . . AR
STAGE 1
STAGE 1
STAGE 1
12 - 21 L24701P01 .WEIGHT, BALANCE . . . . . . . . . . . . . . . AR
12 - 24 L24581G02 .LUG ASSY, LOCKING, STAGE 1 BLADE . . . . . . 2
12 - 24 L24581P02 ..LUG, LOCKING . . . . . . . . . . . . . . . . 1
12 - 24 9022M89P03 ..INSERT, LOCKING . . . . . . . . . . . . . . 1
12 - 25 9107M67P01 ..SCREW, MACHINE . . . . . . . . . . . . . . . 1
12 - 26 1781M30G04 .SPOOL, FAN ROTOR - STAGES 2 THRU 4 (LIFE . . 1
LIMITED PART)
STAGE 2
12 - 28 L24552P18 .BLADE, LOW PRESSURE COMPRESSOR ROTOR - . . . AR
STAGE 2
STAGE 2
GEK 119320
DESCRIPTION USE
1234567 ON

STAGE 2
0.250-28 BY 1.188 LG
USE ON L60016G01
12 - 32 9064M51G06 .LUG ASSY, STAGE 2 LOCKING . . . . . . . . . . 2
12 - 32 9064M51G04 .LUG ASSY, STAGE 2 LOCKING . . . . . . . . . . ALT
12 - 32 9064M51P02 ..LUG, LOCKING . . . . . . . . . . . . . . . . 1
USE ON 9064M51G04
12 - 32 9064M51P04 ..LUG, LOCKING . . . . . . . . . . . . . . . . 1
USE ON 9064M51G06
12 - 33 9107M67P01 ..SCREW, MACHINE . . . . . . . . . . . . . . . 1
12 - 34 9049M30P08 .WEIGHT, BALANCE . . . . . . . . . . . . . . . AR
12 - 37 9146M55P01 .WEIGHT, STAGES 2, 3, AND 4 . . . . . . . . . AR
12 - 38 9146M56P01 .WEIGHT, STAGES 2, 3, AND 4 . . . . . . . . . AR
12 - 39 9064M67P33 .BLADE, FAN ROTOR - STAGE 3 . . . . . . . . . 72
12 - 40 9064M67P34 .BLADE, FAN ROTOR - STAGE 3 . . . . . . . . . AR
12 - 43 9064M52G05 .LOCKING LUG, BLADE-FAN ROTOR, STAGES 3 AND . 2
4 (STAGE 3 ONLY)
12 - 43 9064M52G03 .LOCKING LUG, BLADE-FAN ROTOR, STAGES 3 AND . ALT
4 (STAGE 3 ONLY)
12 - 43 9064M52P01 ..LUG . . . . . . . . . . . . . . . . . . . . 1
USE ON 9064M52G03
12 - 43 9064M52P03 ..LUG . . . . . . . . . . . . . . . . . . . . 1
USE ON 9064M52G05
12 - 44 9107M67P01 ..SCREW, MACHINE . . . . . . . . . . . . . . . 1
12 - 45 9064M52G06 .LUG ASSEMBLY, STAGES 3 AND 4 FAN ROTOR . . . 2
BLADE LOCKING (STAGE 4 ONLY)
12 - 45 9064M52G04 .LUG ASSEMBLY, STAGES 3 AND 4 FAN ROTOR . . . ALT
BLADE LOCKING (STAGE 4 ONLY)
12 - 45 9064M52P02 ..LUG . . . . . . . . . . . . . . . . . . . . 1
USE ON 9064M52G04
12 - 45 9064M52P04 ..LUG . . . . . . . . . . . . . . . . . . . . 1
USE ON 9064M52G06
12 - 46 9107M67P01 ..SCREW, MACHINE . . . . . . . . . . . . . . . 1
12 - 48 9048M63P30 .BLADE, FAN ROTOR - STAGE 4 . . . . . . . . . AR
12 - 51 L44612P01 MANIFOLD, FORWARD, PRESSURIZATION . . . . . . 1
USE ON L65016G01
GEK 119320
LOW PRESSURE COMPRESSOR STATOR ASSEMBLY BREAKDOWN

=
A

= =

=
=

=

=

=

=

=
=

=
= =

=

=
= =
=

=

=
= =

=
B

=
A

=
=
= = =
=

=

=

=

=
=

=

=

=

=
=
=
=

=
=
=

=
=

=
FIGURE 13 LOW PRESSURE COMPRESSOR STATOR ASSEMBLY BREAKDOWN (SHEET 1 OF 2)
GEK 119320
C
B

= =

=
=
=
=

= =

=

=

=
=
=
=

=

=
=

= =
C
=
=

=
FIGURE 13 LOW PRESSURE COMPRESSOR STATOR ASSEMBLY BREAKDOWN (SHEET 2 OF 2)
GEK 119320
DESCRIPTION USE
1234567 ON
LOW PRESSURE COMPRESSOR STATOR ASSEMBLY

BREAKDOWN
13 - 0 WHITE
13 - 0 L43904G03 STATOR ASSEMBLY, LOW PRESSURE COMPRESSOR . . . REF
REFERENCE FROM FIG URE 1-5
13 - 1 L44649G03 ' .CASE, LOW PRESSURE COMPRESSOR STATOR . . . . 1
STAGES 0 THRU 3
NO. 1907/2006
13 - 2 L45133P01 .STRIP, LOCKING . . . . . . . . . . . . . . . 2
13 - 3 NAS1101E3-5 .SCREW, MACHINE . . . . . . . . . . . . . . . 4
13 - 4 J816P058A BOLT, SHEAR, DBL HEX HD, 0.375-24 BY 1.809 . . 34
LG
USE ON L43903G05
13 - 5 J1070P11 WASHER, FLAT . . . . . . . . . . . . . . . . . 68
USE ON L43903G05
13 - 6 J626P06 NUT, SELF-LOCKING, TEN POINT, 0.375-24 . . . . 34
USE ON L43903G05
13 - 7 L24573G06 ' .SHROUD ASSY, LOW PRESSURE COMPRESSOR . . . . 2
STATOR - STAGE 0
NO. 1907/2006
MATCHED ASSEMBLY
13 - 7 L24573P09 ' ..SHROUD, AFT HALF . . . . . . . . . . . . . . 1
SUBSTANCE IN THE EUROPEAN UNION IS
13 - 7 L24573P10 ' ..SHROUD, FWD HALF . . . . . . . . . . . . . . 1
NOTE
SHROUD ASSEMBLIES L24573G06, L24575G06,
AND L24577G06 MUST BE REPLACED AS A SET.
GEK 119320
DESCRIPTION USE
1234567 ON

