Pach 11 para

LM6000 PA GEK 98493
GE Marine & Industrial Engines Volume I
CHAPTER 11
Maintenance Considerations
11-1. Purpose and Scope 11-3.1 Points of Reference
This chapter covers basic maintenance and The following points of reference are used
inspection practices and procedures to be throughout this manual: forward, aft, right,
followed during maintenance operations. left, top, bottom, and clock position. These
points of reference are defined as follows:
11-2. Levels of Maintenance
Forward - the air intake end of the engine
The workscope for level 1 corrective
Aft - the turbine end of the engine
maintenance allows replacement of external
parts, adjustments, and other work (preventive Right - the right side of the engine when
and corrective) up to and including removal viewed from the aft end and when the engine
and replacement of the entire engine. is in the normal operating position (gearbox
down)
The workscope for level 2 corrective
maintenance permits the replacement of major Left - the side opposite the right side
engine sections (modules) and the
replacement or repair of certain internal parts. Top - the side of the engine that is up when
Level 2 maintenance is performed on-site on a the engine is in the normal operating position
noninstalled engine or on an installed engine
in the enclosure, as permitted by the enclosure Bottom - the side of the engine on which the
design. Maintenance is performed with the gearboxes are mounted
engine horizontal. See Volume II. Clock Positions - the positions of the
numbers on a clock face as seen from aft,
11-3. Standard Maintenance looking forward. The 12:00 o’clock position
Practices is at the top, 3:00 o’clock is on the right side,
6:00 o’clock is at the bottom, and 9:00
o’clock is on the left side.
11-1
GEK 98493 LM6000 PA
Volume I GE Marine & Industrial Engines
11-3.2 Maintenance Within b. Ensure the engine will not be started while
an Enclosure personnel are inside the enclosure.
WARNING c. Post an observer at the exit while

maintenance is being performed inside the
• The following steps must be performed enclosure.
before entering the enclosure. These
conditions must be maintained while WARNING Electrical power to system on
inside the enclosure to prevent injury to which maintenance is being performed
personnel. must be turned off to prevent arcing and
possible injury to personnel or damage to
• The fire extinguishing system must be components. Tag the switch “Out of
deactivated before personnel enter the Service for Maintenance” to prevent
enclosure. Suffocation can occur if the inadvertent activation.
fire extinguishing system is activated.
d. Turn off all electrical power, liquid, and
CAUTION All hardware items have been air service to system on which
manufactured to English measurement maintenance is to be performed. Allow
units. Use of substitute metric sizes is not the engine to cool.
recommended and will void the warranty for
interfacing parts. Tools in metric sizes e. The following steps must be performed
should be furnished with suitable adapters to upon exiting the enclosure after
mate with English measurement unit sizes completion of maintenance:
given. Limits, fits, and clearances may be
interpreted in either English or metric units, (1) Ensure no personnel are inside the
as shown in the tables. enclosure.
NOTE Most of the tasks outlined can be (2) Close the enclosure door.
done within the enclosure if the horizontal
maintenance option is selected, provided that (3) Remove tag and turn on electrical
tooling is available. Deviations from the power, and liquid and air services.
procedures in the Volume II work packages
are permitted as necessary to adapt to the 11-3.3 Electrical Bonding Straps
needs dictated by the enclosure design,
provided that these deviations do not Electrical bonding strap contact surfaces shall
compromise the intent of the instruction. be prepared by removing all anoxic film,
Some modular change-out may be done within grease, paint, lacquer, or other high-resistance
the enclosure and some outside, whichever is material from an area at least one and one-half
more convenient. Consult the packager for times the bonding surface contact area.
planning assistance when questions arise. Bonds shall be installed and contact surfaces
sealed within 4 hours of cleaning. The area
Observe all safety precautions listed below, as shall then be painted to match the surrounding
well as those listed in Chapters 1 and 8. area.
a. Wear protective clothing, gloves, safety

glasses, etc. as required by the
maintenance to be performed.
11-2
LM6000 PA GEK 98493
11-3.4 Torque b. It is important to use the correct torque

wrench for the amount of torque being
In these maintenance procedures, it is applied. See table 11-1 for torque wrench
assumed that all threaded parts on the engine ranges and requirements.
will be tightened to a specific torque value.
Special torque values, if required, will be CAUTION If torque should increase
stated in the text; otherwise, standard torque significantly prior to final seating of any
values should be used. threaded fastener, remove and inspect the
fastener for the cause of the torque increase.
a. Torque values are expressed in lb in.
(pound-inches) or lb ft (pound-feet). One c. Never over-torque any fastener. Torque
pound-inch (or one pound-foot) is the limits are provided in the text and in
twisting force of one pound applied to a tables 11-2 through 11-5; these limits
twist-type fastener (such as a bolt or nut) must be observed. Refer to paragraph
with 1 inch (or one foot) of leverage. This 11-3.4.4 for application information.
twisting force is applied to the fastener to
secure the components. d. Do not use lubricant on bolt threads unless
specified in assembly procedures. Start
threads at least two turns by hand to
ensure proper engagement.
Table 11-1 Torque Wrench Ranges and Requirements
Torque Range Torque Wrench Capacity

0 - 25 lb in. (0 - 2.8 Nm) 0 - 30 lb in. (0 - 3.4 Nm)
25 - 140 lb in. (2.8 - 15.8 Nm) 0 - 150 lb in. (0 - 16.8 Nm)
140 - 550 lb in. (15.8 - 62.1 Nm) 0 -600 lb in. (0 - 67.2 Nm)
30 - 140 lb ft (40.7 - 190 Nm) 0 - 150 lb ft (0 - 203 Nm)
140 - 240 lb ft (190 - 325 Nm) 0 - 250 lb ft (0 - 339 Nm)
240 - 1000 lb ft (325 - 1356 Nm) 0 - 1000 lb ft (0 - 1356 Nm)
11-3
GEK 98493 LM6000 PA
Table 11-2 Torque Values for Steel Bolts, Nuts, and Self-Locking Nuts
Torque Value
Size Threads Per Inch lb in. Nm
8 32 13-16 1.5-1.8
10 24 20-23 2.3-2.5
1/4 20 40-60 4.5-6.8
5/16 18 70-110 7.9-12.4
3/8 16 160-210 18.1-23.7
7/16 14 250-320 28.2-36.2
1/2 13 420-510 47.5-57.6
8 36 16-19 1.8-2.1
10 32 33-37 3.7-4.2
1/4 28 55-70 6.2-7.9
5/16 24 100-130 11.3-14.7
3/8 24 190-230 21.5-26.0
7/16 20 300-360 33.9-40.6
1/2 20 480-570 54.2-64.4
Table 11-3 Torque Values for Engine Plugs and Unions
Tube OD Fitting
(inches) Dash No. Torque Value
1/8 2 40-50 lb in. (4.5-5.6 Nm)
3/16 3 90-100 lb in. (10.2-11.3 Nm)
1/4 4 135-150 lb in. (15.3-16.9 Nm)
5/16 5 155-175 lb in. (17.5-19.8 Nm)
3/8 6 180-200 lb in. (20.3-22.6 Nm)
1/2 8 270-300 lb in. (30.5-33.9 Nm)
5/8 10 360-400 lb in. (40.7-45.2 Nm)
3/4 12 45-50 lb ft (61.0-67.8 Nm)
1 16 58-70 lb ft (78.6-94.9 Nm)
1-1/4 20 75-87 lb ft (102-118 Nm)
1-1/2 24 83-100 lb ft (113-136 Nm)
11-4
LM6000 PA GEK 98493
Table 11-4 Torque Values for Tubing Nuts and Hose Fittings
Hose Aluminum Female Steel Female Sealing

Tube OD Dash No. Sealing Surfaces Surfaces
(Inches) (Size) (See Note 1) (See Note 2)
lb in. Nm lb in. Nm
0.125 (1/8) 2 - - 40-50 (4.5-5.6)
0.1875 (3/16) 3 30-50 (3.4-5.6) 90-100 (10.2-11.3)
0.250 (1/4) 4 40-65 (4.5-7.3) 135-150 (15.3-16.9)
0.3125 (5/16) 5 60-80 (6.8-9.0) 180-200 (20.3-22.6)
0.375 (3/8) 6 75-125 (8.5-14.1) 270-300 (30.5-33.9)
0.500 (1/2) 8 150-250 (16.9-28.2) 450-550 (50.8-62.1)
0.625 (5/8) 10 200-350 (22.6-39.5) 650-770 (73.4-87.0)
lb ft Nm lb ft N m
0.750 (3/4) 12 25-41 (33.9-55.6) 75-91 (102-123)
1.000 (1) 16 41-58 (55.6-78.6) 112-128 (152-174)
1.250 (1-1/4) 20 50-75 (67.8-101) 133-150 (180-203)
1.500 (1-1/2) 24 50-75 (67.8-101) 158-183 (214-248)
Notes: 1. These values apply when female sealing surface is aluminum. Male connector and
nut may be either steel or aluminum.
2. These values apply when female sealing surface is steel. Male connector and nut
may be either aluminum or steel.
11-5
GEK 98493 LM6000 PA
Table 11-5 Torque Values for Plugs and Unions Used in Bosses and for Universal Bulkhead Fitting
Locknuts
Dash No. Threads Torque

(Size) Size Per Inch lb in. lb ft Nm
2 0.3125 24 40-50 5.2-5.6
3 0.375 24 90-100 10.2-11.3
4 0.4375 20 135-150 15.3-16.9
5 0.500 20 155-175 17.5-19.8
6 0.5625 18 180-200 20.3-22.6
8 0.750 16 270-300 30.5-33.9
10 0.875 14 360-400 40.7-45.2
12 1.0625 12 540-600 45-50 61.0-67.8
16 1.3125 12 700-850 58-70 78.6-94.9
20 1.635 12 900-1050 75-87 102-118
24 1.875 12 1000-1200 83-100 113-136
Figure 11-1 Tightening Sequence for Threaded Fasteners
11-6
LM6000 PA GEK 98493
11-3.4.1 Tightening Procedures e. Washers are installed beneath the part

that turns when tightening, unless
CAUTION When chilling or heating an otherwise specified.
engine part during assembly, do not torque
spanner nuts, locknuts, or retaining bolts f. The torque wrenches listed in table 11-1
until the part has returned to room are recommended for use within the
temperature. The fastener may loosen as indicated ranges. Larger wrenches have
the part cools or may be overstressed as the too great a tolerance and can result in
part warms and expands. inaccuracies.
a. If possible, tighten at a uniformly g. Torque values specified in this manual

increasing rate until the desired torque is are actual values to be applied to
obtained. In cases where gaskets or fasteners. Whenever an adapter
other parts cause a slow permanent set, (crowfoot, spanner wrench, etc.) is used
be sure to hold the torque at the desired with a torque wrench, torque must be
value until the material is seated. calculated per figure 11-2.
b. Apply uniform torque to a series of bolts h. Inspect all nuts and bolts after tightening
that have different diameters and are to make sure they are seated. If any nut
installed on one flange or in one area. or bolt is not seated after the required
Torque shall be less than the final torque torque has been applied, remove and
required for the smallest diameter bolt. inspect for thread damage.
This prevents shearing or breaking of
tight bolts due to force concentrations. i. Lubricate tube/hose connector threads
and between the B-nut and ferrule of a
c. It is not desirable to tighten to the final connector. Run B-nuts onto fittings by
torque value during the first drawdown; hand to ensure that tubes and hoses are
uneven tension can cause distortion or aligned and threads are free of burrs.
overstressing of parts. Torque mating Two wrenches must be used when
parts by tightening the bolts or nuts loosening or tightening B-nuts, one on
gradually until the parts are firmly the fitting to which the tube or hose is
seated. Loosen each fastener by one- being connected to hold it stationary and
quarter turn, then apply final tightening. one on the B-nut for torquing. This not
Tightening in a diametrically opposite only prevents twisting the tube, but also
(staggered) sequence is desirable in most prevents loosening or over-tightening the
cases (figure 11-1). Do not exceed fitting. When using an extension on a
listed maximum torque values. torque wrench, calculate the correct
torque input before applying torque per
d. All bolts are installed with heads figure 11-2.
forward and up with nuts aft and down,
unless otherwise specified.
11-7
GEK 98493 LM6000 PA
Figure 11-2 Torque Wrench Correction Factor Determination
11-8
LM6000 PA GEK 98493
11-3.4.2 Running Torque 11-3.4.4 Standard Torque
Refer to table 11-6 for minimum breakaway Use the following standard torque tables,
torque on self-locking nuts. This table unless otherwise directed in the text.
applies to silver-plated, lubricated, and
nonlubricated self-locking nuts. Values a. Use the torque values given in table 11-2
given are for nuts with no axial load. To for steel bolts and nuts (including self-
check minimum breakaway torque, screw locking nuts). Values given are for clean
the nut onto a bolt until two to five threads bolts and nuts that are free of nicks and
are exposed beyond the nut. Measure the burrs.
amount of torque required to turn the nut on
or off the bolt. Nuts that do not meet these b. Use half the value given in table 11-2 for
minimum frictional requirements should be the following applications:
replaced.
(1) Thin steel hex nuts - These nuts have
Table 11-6 Minimum Running Torque for Self- a height of less than 0.60 inch (15.2
Locking Nuts mm) of the inside diameter for plain
nuts and less than 0.80 inch (20.3
Minimum Breakaway Torque mm) of the inside diameter for self-
Threads/ locking nuts.
Size Inch lb in. Nm
(2) Nonsteel nuts and bolts except
0.136 (6) 32/40 1.0 0.1 titanium.
0.164 (8) 32/36 1.5 0.2
0.190 (10) 32 2.0 0.2 (3) All bolts threaded directly into
aluminum, magnesium, or other non-
1/4 28 3.5 0.4
steel parts.
5/16 24 6.5 0.7
3/8 24 9.5 1.1 c. Use the torque values given in tables
7/16 24 14.0 1.6 11-3 and 11-4 for gasketed fittings.
Install fittings as illustrated in figure
1/2 20 18.0 2.0
11-3. Torque values given in tables 11-3
9/16 18 32.0 3.6 and 11-4 are for packing made of
5/8 18 50.0 5.6 synthetic material, asbestos compounds,
3/4 16 50.0 5.6 or soft metal (copper, aluminum, etc.).
These values do not apply to steel
11-3.4.3 Loose Fasteners gaskets or special boss seals.
Prior to retightening, examine the fastener