BREAKDOWN
13 - 8 L47201P01 ..PIN, SHOULDER, HEADLESS . . . . . . . . . . 2

13 - 9 J814P050A .BOLT, SHEAR - DOUBLE HEX HEAD, 0.250-28 BY . 50
1.520 LG
13 - 10 133A1624P54 .WASHER, FLAT, AMS 5510, 0.2835 IN ID, . . . . 100
0.470 IN OD, 0.036 IN THICK
13 - 12 L44640P01 .VANE, LOW PRESSURE COMPRESSOR STATOR, . . . . 100
STAGE 0
13 - 13 L44640P02 .VANE, LOW PRESSURE COMPRESSOR STATOR, . . . . AR
STAGE 0
13 - 14 L44690P01 .BUSHING ASSY, VANE (TABBED) . . . . . . . . . 102
STAGE 0
13 - 16 L24579P07 .LINER, DOVETAIL - LOW PRESSURE COMPRESSOR . . 16
STATOR
13 - 17 L24575G06 ' .SHROUD, LOW PRESS COMPRESSOR STATOR - . . . . 2
STAGE 1
NO. 1907/2006
MATCHED ASSEMBLY
13 - 17 L24575P12 ' ..SHROUD, FORWARD HALF . . . . . . . . . . . . 1
1.520 LG
STAGE 1
STAGE 1
GEK 119320
DESCRIPTION USE
1234567 ON

BREAKDOWN

STAGE 1
STAGE 1
STATOR
13 - 28 L24577G06 ' .SHROUD, STATOR, LP COMPR - STG 2 . . . . . . 2
NO. 1907/2006
MATCHED ASSEMBLY
13 - 28 L24577P12 ' ..SHROUD, FORWARD HALF . . . . . . . . . . . . 1
1.520 LG
STAGE 2
STAGE 2
STAGE 2
STAGE 2
STAGE 2
STATOR
0.400 LG
GEK 119320
DESCRIPTION USE
1234567 ON

BREAKDOWN
13 - 41 133A1624P48 .WASHER, FLAT . . . . . . . . . . . . . . . . 1

0.400 LG
13 - 44 133A1624P48 .WASHER, FLAT . . . . . . . . . . . . . . . . 1
13 - 45 L44637G01 ' .SHROUD, FAN BOOSTER, STAGE 3 . . . . . . . . 2
NO. 1907/2006
13 - 45 L44637P01 ' ..SHROUD, FWD HALF . . . . . . . . . . . . . . 1
13 - 47 L24579P10 .LINER, DOVETAIL . . . . . . . . . . . . . . . 8
13 - 48 L24579P11 .LINER, DOVETAIL . . . . . . . . . . . . . . . 8
STAGE 3
STAGE 3
STAGE 3
STAGE 3
STAGE 3
13 - 54 J813P054A .BOLT, SHEAR, DBL HEX HD, 0.190-32 BY 1.492 . 6
LG
13 - 55 133A1624P90 .WASHER, FLAT, 0.191 ID BY 0.390 OD BY . . . . 12
0.030 TH
13 - 55 705B734P30 .WASHER, FLAT . . . . . . . . . . . . . . . . ALT
1.520 LG
13 - 57 J644P21 .BOLT, MACHINE - DOUBLE HEXAGON HEAD, . . . . ALT
0.250-28 BY 1.500 LG
GEK 119320
DESCRIPTION USE
1234567 ON

BREAKDOWN

0.400 LG
13 - 60 133A1624P48 .WASHER, FLAT . . . . . . . . . . . . . . . . 1
13 - 61 L44613G01 .ASSEMBLY, BUSHING FAN BOOSTER STAGE 3 . . . . 112
13 - 62 L45134P01 .DOUBLER . . . . . . . . . . . . . . . . . . . 8
USE ON L43903G05
13 - 63 L45134P02 .DOUBLER . . . . . . . . . . . . . . . . . . . 2
USE ON L43903G05
HEIGHT, 0.250-28
USE ON L43903G05
0.250-28 BY 1.125 LG
USE ON L43903G05
13 - 66 L44650G01 CASE, LOW-PRESSURE COMPRESSOR - SLAVE RING . . 1
USE ON L43903G05
13 - 67 9722M23P07 .NUT, SELF-LOCKING, 0.250-28 . . . . . . . . . 96
13 - 68 AN123483 .RIVET, SOLID, FLUSH HEAD . . . . . . . . . . 192
13 - 69 J644P14A BOLT, MACHINE - DOUBLE HEXAGON HEAD, . . . . . REF
0.250-28 BY 1.062 LG
GEK 119320
INLET GEARBOX ASSEMBLY BREAKDOWN

=

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FIGURE 14 INLET GEARBOX ASSEMBLY BREAKDOWN (SHEET 1 OF 1)
GEK 119320
DESCRIPTION USE
1234567 ON
14 - 0 WHITE
14 - 0 9185M71G31 GEARBOX, ASSY INLET . . . . . . . . . . . . . REF
14 - 1 9032M62G07 .HOUSING, MAIN-INLET GEARBOX . . . . . . . . . 1
SEE FIGURE 15-1
14 - 2 9143M98P01 ..PIN, STRAIGHT, DIAMOND . . . . . . . . . . . 1
SEE FIGURE 15-2
14 - 3 9356M76G03 ' .GEARSHAFT ASSY, IGB . . . . . . . . . . . . . 1
NO. 1907/2006
14 - 3 9356M76G04 ' .GEARSHAFT ASSY, IGB . . . . . . . . . . . . . ALT
NO. 1907/2006
14 - 3 9185M14G03 ' .GEARSHAFT ASSY, IGB . . . . . . . . . . . . . ALT
NO. 1907/2006
14 - 4 9032M68P04 .BEARING, BALL . . . . . . . . . . . . . . . . 1
14 - 4 1962M58P01 .BEARING, BALL THRUST-DUPLEX . . . . . . . . . ALT
14 - 5 9634M47P02 .RETAINER, BALL-BEARING . . . . . . . . . . . 1
14 - 6 1663M92P01 .SHIM ASSY, LAMINATED . . . . . . . . . . . . 1
14 - 7 9032M72P05 ' .NUT, SPANNER . . . . . . . . . . . . . . . . 1
CONTAINS HAZARDOUS OR REGULATED MATERIAL-
4,4-DIAMINODIPHENYLMETHANE (MDA), CAS
#101-77-9 BELOW THE LIMITS OF EU
NO. 1907/2006
14 - 9 9601M52P02 .RETAINER, INLET GEARBOX BEARING . . . . . . . 2
14 - 10 9600M78P01 .BEARING, CYLINDRICAL ROLLER . . . . . . . . . ALT
14 - 10 9600M78P03 .BEARING, CYLINDRICAL ROLLER . . . . . . . . . 1
14 - 10 1962M51P01 .BEARING, ROLLER, CYLINDRICAL . . . . . . . . ALT
14 - 10 2464M51P01 .BEARING, ROLLER, CYLINDRICAL . . . . . . . . ALT
GEK 119320
DESCRIPTION USE
1234567 ON
14 - 11 9601M43P01 .HOUSING, ROLLER BEARING . . . . . . . . . . . ALT