for the cause of the looseness. If safety wire
is missing, tighten to the required torque and
safety-wire the fastener. If the fastener has a
self-locking feature, check breakaway torque
per the preceding step. Replace defective
fasteners as required.
11-9
GEK 98493 LM6000 PA
Figure 11-3 Universal Fittings Installation
11-10
LM6000 PA GEK 98493
Figure 11-4 Tri-Wing Fastener Drive
11-3.5 Tri-Wing Fasteners 11-3.5.1 Installation
Tri-wing recessed-head fasteners are a. Select the correct driver. The driver
available in a wide range of sizes, and each number should match the recess number
size requires the use of a matched driver. of the fastener head as shown in figure
See figure 11-4. When properly used, the 11-4. Table 11-7 lists a range of
tri-wing design permits a higher ratio of standard fastener sizes with their
torque to end-pressure than is possible with corresponding tri-wing recess identifi-
slotted-head or cross-head designs, cation numbers.
minimizing burring and mutilation. The
following procedures should be used for tri- b. Ensure the axis of the drive is aligned
wing fasteners. with the axis of the fastener when
installing or removing the fastener. If
the head of the fastener has been coated
with paint or other material, use a driver
one size smaller than that indicated, to
compensate for the thickness of material
on the walls of the recess.
11-11
GEK 98493 LM6000 PA
Table 11-7 Tri-Wing Drivers and Standard- 11-3.6 Marking of Parts

Thread Fasteners
a. Parts or assemblies designated as
Screw Thread Tension Shear matched sets must be maintained as
Size Head Head matched sets throughout maintenance
0 - 80 0 - activity. Set numbers, part numbers, and
2 - 56 1 - serial numbers shall be protected during
4 - 40 2 1 cleaning or rework to prevent removal.
6 - 32 3 2 When identification markings are
8 - 32 4 3 removed or are no longer legible, the
10 - 32 5 4 item must be re-marked per the original
1/4 - 28 6 5 marking method and at the location
5/16 - 24 7 6 specified on the applicable drawing.
3/8 - 24 8 7
CAUTION Whenever it is necessary to
7/16 - 20 9 8
mark any engine parts, only approved
1/2 - 20 10 9 marking compounds shall be used. Use of
9/16 - 18 11 10 unauthorized marking compounds can
5/8 - 18 12 11 cause damage to engine parts.
3/4 - 16 13 12
7/8 - 14 14 13 b. Marking methods are:
1 - 12 15 14
(1) Electrochemical etch - preferred
11-3.5.2 Extraction
(2) Vibropeen - acceptable
a. There is no slope to the walls of mating
(3) Metal stamp - special use only
surfaces of either fastener or driver, so
that the tendency of the driver to slip out c. Permanent marking of parts should be
of the recess is minimized. Normal done in the area of lowest stress, as
extraction by applying counterclockwise specified on the applicable drawing.
torque is usually successful. Methods are listed below in order of
preference (unless otherwise specified).
b. If corrosion or other factors have caused
Electric etch is not approved.
the fastener to seize so that failure of the
recess occurs, select the proper drill and d. When electrochemical or acid etch
screw extractor for the size of fastener marking is used, the following
involved. The bottom of the fastener requirements shall apply:
recess is shaped so that the drill centers
itself naturally and no special drilling (1) Prior to marking, the surface to be
procedure is required. Drill into the marked shall be cleaned to assure
fastener deep enough to provide absence of dirt, grease, or oxides.
sufficient working depth for the screw
extractor. Tap the extractor to seat it
firmly, then apply counterclockwise
torque to remove the fastener.
11-12
LM6000 PA GEK 98493
(2) Immediately following the marking • Dykem Steel Blue DX100

operations, all chemicals remaining on
the part shall be neutralized and • Soapstone
flushed, and, on corrodible materials,
a corrosion-preventive treatment 11-3.7 Safety-Wiring
compatible with the base metal shall
be applied. Safety-wiring is the securing of two or more
parts with a wire installed in such a manner
(3) When marking is applied to premium that any tendency for a part to loosen will be
quality material, as defined in the counteracted by additional tightening of the
applicable material specification, it wire. This is not a means for obtaining or
must be ensured that the marking maintaining torque, but rather a safety
process is not capable of producing device used to prevent the disengagement of
any evidence of intergranular attack in parts. See figure 11-5 for general safety-
the base metal, when inspected at wiring practices.
400X magnification.
NOTE
CAUTION Grease or lead (graphite)
pencils must not be used to mark • Although not every possible combination
combustion-section or hot-section parts. of safety-wiring is shown in figure 11-5,
These materials plus heat can cause parts all safety-wiring must, in general,
material damage. correspond to the examples shown.
e. Lead- and sulfur-containing materials • GE gas turbines use special locking

should not be used for marking any cables at some locations. When removed
parts. Preferred materials are listed for maintenance, these should be
below: replaced with equivalent cables or safety
wire using standard safety-wiring
• Sharpie T.E.C. procedures in this chapter.
• Chalk 11-3.7.1 Safety-Wiring General

Practices
• Dykem - red, yellow, black
The following rules for safety-wiring shall
• Ink - Justrite Slink Black; Marco S- be observed, unless specific instructions to
1141, black the contrary are given in the text.
• March Stencil Ink • Safety wire shall consist of two strands

of wire twisted together (so called
• Carters Marks-A-Lot - black double-twist method), where one twist is
defined as being produced by twisting
• Carters Marks-A-Lot - blue the strands through an arc of 180°,
equivalent to half a complete turn. Use
• Dixon - black the single-strand method only when
specified.
• Dixon - yellow
11-13
GEK 98493 LM6000 PA
Figure 11-5 Safety-Wiring Practices (Sheet 1 of 2)
11-14
LM6000 PA GEK 98493
Figure 11-5 Safety-Wiring Practices (Sheet 2 of 2)
11-15
GEK 98493 LM6000 PA
• Safety wire shall not be installed in a • Hose and electrical coupling nuts shall
manner to cause the wire to be subjected be safety-wired in the same manner as
to chafing, fatigue through vibration, or tube coupling nuts.
additional tension other than the tension
imposed on the wire to prevent • Caution must be exercised while
loosening. twisting to keep the wire tight without
overstressing it or allowing it to become
• In all cases, safety-wiring must be done nicked, kinked, or otherwise mutilated.
through the holes provided. If no wire
hole is provided, safety-wiring shall be • Only existing safety wire should be
to a neighboring part in a manner not to replaced; do not add safety wire which
interfere with the function of the parts was not previously in place or specified
and in accordance with the basic in text.
principles described.
• When removing safety wire, identify
• The maximum span of safety wire safety-wiring holes on parts.
between tension points shall be 6 inches
(152 mm), unless otherwise specified. 11-3.7.2 Safety Wire Installation
Where multiple groups are safety-wired
either by the double-twist or the single- The following safety-wiring procedures are
strand method, the maximum number in to be used throughout the engine:
a series shall be determined by the
a. Insert the safety wire through the first
number of units that can be safety-wired
part and bend the upper end either over
with a 24-inch (610 mm) length of wire.
the head of the part or around it. If bent
When safety-wiring widely spaced
around it, the direction of wrap and twist
multiple groups with the double-twist
of the strands shall be such that the loop
method, the maximum number in a
around the part comes under the strand
series shall be three units.
protruding from the hole. Done this
• Both 0.020-inch (0.51 mm) and 0.032- way, the loop will not tend to slip
inch (0.81 mm) safety wires are used upward and become slack.
throughout the engine. The application
b. Twist the strands while taut until the
is determined by the size of the hole in
twisted portion is just short of the
the unit to be safety-wired. Whenever
nearest hole in the next part. The twisted
possible, use the 0.032 inch (0.813 mm)
portion should be within 1/8 inch (3.2
safety wire. Only new safety wire shall
mm) of the hole in each part.
be used in each application.
c. If the free strand is to be bent around the
• The safety wire shall be pulled taut while head of the second part, insert the upper
being twisted, and shall have 9 to 12 strand through the hole in this part, then
twists per inch (25 mm) for 0.020 inch repeat the previous step. If the free
(0.51 mm) diameter wire and 7 to 10 strand is to be bent over the unit, the
twists per inch for 0.032 inch (0.81 mm) direction of twist is unimportant. If
diameter wire. there are more than two units in the
series, repeat the preceding steps.
11-16
LM6000 PA GEK 98493
d. After wiring the last part, continue WARNING Use extreme caution in
twisting the wire to form a pigtail of monitoring the safe and complete removal
three to eight twists (1/4-1/2 inch [6-13 of all excess safety wire. Care must be
mm] long) and cut off the excess wire. taken when cutting off the ends of
Bend the pigtail inward toward the part installed wire to ensure complete retrieval
in such a manner as to prevent it from in order to prevent injury to personnel
becoming a hazard to personnel. and/or subsequent engine damage.
NOTE Apply light finger pressure at the h. When removing safety wire, ensure that
midpoint of the safety wire span, and flex the all pieces are removed to prevent them
wire in both directions to check for tautness. from entering engine parts or otherwise
causing damage.
e. If the safety wire is not taut after safety-
wiring per the preceding instructions, 11-3.8 Safety Cable
use the limits shown in table 11-8 to
determine its acceptability. Safety cable is an alternative to safety wire.
Safety cable is installed through two or more
f. If the safety wire fails to meet the limits parts in such a way that as the fastener or
shown in table 11-8, remove it and part loosens the safety cable will tighten.
install new safety wire. When the safety cable tightens, it will not
permit the fastener to part or turn.
Table 11-8 Installed Safety Wire Flex Limit
11-3.8.1 Safety Cable General
Length of Safety Practices
Wire Between Total Flexing at
Parts Center The safety cable system has three
in. mm in. mm components: safety cable, ferrules, and
crimping tool.
1/2 13 1/8 3
1 25 1/4 6 • The safety cable is available in one size,
2 51 3/8 10 0.032 inch (0.81 mm). One end of the
3 76 1/2 13 cable will have a cable end fitting
4 102 3/4 19 swaged to it. The strands of the cable on
5 127 3/4 19 the opposite end of the cable are fused
6 152 3/4 19 together to prevent the cable from
fraying.
g. Always cut, rather than break, safety
wire so that safety wire holes are not • The ferrules have spring-loaded,
torn or pulled out. Instructions for disposable magazine. When the safety
dismantling and disassembly do not cable is installed, the ferrule will be
include safety wire removal because of crimped on the open end of the cable.
the obvious necessity for removing
safety wire.
11-17
GEK 98493 LM6000 PA
• The hand operated crimping tool 11-3.8.2 Crimping Tool Verification

operates in one direction only and has a
cycle end dead stop to tell the operator Do a pulloff load test as necessary to make
when the ferrule is fully crimped. The sure the crimp done by the crimping tool
crimping pressure of the tool is set by meets the necessary requirements. GE
the manufacturer. If necessary, the Aircraft Engines recommends the pulloff
crimping pressure can be adjusted with load test be done at the beginning, middle,
standard hand tools. The Snap-On tool and end of each shift. Refer to
has a spring-loaded crimp rod to hold the manufacturer’s instructions for pulloff load
ferrule in place during the crimping test procedure.
procedure. Cable tension is done
automatically by the internal retraction 11-3.8.3 Safety Cable Installation
mechanism.
a. Do a visual inspection of the holes to be
• Where possible, install the safety cable safety cabled to find all damage. If the
so it does not touch other parts. hole is damaged, replace the part, or if
possible, use another hole to safety
• Make sure the cable is not damaged or cable.
bent when installing safety cable through
the holes in the fastener or part. Frayed NOTE Keep the safety cable as straight as
cable assemblies are not permitted. possible when you safety cable the fasteners
or parts together.
• Install the safety cable through existing
holes only. b. Put the end of the cable without the
cable end fitting into the hole in the part.
• Unless specified differently in the Pull the cable through the hole until the
packager’s manual: cable end fitting is against the part.
The maximum length of the safety cable c. Insert the end of the cable through the
between safety cabled parts is 6.0 inches second part. Choose the hole in the part
(152.4 mm). that permits the cable to be as straight as
possible. Pull the cable through the
No more than three bolts can be safely second part. If three parts must be safety
tied with one safety cable. cabled, do the same procedure for the
third part.
Safety cable can not be used on titanium
fasteners.
11-18
LM6000 PA GEK 98493
NOTE On a two bolt pattern, do not cable h. Push the start cycle button and turn the
in a negative pull direction. Make sure the drive handle clockwise. At the start of
cable has a positive or neutral pull. the cycle, the tension block will move
backwards. This movement backwards
d. Put the end of the safety cable coming provides the cable tension. When the
out of the last part to be safety cabled drive handle is turned, release the start
through a ferrule in the ferrule magazine. cycle button. Turn the drive handle until
Pull the safety cable through the ferrule it stops (approximately two full turns).
and use the safety cable to pull the
ferrule out of the ferrule magazine. i. Pull up on the safety cable end to
remove it from the tension block.
e. Put the end of the safety cable through
the crimping head of the crimping tool. j. Pull back on the retraction knob and
Make sure the large hole in the crimping remove the crimping tool from the
head is on the same side as the ferrule. crimped ferrule and the remaining safety
Move the crimping tool along the safety cable.
cable until the crimping head is against
the ferrule. Pull back on the retraction k. Cut the unused safety cable even with
knob. Put the ferrule in the crimping the crimped ferrule. Use the side
head and release the retraction knob. cushioned cutters. Discard the unused
Make sure the ferrule is fully in the safety cable.
crimping head.
l. Visually inspect safety cable for kinks,
CAUTION Do not put too much tension frayed wires, or improper crimps.
on the safety cable. The crimping tool will Remove and replace safety cable if a
automatically set the tension. Too much problem exists.
tension will break the safety cable.
m. Push against the safety cable with light
f. Pull the safety cable to the tension post finger pressure halfway between the
on the crimping tool. Wrap the cable safety cabled parts. If the cable feels
completely around the post. Make sure loose, do a dimensional check to make
the cable is in the groove at the top of sure the safety cable is serviceable as
the post. Pull the cable toward the drive follows (see figure 11-6):
handle until the cable goes behind the
locking ball. (1) Measure the distance between the
safety cabled parts. Write this
g. Hold the crimping tool perpendicular to measurement down as Dimension A.
the cable in the bolt head. Make sure the If three parts are safety cabled
ferrule is tightly against the bolt head. together, measure the distance
Lightly pull on the end of the safety between each of the parts and add the
cable to remove slack. two measurements together to get
Dimension A.
11-19
GEK 98493 LM6000 PA
(2) Push against the safety cable with 11-3.10 Unpacking and Repacking
light finger pressure halfway between
two safety cabled parts. Measure the The following general instructions apply
distance the safety cable moves during unpacking and repacking to minimize
laterally. Write this measurement possible part damage and contamination.
down as Dimension C.
a. Initially, remove only that portion of the
(3) Compare the dimensions that were packing material necessary to mount the
written down to the limits given in part. Where possible, remove the
figure 11-6. remainder of the packing material,
including protective caps and plugs, one
CAUTION Do not try to break the safety at a time as each connection (fluid, air,
cable. If the safety cable must be removed, or electrical) is made.
cut the safety cable to avoid damage to the
holes in the parts. b. Retain protective caps and plugs and
reusable packing components for
n. If the safety cable is not in the limits repacking purposes.
given in figure 11-6, cut the safety cable
with wire cutters and remove the c. Install a cap or plug on each connection
installed safety cable. Install new safety (fluid, air, or electrical) as it is
cable. disconnected.
11-3.9 Correction of Leaks d. When possible, repack the part for