14 - 11 9601M43P02 .HOUSING, ROLLER BEARING . . . . . . . . . . . 1
14 - 12 9181M93G02 .NOZZLE ASSY, OIL . . . . . . . . . . . . . . 1
14 - 12 L59042G01 .NOZZLE, OIL - INLET GEARBOX . . . . . . . . . ALT
14 - 12 L59043G01 .NOZZLE, OIL - INLET GEARBOX . . . . . . . . . ALT
14 - 13 9607M33P04 .GASKET, OIL NOZZLE . . . . . . . . . . . . . 1
14 - 13 2529M19P01 .GASKET, OIL NOZZLE- NO 3 BRG . . . . . . . . ALT
14 - 14 3016M79P04 .STRAP, LOWER . . . . . . . . . . . . . . . . 1
14 - 14A 3016M78P04 .STRAP, UPPER . . . . . . . . . . . . . . . . 1
14 - 15 MS122902 .CLAMP, LOOP, 0.250 TUBE DIA . . . . . . . . . 1
WASHER, 0.190-32 BY 0.938 LG
14 - 18 9032M63G02 .ADAPTER ASSY, BOTTOM . . . . . . . . . . . . 1
14 - 19 1663M93P01 .SHIM ASSY, LAMINATED . . . . . . . . . . . . 1
14 - 20 9600M76P07 .BEARING, DUPLEX THRUST BALL . . . . . . . . . 1
14 - 20 9600M76P09 .BEARING, DUPLEX THRUST BALL . . . . . . . . . ALT
14 - 20 1962M50P01 .BEARING, BALL, THRUST - DUPLEX . . . . . . . ALT
14 - 20 2464M50P01 .BEARING, BALL, THRUST - DUPLEX . . . . . . . ALT
14 - 21 9634M08P01 .RETAINER, DUPLEX BEARING . . . . . . . . . . 1
14 - 22 9601M42P01 .HOUSING, GEARSHAFT BEARING . . . . . . . . . ALT
14 - 22 9601M42P02 .HOUSING, GEARSHAFT BEARING . . . . . . . . . 1
WASHER, 0.190-32 BY 0.812 LG
14 - 24 9601M36P02 .NUT, PLAIN, ROUND, GEARSHAFT, 1.750-16 . . . 1
LEFT-HAND, MODIFIED
14 - 24 9601M36P04 .NUT, PLAIN, ROUND, GEARSHAFT, 1.750-16 . . . ALT
14 - 25 9032M64P08 .GEARSHAFT, BEVEL . . . . . . . . . . . . . . 1
14 - 26 1304M80P04 .RING, DAMPER . . . . . . . . . . . . . . . . 1
14 - 27 1665M92P03 INSERT, INLET GEARBOX . . . . . . . . . . . . 1
14 - 28 J1212P04 NUT, SELF-LOCKING, DBL HEX, 0.250-28 . . . . . REF
14 - 29 NAS1149C0432R WASHER, FLAT, 0.265 ID . . . . . . . . . . . . REF
14 - 30 9329M84G09 HOUSING, DAMPER, BEARING NO. 3R . . . . . . . REF
GEK 119320
INLET GEARBOX HOUSING HARDWARE

=

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=
=
=
FIGURE 15 INLET GEARBOX HOUSING HARDWARE (SHEET 1 OF 1)
81&21752//(':+(135,17('2575$160,77('(/(&7521,&$//<
GEK 119320
DESCRIPTION USE
1234567 ON
INLET GEARBOX HOUSING HARDWARE
15 - 0 WHITE
15 - 1 9032M62G07 HOUSING, MAIN-INLET GEARBOX . . . . . . . . . REF
15 - 2 9143M98P01 .PIN, STRAIGHT, DIAMOND . . . . . . . . . . . REF
15 - 3 J112P06 .STUD, PLAIN-LOCK THREAD, 0.190-24 AND . . . . 6
0.190-32 BY 1.062 LG 0.190-24 X 0.190-32
BY 1.062 LG
15 - 4 9601M57P02 ' .JET, FLUID FLOW . . . . . . . . . . . . . . . 1
NO. 1907/2006
15 - 5 9601M67P02 .PLUG, METERING-INLET GEARBOX . . . . . . . . 1
15 - 6 9608M37P03 .NOZZLE, OIL-INLET GEARBOX . . . . . . . . . . 2
0.190-32 BY 0.875 LG
0.190-32 BY 1.188 LG
81&21752//(':+(135,17('2575$160,77('(/(&7521,&$//<
GEK 119320
RADIAL ADAPTER ASSEMBLY BREAKDOWN

=

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=
FIGURE 16 RADIAL ADAPTER ASSEMBLY BREAKDOWN (SHEET 1 OF 1)
81&21752//(':+(135,17('2575$160,77('(/(&7521,&$//<
GEK 119320
DESCRIPTION USE
1234567 ON
RADIAL ADAPTER ASSEMBLY BREAKDOWN
16 - 0 WHITE
16 - 1 L31867G02 .ADAPTER ASSY, RADIAL . . . . . . . . . . . . 1
16 - 2 9699M71P02 ..STUD PLAIN . . . . . . . . . . . . . . . . . 3
16 - 4 L24597P01 ' .SHAFT, RADIAL DRIVE . . . . . . . . . . . . . 1
NO. 1907/2006
16 - 5 L31868P01 .BEARING . . . . . . . . . . . . . . . . . . . 1
16 - 6 L31869P02 .SHIELD, BEARING . . . . . . . . . . . . . . . 1
16 - 8 9699M72P03 .NUT, PLAIN . . . . . . . . . . . . . . . . . 1
16 - 8 9699M72P02 .NUT, PLAIN . . . . . . . . . . . . . . . . . ALT
0.250-28 BY 0.875 LG
16 - 9 J644P11F .BOLT, MACHINE - DOUBLE HEXAGON HEAD, . . . . ALT
0.250-28 BY 0.875 LG
16 - 11 9699M70P01 .NOZZLE, OIL . . . . . . . . . . . . . . . . . 1
16 - 12 J221P028 PACKING, PREFORMED, 1.358 ID . . . . . . . . . 1
USE ON L43791G16
16 - 13 705B276P5 RING, RETAINING . . . . . . . . . . . . . . . 1
USE ON L43791G16
16 - 14 L62868P01 HOUSING, SHAFT-RADIAL DRIVE . . . . . . . . . 1
USE ON L43791G16
16 - 15 L63875P01 CLAMP, HOSE . . . . . . . . . . . . . . . . . 2
USE ON L43791G16
16 - 16 L24598P01 SHAFT, RADIAL DRIVE . . . . . . . . . . . . . 1
USE ON L43791G16
16 - 17 L21434P02 SPACER, RADIAL . . . . . . . . . . . . . . . . 1
USE ON L43791G16
16 - 18 L24644G07 GEARBOX ASSEMBLY-TRANSFER . . . . . . . . . . REF
81&21752//(':+(135,17('2575$160,77('(/(&7521,&$//<
GEK 119320
TRANSFER AND ACCESSORY GEARBOX ASSEMBLY BREAKDOWN

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FIGURE 17 TRANSFER AND ACCESSORY GEARBOX ASSEMBLY BREAKDOWN (SHEET 1 OF 5)
81&21752//(':+(135,17('2575$160,77('(/(&7521,&$//<
GEK 119320

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81&21752//(':+(135,17('2575$160,77('(/(&7521,&$//<
GEK 119320

=

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=
81&21752//(':+(135,17('2575$160,77('(/(&7521,&$//<
GEK 119320

=

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81&21752//(':+(135,17('2575$160,77('(/(&7521,&$//<
GEK 119320

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81&21752//(':+(135,17('2575$160,77('(/(&7521,&$//<
GEK 119320
DESCRIPTION USE
1234567 ON
TRANSFER AND ACCESSORY GEARBOX ASSEMBLY

BREAKDOWN
17 - 0 WHITE
17 - 0 L43540G05 DRIVE, ACCESSORY ASSEMBLY LM6000 . . . . . . . REF
17 - 1 L21409P02 .BRACKET, MOUNTING - TRANSFER GEARBOX, FWD . . 1
SEE FIGURE 59-188
SEE FIGURE 59-193
SEE FIGURE 59-192
17 - 4 AS3580-6-28 .BOLT, MACHINE, DBL HEX HD, 0.375-24 BY . . . 4
1.750 LG
SEE FIGURE 59-191
17 - 5 L24644G07 .GEARBOX ASSEMBLY-TRANSFER . . . . . . . . . . REF
17 - 6 L21412G09 Δ ..HOUSING, BEVEL, GEAR - TRANSFER GEARBOX . . 1
SEE FIGURE 18-6
17 - 7 L21417P04 Δ ..COVER, HORIZONTAL - TRANSFER GEARBOX . . . . 1
MAY CONTAIN HAZARDOUS MATERIAL - CADMIUM,
CAS #7440-43-9
CAS #7789-12-0, OR
SODIUM DICHROMATE, CAS #10588-01-9, OR
POTASSIUM DICHROMATE, CAS #7779-50-9, OR
CHROMIUM TRIOXIDE, CAS #1333-82-0 BELOW
THE LIMITS OF EU REGULATION (EC)
NO. 1272/2008 ANNEX VI, PART 3,
TABLE 3.2. NO NOTIFICATION REQUIRED.
MANUFACTURE AND REPAIR OF THIS SUBSTANCE
IN THE EUROPEAN UNION IS SUBJECT TO
AUTHORIZATION UNDER EU REGULATION (EC)
NO. 1907/2006
17 - 7 L61431P01 ..COVER, HORIZONTAL - TRANSFER GEARBOX . . . . ALT
17 - 8 J221P36 ..PACKING, PREFORMED, 2.550 ID . . . . . . . . 1
17 - 9 9610M50P02 ..NUT, SELF-LOCKING DOUBLE HEXAGON, 0.250-28 . 18
17 - 10 9610M50P04 ..NUT, SELF-LOCKING DOUBLE HEXAGON, 0.375-24 . 11
17 - 11 NAS1149C0432R ..WASHER, FLAT, 0.265 ID . . . . . . . . . . . 64
17 - 13 L21416G02 ..COVER, RADIAL-TRANSFER GEARBOX . . . . . . . 1
SEE FIGURE 18-38
17 - 13 L61430G01 ..COVER, RADIAL-TRANSFER GEARBOX . . . . . . . ALT
SEE FIGURE 18-38
17 - 15 MS9404-05 ..PLUG, MACHINE . . . . . . . . . . . . . . . 2
17 - 16 M83248/1-905 ..PACKING, PREFORMED, 0.409 ID . . . . . . . . ALT
17 - 17 9009M90P04 ..GEARSHAFT, 45 TOOTH BEVEL . . . . . . . . . 1
81&21752//(':+(135,17('2575$160,77('(/(&7521,&$//<
GEK 119320
DESCRIPTION USE
1234567 ON

BREAKDOWN
17 - 18 705B276P10 Δ ..RING, INTERNAL RETAINING . . . . . . . . . . 2

17 - 19 J201P01 ..NUT, SELF-LOCKING-DOUBLE HEX THIN, . . . . . 20
0.190-32
17 - 20 9699M83P01 ..RETAINER, BEARING . . . . . . . . . . . . . 1
17 - 21 9699M15P01 ..BEARING, CYLINDRICAL ROLLER . . . . . . . . ALT
17 - 21 9699M15P02 ..BEARING, CYLINDRICAL ROLLER . . . . . . . . 1
17 - 21 2464M85P01 ..BEARING, ROLLER, CYLINDRICAL . . . . . . . . ALT
17 - 22 9699M82P02 ..HOUSING, ROLLER BEARING . . . . . . . . . . ALT
17 - 22 9699M82P03 ..HOUSING, ROLLER BEARING . . . . . . . . . . 1
17 - 23 L21410P01 ..NOZZLE, LUBE . . . . . . . . . . . . . . . . 1
17 - 25 L24604G01 ..ADAPTER-TRANSFER GEARBOX . . . . . . . . . . 1
SEE FIGURE 18-25
17 - 25 L62870G01 ..ADAPTER-TRANSFER GEARBOX . . . . . . . . . . ALT
SEE FIGURE 18-25
17 - 27 L21432P01 ..SHIM, LAMINATED . . . . . . . . . . . . . . 1
17 - 29 9699M87P02 ..HOUSING, DUPLEX BEARING . . . . . . . . . . ALT
17 - 29 9699M87P03 ..HOUSING, DUPLEX BEARING . . . . . . . . . . 1
17 - 30 9600M76P09 ..BEARING, DUPLEX THRUST BALL . . . . . . . . 1
17 - 30 9600M76P07 ..BEARING, DUPLEX THRUST BALL . . . . . . . . ALT
17 - 30 1962M50P01 ..BEARING, BALL, THRUST - DUPLEX . . . . . . . ALT
17 - 30 2464M50P01 ..BEARING, BALL, THRUST - DUPLEX . . . . . . . ALT
17 - 31 9009M53P02 ..NUT, GEARSHAFT SELF-LOCKING . . . . . . . . 1
17 - 32 L21421P03 ..GEARSHAFT, 29 TOOTH BEVEL . . . . . . . . . 1
17 - 33 9699M81P01 ..RETAINER, GEARBOX BEARING . . . . . . . . . 1
17 - 34 9699M14P01 ..BEARING, ROLLER . . . . . . . . . . . . . . ALT
17 - 34 9699M14P02 ..BEARING, ROLLER . . . . . . . . . . . . . . 1
17 - 35 9699M80P02 ..HOUSING, GEARBOX ROLLER BEARING . . . . . . ALT
17 - 35 9699M80P03 ..HOUSING, GEARBOX ROLLER BEARING . . . . . . 1
81&21752//(':+(135,17('2575$160,77('(/(&7521,&$//<
GEK 119320
DESCRIPTION USE
1234567 ON