storage or shipment, using the same
CAUTION Do not over-torque threaded packing material in which the
fasteners as a method of correcting leaking replacement part was received.
connections. Over-torquing could result in
part failure. e. When original packing components are
not available, use locally available
a. Disassemble the connection. packing materials and containers to pack
the part. Make sure all ports, openings,
b. Discard the seal, gasket, or packing, if connections, and mating surfaces are
present. capped or covered, and that the part is
protected from potential handling or
c. Inspect mating surfaces for environmental damage.
contamination, scratches, dents, or other
surface defects. f. Bearings shall be handled per paragraph
11-3.20 in this chapter.
d. Inspect threaded fasteners for thread
damage and ensure that fasteners seat
properly when torqued to specified
values.
e. Replace nonserviceable parts and

assemble the connection, using new
seals, gaskets, or packing as required.
11-20
LM6000 PA GEK 98493
Figure 11-6. Safety Cable Flex Limits
11-21
GEK 98493 LM6000 PA
11-3.11 Jackscrews b. Wrap precision parts and cap or plug all

openings and connections. It is most
a. When using jackscrews to remove important that all engine parts be kept
components, do not bend flanges or strip clean and free of corrosion. All
threads. Lubricate jackscrews with instructions that specify special handling
engine lube oil before installing. Turn of parts must be followed without
jackscrews inward evenly and in small exception.
increments. Always check for and
remove burrs or rough edges before c. Accessories, tubes, and hoses may
using jackscrews. If regular bolts are contain fuel or oil at the time of removal.
used as jackscrews, the tips must be Drain these fluids from the accessory
blunt and polished. Do not allow being removed and cap all connecting
components to fall free as jackscrews are hoses or tubes. Do not use tape.
tightened.
d. Do not remove plugs, caps, etc., until the
b. Jackscrew holes are often in flanges that part is ready for assembly. Check both
are only thick enough for three or four seating surfaces for removal of plugs,
threads. The ends of most standard bolts etc. prior to assembly.
are chamfered, and the first couple of
threads are missing or incomplete. 11-3.13 Universal Fittings
These should not be used as jackscrews
without modification, since only one or Universal fittings should be installed
two threads will engage and the threads according to the procedures described below
in the flange are likely to strip. (figure 11-3).
c. Jackscrews, frequently designed as Pipe fitting

special tools and identified as such, are
not chamfered and full thread a. Inspect the fitting visually.
engagement will occur. If specially
b. Clean if necessary.
manufactured jackscrews are not
available and must be manufactured c. Lubricate mating fittings.
locally, be sure that the ends are ground
to remove the chamfer and the d. Install the fitting, screwing it down to
incomplete thread so that the maximum within one-half turn of final position.
number of threads may be engaged.
e. Remove the fitting, clean, inspect, and
11-3.12 Protective Closures and lubricate the male thread.
Caps
f. Reinstall the fitting and screw it down to
a. Preventing foreign material from lodging its final position.
in drilled passages, fuel lines, oil lines,
air lines, and open engine ports is
extremely important. Machined surfaces
must be properly protected to prevent
damage.
11-22
LM6000 PA GEK 98493
Union d. Roll the packing over the threads into

the groove in the fitting.
a. Lubricate the packing and roll it over the
threads into the groove in the union. e. Adjust the nut so the backup ring forces
the packing firmly against the lower
b. Screw the union into the boss until the threaded portion of the fitting.
packing contacts the surface of the boss.
f. Screw the fitting and nut simultaneously
c. Tighten the union to the proper torque into the boss until the packing contacts
value. the chamfer at the face of the boss.
Bulkhead fitting g. Hold the nut and turn the fitting one-
and-a-half turns into the boss. The
a. Lubricate the fitting end. Screw the nut fitting may be positioned further by one
onto the fitting until the washer face of additional turn.
the nut is aligned with the upper corner
of the seal groove. h. Attach the line to the fitting and check
the alignment of the fitting.
b. Lubricate the packing and roll it over the
threads into the groove in the fitting so i. Hold the fitting and tighten the nut to the
that it contacts the nut. proper torque.
c. Screw the fitting and nut simultaneously 11-3.14 Cleanliness
into the boss until the seal contacts the
chamfer at the face of the boss and the Cleanliness is important for equipment life
nut contacts the boss. and proper operation. The major cause of
premature engine removal is foreign object
d. Position the fitting either by turning in as damage (FOD).
much as three-quarters of a turn (270°
clockwise) or turning out as much as a. The enclosure must be kept clean and
one-quarter turn (90° counterclockwise). free of dirt and loose objects. It is
Attach the line to the fitting and check recommended that small FOD containers
the alignment of the fitting. Tighten the be kept in the work area or in tool boxes.
nut to the proper torque.
b. All parts shall be inspected for
Fittings with backup rings cleanliness before being installed.
a. Lubricate the male threads of the fitting, c. Gaskets and packing shall be free from
the backup ring, and the packing. dirt, lint, and/or grit.
b. Screw the nut onto the fitting, with the d. Mating flanges, tube flanges, and
counterbore side facing the fitting end. couplings shall be wiped clean to make
sure that a good seal will be obtained.
c. Put the backup ring on the fitting and
seat it in the counterbore of the nut, with e. Hands and gloves must be clean when
its convex side facing the fitting end. handling machined surfaces.
11-23
GEK 98493 LM6000 PA
f. The engine shall not be used as a shelf • Maintain a minimum clearance of

for holding tools or parts while 0.125 inch (3.2 mm) between tubes
maintenance is being performed. and adjacent parts.
g. After performing any maintenance, the • Tubes and manifolds must fit within
work area shall be thoroughly inspected 0.063 inch (1.6 mm) radius in a free
for loose parts, rags, tools, and other state during assembly or be replaced.
materials. The area shall be cleaned to
remove grit, dust, chips, safety wire, and • Coupling nuts shall thread freely by
other small objects. hand.
11-3.15 Gaskets and Packing • Mating flanges on tubes shall seal

flush within 0.005 inch (0.13 mm).
a. Gaskets, packing, key washers, and
• The distance between faces of
cotter pins shall not be reused, unless
mating surfaces or flanges shall not
otherwise specified.
exceed 0.063 inch (1.6 mm).
b. Gaskets and packing shall be lightly • If tubes are reworked, the bend radii
lubricated with engine lube oil prior to shall not be less than twice the tube
installation, unless otherwise specified. diameter and the bend angle shall not
Ensure parts are properly seated. When be changed by more than 3 degrees.
a fitting with a jamnut and packing is No kinks or wrinkles are permitted.
used, see figure 11-3 for the proper
installation procedure. See figure 11-7 • Do not bend tubes at fitting or weld
for packing used with flexible sleeve areas.
type fittings.
• Original bends in a tube may be bent
11-3.16 Tubes in the same direction, but reverse
bending is not allowed.
When installing tubes, the following
precautions and instructions apply. See • Bend tubes in existing straight
figure 11-7. sections, if possible.
a. As tubes are installed, tighten all end Use bending tools on any tube 1 inch or
fittings and clamps finger-tight. After a more in diameter to prevent the tube from
complete system is installed, torque collapsing.
clamps first and then end-fittings.
11-24
LM6000 PA GEK 98493
Figure 11-7 Flexible Coupling Assembly
11-25
GEK 98493 LM6000 PA
11-3.17 Hoses b. Fluid fittings shall be tightened