BREAKDOWN
17 - 36 L61399G01 Δ ..HOUSING, BEVEL AND ACCESSORY GEAR - . . . . 1

TRANSFER GEARBOX
CAS #7440-43-9
CAS #7789-12-0, OR
NO. 1907/2006
SEE FIGURE 18-31
17 - 37 MS9568-13 ..BOLT, MACHINE, DBL HEX, EXTENDED WASHER . . 15
HD, 0.375-24 BY 1.188 LG
17 - 39 L21398P03 ..COVER, PLATE-TRANSFER GEARBOX . . . . . . . 2
17 - 40 J201P03 ..NUT, SELF-LOCKING-DOUBLE HEX THIN, . . . . . 8
0.3125-24
17 - 43 L21415G01 Δ ..ADAPTER, HORIZONTAL TRANSFER GEARBOX . . . . 1
CAS #7440-43-9
CAS #7789-12-0, OR
NO. 1907/2006
SEE FIGURE 18-28
17 - 43 L61429G01 ..ADAPTER, HORIZONTAL TRANSFER GEARBOX . . . . ALT
SEE FIGURE 18-28
17 - 44 L21433P01 ..SHIM, LAMINATED . . . . . . . . . . . . . . 1
17 - 47 9009M45P03 ..BEARING, DUPLEX BALL . . . . . . . . . . . . 1
17 - 47 9009M45P05 ..BEARING, DUPLEX BALL . . . . . . . . . . . . ALT
17 - 47 9009M45P04 ..BEARING, DUPLEX BALL . . . . . . . . . . . . ALT
17 - 48 9009M49P01 ..HOUSING, DUPLEX BALL BEARING . . . . . . . . ALT
17 - 48 9009M49P02 ..HOUSING, DUPLEX BALL BEARING . . . . . . . . 1
17 - 49 9009M51P03 ..NUT, SELF-LOCKING, ROUND - GEARSHAFT, . . . 1
TRANSFER GEARBOX
17 - 49 9009M51P02 ..NUT, SELF-LOCKING, ROUND - GEARSHAFT, . . . ALT
TRANSFER GEARBOX
17 - 50 L21429P02 ..SHAFT, HORIZONTAL DRIVE . . . . . . . . . . 1
81&21752//(':+(135,17('2575$160,77('(/(&7521,&$//<
GEK 119320
DESCRIPTION USE
1234567 ON

BREAKDOWN
17 - 51 705B276P4 ..RING, INTERNAL RETAINING . . . . . . . . . . 1

17 - 52 705B276P5 ..RING, RETAINING . . . . . . . . . . . . . . 1
17 - 55 MS9404-08 ..PLUG, MACHINE THREAD, 0.750-16 . . . . . . . 1
17 - 57 9699M34G05 Δ ..ADAPTER, IDLER-ACCESSORY GEARBOX . . . . . . 1
CAS #7440-43-9
CAS #7789-12-0, OR
NO. 1907/2006
SEE FIGURE 18-40
17 - 57 L61434G01 ..ADAPTER, IDLER-ACCESSORY GEARBOX . . . . . . ALT
SEE FIGURE 18-40
17 - 58 MS9501-12 ..BOLT, MACHINE-HEX HD, DRILLED, 0.250-28 . . 7
BY 0.875 LG
SEE FIGURE 59-199
17 - 61 9699M66P01 ..BOLT, MACHINE, SQUARE HD, 0.190-32 BY . . . 51
0.560 LG
17 - 62 9009M32P01 ..WASHER, KEY . . . . . . . . . . . . . . . . 51
17 - 63 9699M12P01 ..BEARING, ANNULAR BALL . . . . . . . . . . . 1
17 - 63 9699M12P02 ..BEARING, ANNULAR BALL . . . . . . . . . . . ALT
17 - 63 2464M58P01 ..BEARING, BALL, ANNULAR . . . . . . . . . . . ALT
17 - 64 9699M65P20 ..HOUSING, BEARING . . . . . . . . . . . . . . ALT
17 - 64 9699M65P26 ..HOUSING, BEARING . . . . . . . . . . . . . . 1
17 - 66 9699M03P01 ..BEARING, CYLINDRICAL ROLLER . . . . . . . . ALT
17 - 66 9699M03P02 ..BEARING, CYLINDRICAL ROLLER . . . . . . . . 4
17 - 67 L21422P02 ..GEARSHAFT, SPUR, 52 TOOTH . . . . . . . . . 1
17 - 68 L24699G03 ..ADAPTER, PUMP-TRANSFER GEARBOX . . . . . . . REF
17 - 68 L24699G04 ..ADAPTER, PUMP-TRANSFER GEARBOX . . . . . . . REF
17 - 69 MS9566-12 ..BOLT, MACHINE, DBL HEX HD, EXTENDED . . . . 39
WASHER, 0.250-28 BY 0.875 LG
SEE FIGURE 59-200
81&21752//(':+(135,17('2575$160,77('(/(&7521,&$//<
GEK 119320
DESCRIPTION USE
1234567 ON

BREAKDOWN

17 - 74 L21427P02 ..GEARSHAFT, 77 TOOTH SPUR . . . . . . . . . . 1
17 - 75 L21397G05 ..ADAPTER, MANUAL DRIVE-TRANSFER GEARBOX . . . 1
SEE FIGURE 18-58
17 - 75 L61433G01 ..ADAPTER, MANUAL DRIVE-TRANSFER GEARBOX . . . ALT
SEE FIGURE 18-58
17 - 79 L21407G02 ..NOZZLE ASSY, OIL . . . . . . . . . . . . . . 1
17 - 79 L61833G01 ..NOZZLE, OIL-TRANSFER GEARBOX . . . . . . . . ALT
17 - 81 L61834G01 ..NOZZLE, OIL-TRANSFER GEARBOX . . . . . . . . ALT
17 - 83 L21395G03 Δ ..ADAPTER, STARTER-TRANSFER GEARBOX . . . . . 1
CAS #7440-43-9
CAS #7789-12-0, OR
NO. 1907/2006
SEE FIGURE 18-54
17 - 83 L61420G01 ..ADAPTER, STARTER-TRANSFER GEARBOX . . . . . ALT
SEE FIGURE 18-54
17 - 84 9699M98P01 ..RETAINER, SEAL . . . . . . . . . . . . . . . 1
17 - 85 9601M73P04 ..SEAL, FLANGED OIL . . . . . . . . . . . . . 1
17 - 85 9601M73P07 ..SEAL, FLANGED OIL . . . . . . . . . . . . . ALT
17 - 85 9032M84P02 ..SEAL, OIL . . . . . . . . . . . . . . . . . ALT
17 - 86 9365M41P229 ..SEAL, O-RING, 3.100 ID . . . . . . . . . . . 1
17 - 91 9634M85P01 ..RING, SEAL MATING . . . . . . . . . . . . . 1
17 - 93 9600M91P06 ..BEARING, ROLLER, CYLINDRICAL . . . . . . . . 1
81&21752//(':+(135,17('2575$160,77('(/(&7521,&$//<
GEK 119320
DESCRIPTION USE
1234567 ON