gradually to the required torque value,
a. No hose should be bent more than the backed off one-quarter turn, and then
bend radius specified in table 11-9, tightened again. Do not attempt to
especially when parts are cold, because correct leaks by excessive tightening.
of possible damage to Teflon liners. Always use two wrenches when
Kinked hoses must not be used. During tightening swivel coupling nuts on
installation, be sure that no hose is hoses, tubes, or fittings. Hold the
twisted or stretched. Never over-torque stationary part with one wrench while
connectors. When hoses are removed, applying torque with second wrench.
cap the open ends. Do not use tape to Apply engine lube oil between the
cover open ends. tube/hose coupling nut and the ferrule
prior to tightening. See figure 11-8.
Table 11-9 Hose Minimum-Bend Radii
c. Preformed hoses or hoses of large
Dash Minimum-Bend Radius diameter shall not be bent or
Size in. mm straightened. See figure 11-9. When
hoses are removed, cap the open ends.
3 1.50 38
Do not use tape to cover open ends.
4 2.00 51
5 2.00 51 d. Before installing preformed hoses,
6 4.00 102 visually inspect the hose interior to
8 4.62 117 assure that the Teflon lining has not been
10 5.50 140 damaged. If damaged, replace the hose.
12 6.50 165
16 7.38 187 11-3.18 Clamps
20 11.00 279
24 14.00 356 a. Chafing of hoses and tubes must be
32 22.00 559 avoided. Clamp parts loosely in place,
shift the hoses until the best clearance is
CAUTION Natural gas fuel hoses and
obtained, and then tighten the clamps
fuel nozzle steam hoses have different and
(figure 11-10).
more restrictive requirements. Refer to the
appropriate work package in Volume II for b. Clamps must be of the proper size for
details. the piping to permit slippage during
engine thermal growth. The cushion
clamp liner position should also be
checked before tightening the clamp
(figure 11-11). Clamps must be
positioned over the wear sleeves on the
tube.
11-26
LM6000 PA GEK 98493
Figure 11-8. Hose Assemblies Installation
11-27
GEK 98493 LM6000 PA
Figure 11-9. Factory Preformed Hoses
Figure 11-10. Routing and Clamping Techniques
11-28
LM6000 PA GEK 98493
Figure 11-11. Cushion Clamps Installation
11-3.19 Electrical Cables and CAUTION Do not allow the seal to tip
Connectors and flatten. An incorrectly installed seal
could affect the usefulness of the seal
During electrical cable installation, adjust and/or connector.
the cable through the clamps to get the
smoothest and largest radius. Sharp bends, c. Push the seal to its seated position
twists, and kinks must be avoided. against the internal shoulder in the
Minimum clearance between the electrical connector using a mating connector or
cable and any component other than hoses or blunt screwdriver.
other electrical cables is 0.125 inch (3.18
mm). CAUTION Do not force the connectors
together. If the pins are not aligned, they
A seal ring is located in the coupling nut of will be bent or distorted and will not make
each electrical connector. Inspect to ensure contact.
the seal is present and serviceable before
attaching the connector. Replace d. Inspect electrical connector pins for
unserviceable seals as follows: straightness before connecting. Insert
the mating cable connector, hand-tighten
a. Remove the unserviceable seal. the retaining nut, push the mating parts
together until seated, and tighten the
b. Engage the new seal over the barrel of retaining nut as required.
the connector.
11-29
GEK 98493 LM6000 PA
e. If the connector is a locking connector, 11-3.20.1 Preservation

engage the connector and wiggle the
backshell while tightening the coupling WARNING Lubricating oil, MIL-L-
ring hand-tight. A clicking sound is 6085, is flammable and toxic to skin, eyes,
produced during tightening of the and respiratory tract. Skin, eye, and
connector. Ensure that the full coupling respiratory protection is required.
color band on the receptacle is not
visible and that the backshell has no At the point where bearings are accessible in
movement. the disassembly cycle, the bearings shall be
thoroughly covered with lubricating oil,
f. Electrical connectors on flexible MIL-C-6085.
harnesses and leads shall be hand-
tightened beyond finger-tight (20° Use of engine lubricating oil as a lubricant
maximum) until connecting parts are in or preservative is specifically prohibited.
solid contact without damage. Safety-
wire the connectors only when specified Personnel handling bearings must wear
in the procedure. either synthetic rubber or nylon-mesh gloves
with polyethylene palms and fingers.
g. Do not sharply bend, kink, or twist rigid
leads. When tightening the connection, WARNING Corrosion preventive, MIL-
always hold both mating connectors to C-11796, is flammable and toxic to skin,
prevent damage to the leads. eyes, and respiratory tract. Skin, eye, and
respiratory protection is required.
11-3.20 Bearing Handling
Bearings returned to storage shall be
CAUTION Ball and roller bearings preserved with corrosion preventive,
require special care to prevent corrosion. MIL-C-11796, Class 3, and wrapped in
Bearings must not be handled with bare barrier paper, MIL-B-121, Grade A, Type 2,
hands nor with any device that might cause Class 2, glossy side toward bearing.
contamination. Clean rubber or nylon
After installation, bearings shall be returned
gloves or a protective hand cream shall be
to room temperature and be preserved with
used at all times when handling bearings.
lubricating oil, MIL-C-6085.
11-30
LM6000 PA GEK 98493
11-3.20.2 Heating and Chilling NOTE Heating and chilling are defined as
any temperature 10°F (6°C) or more above
WARNING or below room temperature.
• Corrosion preventive, MIL-C-6529, is a. When it is necessary to chill a bearing in