BREAKDOWN

17 - 95 L31056P01 Δ ..GEARSHAFT, 67 TOOTH SPUR . . . . . . . . . . 1
MATERIAL - CHROMIUM TRIOXIDE,
17 - 98 9699M09P01 ..BEARING, BALL . . . . . . . . . . . . . . . 1
17 - 98 9699M09P03 ..BEARING, BALL . . . . . . . . . . . . . . . ALT
17 - 100 9608M12P04 GASKET, ROUND . . . . . . . . . . . . . . . . REF
17 - 101 9009M39P01 ..SEAL, FLANGED OIL . . . . . . . . . . . . . 2
17 - 101 9032M81P03 ..SEAL, OIL, FLANGED . . . . . . . . . . . . . ALT
17 - 103 L21393G05 Δ ..ADAPTER, MAIN FUEL PUMP-TRANSFER GEARBOX . . 1
CAS #7440-43-9
CAS #7789-12-0, OR
NO. 1907/2006
SEE FIGURE 18-47
17 - 103 L61432G01 ..ADAPTER, MAIN FUEL PUMP-TRANSFER GEARBOX . . ALT
SEE FIGURE 18-47
17 - 109 L21423G02 ..GEARSHAFT ASSY, 77 TOOTH SPUR . . . . . . . 1
17 - 109A 9009M84P01 ...SCOOP, OIL . . . . . . . . . . . . . . . . 2
MATCHED ASSEMBLY
17 - 111 9699M04P02 ..BEARING, ROLLER, CYLINDRICAL . . . . . . . . 1
MATCHED ASSEMBLY
81&21752//(':+(135,17('2575$160,77('(/(&7521,&$//<
GEK 119320
DESCRIPTION USE
1234567 ON

BREAKDOWN

MATCHED ASSEMBLY
MATCHED ASSEMBLY
17 - 113 MS9565-08 ..BOLT, MACHINE, DBL HEX HD, EXTENDED . . . . 12
WASHER, 0.190-32 BY 0.625 LG
17 - 114 9713M89P03 ..PLATE, ACCESSORY COVER . . . . . . . . . . . 3
17 - 115 J219P04 ..GASKET, SEAL-FLANGE, FUEL AND OIL . . . . . 3
17 - 116 L21391G06 ..HOUSING, ACCESSORY GEAR-TRANSFER GEARBOX . . 1
17 - 116 L21391G07 ..HOUSING, ACCESSORY GEAR-TRANSFER GEARBOX . . ALT
17 - 117 L21431G01 SEAL ASSY-SHAFT . . . . . . . . . . . . . . . REF
17 - 118 L21431P02 .TIE ROD . . . . . . . . . . . . . . . . . . . NP
NOT PROCURABLE. ORDER L21431G01
17 - 121 L21431P01 .ADAPTER . . . . . . . . . . . . . . . . . . . NP
17 - 122 J221P014 .PACKING, PREFORMED - "O" RING, 0.484 ID . . . 1
17 - 123 L21431P04 .CLEVIS . . . . . . . . . . . . . . . . . . . NP
17 - 124 MS9390-310 .PIN, STRAIGHT, HEADLESS, DOWEL, 0.625 LG . . 1
17 - 125 L21440P01 COVER, FUEL PUMP . . . . . . . . . . . . . . . REF
17 - 126 J646P12B BOLT, MACHINE - DOUBLE HEXAGON HEAD, . . . . . REF
0.375-24 BY 0.938 LG
17 - 127 NAS1149C0632R WASHER, FLAT, 0.390 ID . . . . . . . . . . . . REF
17 - 128 9009M74P03 GASKET, ROUND . . . . . . . . . . . . . . . . REF
17 - 128 L62762P01 GASKET, FUEL PUMP . . . . . . . . . . . . . . REF
17 - 129 L21431G02 SEAL ASSY - SHAFT . . . . . . . . . . . . . . REF
17 - 130 L21431P03 .TIE ROD . . . . . . . . . . . . . . . . . . . NP
17 - 133 L21431P01 .ADAPTER . . . . . . . . . . . . . . . . . . . NP
17 - 134 J221P014 .PACKING, PREFORMED - "O" RING, 0.484 ID . . . 1
17 - 135 L21431P04 .CLEVIS . . . . . . . . . . . . . . . . . . . NP
17 - 136 MS9390-310 .PIN, STRAIGHT, HEADLESS, DOWEL, 0.625 LG . . 1
81&21752//(':+(135,17('2575$160,77('(/(&7521,&$//<
GEK 119320
TRANSFER GEARBOX HOUSING STUDS AND BUSHINGS

=
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=
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=
FIGURE 18 TRANSFER GEARBOX HOUSING STUDS AND BUSHINGS (SHEET 1 OF 1)
81&21752//(':+(135,17('2575$160,77('(/(&7521,&$//<
GEK 119320
DESCRIPTION USE
1234567 ON
18 - 0 WHITE
18 - 0 L43540G05 DRIVE, ACCESSORY ASSEMBLY LM6000 . . . . . . . REF
18 - 1 L21418G01 .BRACKET, MOUNTING-TRANSFER GEARBOX . . . . . 2
18 - 1 L21418P01 ..BRACKET, MOUNTING-TRANSFER GEARBOX . . . . . 1
18 - 2 9009M14P03 ..BUSHING, FLANGED SLEEVE . . . . . . . . . . 1
18 - 3 9009M14P07 ..BUSHING, FLANGED SLEEVE . . . . . . . . . . 1
0.375-24 BY 1.250 LG
SEE FIGURE 59-190
18 - 5 L24644G07 .GEARBOX ASSEMBLY-TRANSFER (NOT ILLUSTRATED) . REF
18 - 6 L21412G09 Δ ..HOUSING, BEVEL, GEAR - TRANSFER GEARBOX . . REF
18 - 7 L21411G01 ...HOUSING, BEVEL, GEAR CASTING - TRANSFER . . NP
GEARBOX
NOT PROCURABLE
ORDER NEXT HIGHER ASSEMBLY
18 - 7 L21411P01 ....HOUSING, BEVEL GEAR . . . . . . . . . . . NP
NOT PROCURABLE
ORDER NEXT HIGHER ASSEMBLY
18 - 8 L21411P02 ....PIN . . . . . . . . . . . . . . . . . . . 3
18 - 9 1518M32P01 ...STUD, LOK-THREAD, 0.375-24 BY 1.96 LG . . . 11
18 - 10 J110P06 ...STUD, PLAIN-LOCK THREAD, 0.250-20 AND . . . 1
0.250-28 BY 1.438 LG
0.250-28 BY 1.500 LG
0.250-28 BY 1.562 LG
0.190-32 BY 0.938 LG
0.250-28 BY 1.375 LG
0.250-28 BY 1.438 LG
0.190-32 BY 0.875 LG
18 - 17 1518M34P01 ...INSERT, THREADED, 0.190-32 INTERNAL THD, . 4
0.297-24 EXTERNAL THD
18 - 18 9608M37P02 ...NOZZLE, OIL . . . . . . . . . . . . . . . . 2
18 - 19 9600M90P05 ...NOZZLE, OIL . . . . . . . . . . . . . . . . 2
18 - 20 9143M42P02 ...INSERT, SCREW THREAD, 0.6250-24 AND . . . . 3
0.500-20
18 - 21 9143M41P02 ...RING, SERRATED LOCK, DIA 0.892 . . . . . . 3
18 - 22 J221P015 ...PACKING, PREFORMED, 0.546 ID . . . . . . . 3
18 - 23 MS9390-550 ...PIN, STRAIGHT, HEADLESS, CRES AMS 5735, . . 1
0.625 LG
18 - 24 9009M52P01 ...PIN, SHOULDER, HEADLESS, LG 1.00 . . . . . 1
81&21752//(':+(135,17('2575$160,77('(/(&7521,&$//<
GEK 119320
DESCRIPTION USE
1234567 ON
18 - 25 L24604G01 ..ADAPTER-TRANSFER GEARBOX . . . . . . . . . . REF

18 - 25 L62870G01 ..ADAPTER-TRANSFER GEARBOX . . . . . . . . . . REF
18 - 26 MS51830-202 Δ ...INSERT, SCREW THREAD, LOCKED IN, KEY . . . 3
LOCKED, 0.375-16 EXT THD, 0.250-20 INT
THD
0.190-32 BY 0.938 LG
18 - 28 L21415G01 Δ ..ADAPTER, HORIZONTAL TRANSFER GEARBOX . . . . REF
CAS #7440-43-9
CAS #7789-12-0, OR
NO. 1907/2006
18 - 28 L61429G01 ..ADAPTER, HORIZONTAL TRANSFER GEARBOX . . . . REF
0.190-32 BY 0.938 LG
THD
18 - 31 L61399G01 Δ ..HOUSING, BEVEL AND ACCESSORY GEAR - . . . . REF
TRANSFER GEARBOX
CAS #7440-43-9
CAS #7789-12-0, OR
NO. 1907/2006
18 - 32 MS51833C203-13 ...STUD, LOCKED IN-KEY LOCKED, LIGHTWEIGHT . . 4
0.250-28 BY 1.500 LG
18 - 34 1518M33P01 ...INSERT, SCREW THREAD, 0.4375-20 . . . . . . 3
81&21752//(':+(135,17('2575$160,77('(/(&7521,&$//<
GEK 119320
DESCRIPTION USE
1234567 ON
18 - 35 576C432P1 Δ ...INSERT, SCREW THREAD, SELF-TAPPING . . . . 3

18 - 36 1518M33P02 ...INSERT, SCREW THREAD, 0.4375-20 . . . . . . ALT
18 - 37 MS27769W1 ...PLUG, PIPE . . . . . . . . . . . . . . . . 1
18 - 38 L21416G02 ..COVER, RADIAL-TRANSFER GEARBOX . . . . . . . REF
18 - 38 L61430G01 ..COVER, RADIAL-TRANSFER GEARBOX . . . . . . . REF
THD
18 - 40 9699M34G05 Δ ..ADAPTER, IDLER-ACCESSORY GEARBOX . . . . . . REF
CAS #7440-43-9
CAS #7789-12-0, OR
NO. 1907/2006
18 - 40 L61434G01 ..ADAPTER, IDLER-ACCESSORY GEARBOX . . . . . . REF
18 - 43 L24699G03 ..ADAPTER, PUMP-TRANSFER GEARBOX . . . . . . . 1
SEE FIGURE 17-68
18 - 43 L24699G04 ..ADAPTER, PUMP-TRANSFER GEARBOX . . . . . . . ALT
SEE FIGURE 17-68
18 - 44 1518M32P03 ...STUD, LOK THREAD . . . . . . . . . . . . . 8
81&21752//(':+(135,17('2575$160,77('(/(&7521,&$//<
GEK 119320
DESCRIPTION USE
1234567 ON

18 - 47 L21393G05 Δ ..ADAPTER, MAIN FUEL PUMP-TRANSFER GEARBOX . . REF
CAS #7440-43-9
CAS #7789-12-0, OR
NO. 1907/2006
18 - 47 L61432G01 ..ADAPTER, MAIN FUEL PUMP-TRANSFER GEARBOX . . REF
18 - 48 704B139P8 ...PIN, DOWEL, HEADLESS, AMS 6370, 0.375 . . . 2
INCH DIA, 0.750 INCH LONG
18 - 52 9010M93P04 ...INSERT, NYLON LOCKING ELEMENT . . . . . . . 8
18 - 52 J970P06 ...INSERT, SCREW THREAD, SELF-LOCKING . . . . ALT
LOCKED IN, KEY LOCKED, DRY FILM, PLASTIC
LOCKING DEVICE
18 - 53 9010M93P04 ...INSERT, NYLON LOCKING ELEMENT . . . . . . . 2
18 - 53 J970P06 ...INSERT, SCREW THREAD, SELF-LOCKING . . . . ALT
LOCKED IN, KEY LOCKED, DRY FILM, PLASTIC
LOCKING DEVICE
81&21752//(':+(135,17('2575$160,77('(/(&7521,&$//<
GEK 119320
DESCRIPTION USE
1234567 ON
18 - 54 L21395G03 Δ ..ADAPTER, STARTER-TRANSFER GEARBOX . . . . . REF

CAS #7440-43-9
CAS #7789-12-0, OR
NO. 1907/2006
18 - 54 L61420G01 ..ADAPTER, STARTER-TRANSFER GEARBOX . . . . . REF
18 - 58 L21397G05 ..ADAPTER, MANUAL DRIVE-TRANSFER GEARBOX . . . REF
18 - 58 L61433G01 ..ADAPTER, MANUAL DRIVE-TRANSFER GEARBOX . . . REF
18 - 61 1518M34P01 ...INSERT, THREADED, 0.190-32 INTERNAL THD, . 1
18 - 62 MS51833A203-13 ...STUD, LOCKED IN-KEY LOCKED, LIGHTWEIGHT . . 4
81&21752//(':+(135,17('2575$160,77('(/(&7521,&$//<
GEK 119320
TRANSFER GEARBOX HOUSING INSERTS AND LOCK RINGS

=

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=

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=
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= = =

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=
FIGURE 19 TRANSFER GEARBOX HOUSING INSERTS AND LOCK RINGS (SHEET 1 OF 1)
81&21752//(':+(135,17('2575$160,77('(/(&7521,&$//<
GEK 119320
DESCRIPTION USE
1234567 ON
TRANSFER GEARBOX HOUSING INSERTS AND