toxic to skin, eyes, and respiratory dry ice, coat the bearing thoroughly with
tract. Skin, eye, and respiratory corrosion preventive, MIL-C-6529, Type
protection is required. III, and place in a plastic bag prior to
chill.
• Dry ice, BB-C-104, is extremely cold
and can cause serious low- b. Immediately after installation of a
temperature burns. Wear insulated chilled bearing, apply heat with a heat
gloves when handling material. gun until bearing and adjacent parts are
brought to room temperature. Remove
• Wear insulated gloves to prevent any moisture using clean, dry shop air,
injury when handling hot parts. and coat the bearing with corrosion
preventive, MIL-C-6529, Type III.
• When using compressed air for
cleaning, cooling, or drying, do not c. Heat bearings using ovens or heat guns.
exceed 30 psig. Wear eye protection No direct heat source, such as a blow
and do not direct compressed air at torch, may be used. When the bearing
self or others. returns to room temperature, coat with
corrosion preventive, MIL-C-6529, Type
CAUTION III.
• Immediately after installing or 11-3.21 Spray Shields
removing a chilled bearing, use a heat
gun to restore the bearing and any Spray shields shall be positioned on tubing
adjacent cold area to room temperature so as to prevent fluid from spraying on the
so that condensation of moisture will be engine if a leak occurs at the shielded area of
minimized. Check carefully for a tube.
evidence of moisture and continue
heating until the bearing is completely 11-3.22 Blending
dry. Apply corrosion preventive, MIL-
C-6529, Type III, at once to the bearing NOTE Refer to specific engine manual
after complete drying. section or service bulletin for blend limits
for the piece part under review. Use the
• When heat is required to relieve shrink limits in this procedure only when no
fits of bearings, use heat guns or ovens. specific limits are specified for the
Do not use direct-heat sources to apply component in the engine manual or
the heat and do not heat the bearings to appropriate service bulletin.
a temperature higher than 350°F
(175°C). Apply corrosion preventive, Blending is a repair procedure that is used to
MIL-C-6529, Type III, to the bearings remove stress concentrations caused by
before heating and after they have nicks, scratches, or other sharp-edged
cooled to room temperature. damage marks on critical parts. Removal of
the material surrounding the stress
11-31
GEK 98493 LM6000 PA
concentration, so that the sharp edges are WARNING Particles from grinding or
blended into smooth contour, relieves the sanding abradable material could be
stress concentration and permits further use harmful to eyes and respiratory tract.
of the part by lessening the danger of Eye and respiratory protection is
cracking. required.
Blending is also used to remove sharp edges NOTE Refer to the inspection and repair
resulting from machining, drilling, etc., and limits for specific instructions on blending
to restore the original contour and/or surface limits applicable to each part of the engine.
finish to parts that have been repaired by
welding, brazing, etc. a. When blending compressor rotor blades,
stator vanes, turbine blades, and similar
11-3.22.1 Blending General parts, blend in a radial direction in
Practices relation to the engine. Avoid removing
metal from leading and trailing edges of
The following rules for blending shall be airfoil sections in such a way that the
observed, unless specific instructions to the edges become thin or sharp; blend so as
contrary are given in the text: to maintain approximately the original
contour.
CAUTION Do not repair titanium parts
with tools, such as grinding wheels, files, b. When blending a cylindrical part, blend
stones, or emery cloth, that have been used in a circumferential direction, not along
to repair other types of metal. Damage to the axis of the part.
parent metal could occur.
c. The finish on the blended area shall be
• Defects more than 0.25 inch (6.4 mm) as close to the original finish as possible.
apart shall be blended separately. Those
less than 0.25 inch (6.4 mm) apart d. When blending on a part involving a
(except splines) shall be blended radius, keep the radius as specified in the
together. Splines that are closer together repair section. If the radius is not
than 0.25 inch (6.4 mm) and defects specified, keep it as close as possible to
shall be repaired separately. the original contour. Refer to a similar
part, if necessary, to determine original
• The finish on the blended area must be radius.
as close as possible to the original finish
of the part. e. Etch reworked area per paragraph
11-3.23 and inspect by spot fluorescent-
11-3.22.2 Hand Blending penetrant method, per paragraph
11-3.24, after blending
Sharp edges can be blended out using
abrasive stones or papers, files, or crocus 11-3.22.3 Power Blending
cloth. Coarse grades of abrasives or files
may be used for fast metal removal, but the Blending on most parts may be done by
parts must then be given a smooth surface using a power-driven polishing wheel or
finish with fine grades of abrasives or crocus rubber-bonded abrasive points, and any
cloth. special instructions for the individual part
must be followed.
11-32
LM6000 PA GEK 98493
WARNING Particles from grinding or a. Blending Airfoils.

sanding abradable material could be
harmful to eyes and respiratory tract. (l) The types of airfoil damage described
Eye and respiratory protection is below may be repaired by hand
required. blending or by power blending.
Always refer to applicable part
CAUTION Power blending of airfoil inspection paragraph for a description
sections may be done only when specified of airfoil defect limits as follows:
by individual part instructions. When doing
power blending, be sure to avoid building (a) Nick A V-shaped depression in
up excessive heat and resulting thermal the airfoil made by a sharp-edge
stresses in the part. object pushing the metal inward.
NOTE After power blending of a titanium (b) Pit – A round sharp-edged hole
part is completed, hand-blend the same area with a rounded bottom caused by
approximately 0.002 inch (0.05 mm) deeper corrosion.
to remove any residual stresses in the
surface material. (c) Scratch – A V-shaped line or fur-
row in the airfoil such as would be
a. Rough out defects using coarse grades of made by dragging a sharp object
resilient flexible abrasive impregnated across the surface.
wheels, brushes, or points. Use fine or
extra fine grades to finish the blend (d) Dent – A smooth rounded depress-
areas. ion in the airfoil made by impact
with a rounded object. If there is
b. Follow the requirements described-in any noticeable sharp discontinuity
paragraph 11-3.22.2 when doing power in the depression, it should be
blending. considered as a nick. Waviness of
leading or trailing edges is to be
c. Etch reworked area per paragraph treated as a dent.
11-3.23 and inspect by spot fluorescent-
penetrant method, per paragraph (e) Erosion A sand- or shot-blasting
11-3.24, after blending. effect on the leading edges or the
leading portion of the concave side
11-3.22.4 Component Specific caused by sand or dust going
Requirements through the engine.
NOTE Requirements in specific engine (f) Torn Metal A separation or pull-
manual section or appropriate service ing apart of material by force,
bulletin take precedence over the following leaving jagged edges.
procedures. The requirements in this
section should be used with engine manual
or service bulletin criteria or when no
criteria are specified.
11-33
GEK 98493 LM6000 PA
(2) Hand-blending of airfoils may be done (d) Blending limits are given as depth
as specified below: dimensions to make it easier to see
how much can be repaired.
(a) Blending is done to remove stress Experience has shown that depth
caused by nicks, pits, and scratches limits are used for most rework.
to prevent blade failure. Remove However, the minimum chord limit
high metal and straighten dents is the most important dimension; it
(where permitted) to restore the should be checked in borderline
airfoil shape as closely as possible cases or where previous rework is
to its' original aerodynamic contour. evident in the same area. For
convenience, the depth limits and
(b) Blending shall be finished with fine minimum chord limits are given in
stone or crocus cloth. Coarser tools both decimals and fractions. In
may be used for initial removal of borderline cases where depth limits
material. Finish blending in a and minimum chord limits conflict
direction along the length of the with one another, use the decimal
blade or vane and remove all minimum chord dimension to
evidence of marks across the airfoil decide if the part is usable.
that may have been made during
initial blending. (e) Defect limits are given as depth
dimensions since this is the
(c) Defects more than 0.25 inch dimension that affects strength.
(6.4 mm) apart shall be blended However, accurate depth
separately; those 0.25 inch measurements require special
(6.4 mm) or less apart may be equipment not normally available.
blended together. All blends must Comparing the depth of a defect
have a minimum radius of 0.25 inch with the thickness of a leaf of
(6.4 mm). The total reduction in thickness gage or with the thickness
chord width may be taken on either of a piece of safety wire is a reason-
side or divided between the sides. ably accurate way of measuring
The amount of rework is controlled depth (see Figure 11-13).
by the minimum chord width limit.
The minimum allowable chord is (f) Swab etch reworked area per
given for root and tip of airfoil, the paragraph 11-3.23 and spot-
minimum chord at other points is fluorescent-penetrant inspect per
proportional. To minimize the paragraph 11-3.24. Brush or swab
possibility of an engine stall, keep on penetrant where air passages are
the shape of the blended airfoil present to prevent excessive
leading edge as close as possible to penetrant entrapment.
the original contour (see Figure
11-12).
11-34
LM6000 PA GEK 98493
Figure 11-12. Airfoil Leading Edge Blending
Figure 11-13. Airfoil Defect Measurement
11-35
GEK 98493 LM6000 PA
(3) Power-blending of rotor blades, close as practical to the original finish