LOCK RINGS
19 - 0 WHITE
19 - 0 L21391G06 HOUSING, ACCESSORY GEAR-TRANSFER GEARBOX . . . REF
19 - 0 L21391G07 HOUSING, ACCESSORY GEAR-TRANSFER GEARBOX . . . REF
19 - 1 L21390G01 .HOUSING ASSY, GEAR . . . . . . . . . . . . . 1
19 - 2 L21390P02 ..PIN, LOCKING . . . . . . . . . . . . . . . . 2
19 - 3 1518M34P03 .INSERT, THREADED, 0.375-24 INTERNAL THD, . . 4
19 - 5 9009M14P04 .BUSHING, FLANGED SLEEVE . . . . . . . . . . . 1
19 - 6 9009M14P08 .BUSHING, FLANGED SLEEVE . . . . . . . . . . . 1
19 - 10 9143M41P02 .RING, SERRATED LOCK, DIA 0.892 . . . . . . . 1
19 - 12 9143M42P02 .INSERT, SCREW THREAD, 0.6250-24 AND . . . . . 1
0.500-20
19 - 13 9143M42P04 .INSERT, SCREW THREAD, 0.9375-20 AND . . . . . 1
0.750-16
19 - 14 9143M41P04 .RING, SERRATED LOCK, DIA 1.190 . . . . . . . 1
19 - 16 1518M32P01 .STUD, LOK-THREAD, 0.375-24 BY 1.96 LG . . . . 12
19 - 16 5000M97P89 .STUD, LOK-THREAD, OVERSIZE SPD . . . . . . . AR
19 - 16 5000M97P90 .STUD, LOK-THREAD, OVERSIZE SPD . . . . . . . AR
19 - 17 576C432P1 ' .INSERT, SCREW THREAD, SELF-TAPPING . . . . . 27
NO. 1907/2006
81&21752//(':+(135,17('2575$160,77('(/(&7521,&$//<
GEK 119320
FAN MID SHAFT BREAKDOWN
<=
<=
<=
<=
<=
<=
<=
<=
<=
<=
<=
<=
<=
<= <=
FIGURE 20 FAN MID SHAFT BREAKDOWN (SHEET 1 OF 2)
81&21752//(':+(135,17('2575$160,77('(/(&7521,&$//<
GEK 119320
<=>
<=
FIGURE 20 FAN MID SHAFT BREAKDOWN (SHEET 2 OF 2)
81&21752//(':+(135,17('2575$160,77('(/(&7521,&$//<
GEK 119320
DESCRIPTION USE
1234567 ON
FAN MID SHAFT BREAKDOWN
20 - 0 WHITE
20 - 0 L60043G01 FWD, MID SHAFT ASSEMBLY LM6000 PG . . . . . . REF
20 - 1 L59074P02 .SHAFT, FWD (LIFE LIMITED PART) . . . . . . . 1
20 - 2 9010M11P03 BOLT, SHEAR, DBL HEX HD, 0.750-16 BY 2.760 . . 20
LG
USE ON L65016G01
SEE FIGURES 12-13 AND 12-14 FOR WASHER AND
NUT
20 - 3 L59084P01 .BEARING, BALL, ANNULAR - NO. 1B . . . . . . . ALT
20 - 3 L59084P02 .BEARING, BALL, ANNULAR - NO. 1B . . . . . . . 1
20 - 4 L44828P01 .SEAL, AIR AND OIL, ROTATING - BRG NO. 1 . . . 1
20 - 5 9690M54P02 .NUT, ROUND . . . . . . . . . . . . . . . . . 1
20 - 6 L61427P01 .NUT, COUPLING - FORWARD FAN SHAFT . . . . . . 1
20 - 7 9106M66P04 .RING, RETAINING . . . . . . . . . . . . . . . 1
20 - 8 9146M72P01 .RING, BEARING - INNER . . . . . . . . . . . . 1
20 - 9 9032M25G02 .NUT - SEAL, ROUND, SLOTTED - BRG NO.2 . . . . 1
20 - 12 L59076P01 Δ .SHAFT, MID (LIFE LIMITED PART) . . . . . . . 1
NO. 1907/2006
0.3125-24 BY 1.500 LG
USE ON L65016G01
20 - 13 J645P20A BOLT, MACHINE - DOUBLE HEXAGON HEAD, . . . . . ALT
0.3125-24 BY 1.438 LG
USE ON L65016G01
20 - 14 9610M50P03 NUT, SELF-LOCKING DOUBLE HEXAGON, 0.3125-24 . 20
USE ON L65016G01
20 - 15 L47746P01 SHAFT, LOW PRESSURE TURBINE ROTOR (LIFE . . . REF
LIMITED PART)
REFERENCE FROM 31-18
20 - 16 9065M62G11 HOUSING, NO. 1 BRG - FAN FRAME . . . . . . . . REF
81&21752//(':+(135,17('2575$160,77('(/(&7521,&$//<
GEK 119320
HIGH PRESSURE COMPRESSOR ROTOR ASSEMBLY BREAKDOWN

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FIGURE 21 HIGH PRESSURE COMPRESSOR ROTOR ASSEMBLY BREAKDOWN (SHEET 1 OF 2)
*(35235,(7$5<,1)250$7,216XEMHFWWRWKHUHVWULFWLRQVRQWKH7LWOHSDJH

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Main Table Of Contents

GEK 119319 - Operation and Maintenance

Planta de Generación Termoyopal August 2019

GEK 119319 - Operation and Maintenance

GEK 119319 Volume I

Planta de Generación Termoyopal August 2019

GEK 119319 Volume II / Level 1 Maintenance

Planta de Generación Termoyopal August 2019

WP 1610 00 Compressor Discharge Pressure (CDP) GEK119319_1610.00.

GEK 119319 Volume II / Level 2 Maintenance

Planta de Generación Termoyopal August 2019

Assembly Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C00

Planta de Generación Termoyopal August 2019

GEK 119319 Volume II / Preservation, Handling, Storage, and Balance

Planta de Generación Termoyopal August 2019

Planta de Generación Termoyopal August 2019

ON-SITE OPERATION AND MAINTENANCE MANUAL

GE Industrial AeroDerivative Gas Turbines

&+$37(5 /2&$7,21 '(6&5,37,212)&+$1*(

COPYRIGHT 2018 General Electric Company, USA

GE Industrial AeroDerivative Gas Turbines

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1-4 Changes to Technical Manual 1-5 Measurement Units

Illustrations (line art and photographs) represent the

Changes or additions deemed necessary for proper

TECHNICAL MANUAL GE Marine Engines &

SPECIFIC CHANGE REQUIRED:

Figure 1-1. Publication Change Request

Table 1-1. Metric and SI Unit Conversion Factors

To Convert From To Multiply By

Table 1-1. Metric and SI Unit Conversion Factors (Continued)

To Convert From To Multiply By

Table 1-1. Metric and SI Unit Conversion Factors (Continued)

To Convert From To Multiply By

Note 1: Also known as mechanical horsepower

Table 1-2. Pressure Conversions

Kilograms per Pounds per

1.0000 0.9869 1.0197 14.5038 100,000

Table 1-3. Temperature Conversion Chart

Table 1-3. Temperature Conversion Chart (Continued)

Table 1-3. Temperature Conversion Chart (Continued)

Table 1-4. Conversion Table - Fractions to Decimals to Metric

1-6 Glossary of Terms • CADMIUM, CAS # 7440-43-9

• SODIUM DICHROMATE, DIHYDRATE, CAS

• STRONTIUM CHROMATE, CAS

Example: 9644M07G01 ' • URANIUM, U-238, CAS # 7440-61-1

OBEY ALL SPECIFIED SITE, LOCAL, STATE, NOTE

THE IGNITION EXCITER CONTAINS A

• KRYPTON 85, Kr-85, CAS # 13983-27-2

POTENTIAL SAFETY AND EXPOSURE RISKS

ADDITIONAL INSTRUCTIONS ARE AVAILABLE.

Table 1-5. Abbreviations

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: 0 0

: 0 DO NOT GET CHEMICALS IN YOUR EYES. PUT

: DO NOT LET CHEMICALS TOUCH YOUR SKIN.

: 0 0 0 DO NOT SPILL COLD CHEMICALS ON YOUR

CERTIFICATES INCLUDE GE AVIATION :

: 0 :

: 0 0 1-7.8 Hot or Cold Parts Hazards

: 0 :

: 0 : 0

PUT ON GOGGLES AND OTHER PERSONAL : 0

: 3 :

: 3 :

WARNING 1-7.11 SPRINT System Hazard

GAS TURBINES USE A NUMBER OF :