variable vanes, and vane segments of the part.
may be done as follows:
c. Removing High Metal. High metal is
(a) To avoid damaging the airfoil, use caused by the displacement of metal
masking tape and mask off the above a surface. It is found around
airfoil next to the rework area. defects like nicks and scratches.
Remove high metal as follows:
(b) Use coarse grade, silicon-carbide
impregnated rubber wheels and (l) Use a fine abrasive stone, a small file,
points for the initial benching of the emery cloth, or crocus cloth to remove
blades and vanes. high metal.
NOTE During finish blending of defects, (2) Remove only the material that is
make a radius on both the leading and projecting above the original surface
trailing edges of the airfoil. To do this, contour (see Figure 11-14).
apply light pressure with the rubberized
abrasive wheel, and let the cushion action of (3) Swab etch reworked area per
the wheel do both the blending of the radius paragraph 11-3.23 and spot-
and the buffing of the defect. fluorescent-penetrant inspect per
paragraph 11-3.24.
(c) Finish blending the defects, using
the fine and extra fine grade of 11-3.23 Swab Etching Procedure
rubberized abrasive wheels.
Remove only enough material to This procedure describes the materials and
repair the defect. process for swab etching used as a
preliminary step before fluorescent-
(d) Swab etch reworked areas per penetrant inspection. Etching solutions are
paragraph 11-3.23 and spot- used as described herein or with exceptions
fluorescent-penetrant inspect per as specified for individual parts in the Shop
paragraph 11-3.24. Manual.
(e) Place the repaired blades and vanes WARNING Etching solution contains
in separate containers to prevent acid and is highly toxic to skin, eyes, and
damage during handling. respiratory tract. Skin and eye
protection, and vapor control are
(f) Carefully inspect the blades and required. Avoid all contact.
vanes.
CAUTION Refer to the Material Safety
b. Blending Minor Indications in Tubing. Data Sheets (MSDS) for storage and
handling instructions for etchant solution.
(l) Use a fine abrasive stone, a small file, Etchant solutions can become hazardous to
emery cloth, or crocus cloth for personnel if not handled appropriately.
blending.
a. All surfaces to be etched must be free
(2) Blend around the circumference of the from oil, grease, scale, or other
tubing. The finished blend shall be as extraneous material.
11-36
LM6000 PA GEK 98493
Figure 11-14. Blending and High Metal Removal
b. Pour a small quantity of stock solution NOTE Keep fresh solution in contact with
into a clean plastic beaker or dish. This the metal surface at all times by dipping the
quantity will be the working solution, swab into the working solution periodically.
and is not to be returned to the stock Rub the swab continuously over the surface
bottle. of the metal being etched, to prevent the
formation of an inert sludge.
c. Saturate a cotton swab with the working
solution, and swab the surface to be d. After etching, blot up etching solution
etched for 60-90 seconds, all Classes, from the metal surface with a clean
except Class G. Class G etching time is paper towel or cloth.
3-4 minutes. (Refer to MSDS for
classification of etchant being used.) e. Gently wipe the etched area at least three
Keep the etching solution within defined times with a cloth or paper towel
boundaries of the area to be etched. saturated with clean water. Blot dry
Masking may be required to contain with clean cloth or paper towel.
etchant to areas for etching.
11-37
GEK 98493 LM6000 PA
CAUTION Do not pour working solution (1) Inspection booth, darkroom, or black
back into stock container. Although the cloth hood (for remote locations) to
small quantities involved do not ordinarily prevent excessive admission of white
constitute an environmental hazard, flush light.
away discarded solutions with several
volumes of water to ensure adequate (2) Compressed air supply for drying
dilution. parts. Air supply must have filters to
remove oil and moisture which can
f. Discard used working solution, rinse, contaminate parts or inspection
and dry plastic container for future use. materials.
11-3.24 Spot-Fluorescent-Penetrant (3) Ultraviolet lamp to detect fluorescent

Inspection indications. The ultraviolet (black)
light source used for the detection of
The spot-fluorescent-penetrant inspection fluorescent indications shall have an
process is intended for inspections at remote intensity no less than 1,000
locations. It is a localized process, limited microwatts per sq. centimeter when
to small specific areas for inspection. It is measured at 15 inches. (381.0 mm).
not intended as a substitute for normal The black light should be checked on
inspection. It is convenient to use for a weekly basis or before use,
inspection of welded or other localized whichever is less frequent.
repair areas.
(4) White light lamp for visual inspection
Personnel performing this inspection must of parts.
be certified in accordance with MIL-STD-
410, American Society of Non-Destructive (5) Time piece for timing operations.
Testing (ASNT-TC-IA), Air Transport
Association Specification No. 105 (ATA (6) Tools for inspection personnel:
105), or locally approved certification
program. (a) Three power and 10 power
magnifying lenses
Any training which may be provided by GE
for a technique requiring the performance of (b) Cotton swabs or small fine hair art
this inspection method does not imply that brush to apply solvents for
the personnel who receive that training have evaluating questionable indications
met the requirements for inspector
b. Materials required:
certification in accordance with MIL-STD-
410, ASNT-TC-IA, or ATA 105. NOTE Qualified Products listed in MIL-I-
25135 QPL (Qualified Products List) as
11-3.24.1 Spot-Fluorescent-
Level 3, Method D, are considered
Penetrant Inspection Equipment/
acceptable alternates to the products listed.
Materials
(1) Post-Emulsification Fluorescent-
a. Equipment required:
Penetrant Oils: ZL22A, B, or C,
ZL27 or ZL27A (Magnaflux
Corporation)
11-38
LM6000 PA GEK 98493
(2) Hydrophilic Removers: ZR10A or b. Apply penetrant oil with soft-bristle

ZR10B (Magnaflux Corporation) brush, cotton swab, or spray application.
Allow a minimum of 30 minutes for
(3) Dry Powders: ZP4A or ZP4B penetration.
(Magnaflux Corporation)
WARNING Acetone, O-A-51 and
(4) Non-Aqueous Wet Developers Isopropyl Alcohol, TT-I-735 are explosive
(NAWD): ZP9B, C, E, F, or D499C when subjected to high temperature,
(Magnaflux Corporation) source of ignition, high pressure, or other
chemicals. Flammable near sparks, open
(5) Halogen-free solvents: Isopropyl flames, welding areas, hot surfaces, other
Alcohol (TT-I-735) or Acetone (O-A- sources of ignition, or while smoking.
51) Inhalation, contact, or ingestion may
cause irritation or burning of respiratory
11-3.24.2 Spot-Fluorescent-
system, eyes, face, skin, or digestive
Penetrant Inspection Procedure system. Personal protective equipment
required when handling or using this
This procedure is to be used wherever the
material. May lead to allergic sensitivity
shop manual calls out specific classes using
in some individuals. Thermal
either waterwashable or post-emulsifiable
decomposition may release toxic by-
penetrant systems.
products. Provide local exhaust or
NOTE general dilution ventilation to meet
published exposure limits. If these are
• If visible color dye penetrant has been not available, use respirator having niosh
used on parts which are to be approval for the materials released.
subsequently inspected with fluorescent
penetrants, the contamination by the dye CAUTION Titanium alloy parts are
may prevent reliable fluorescent subject to stress corrosion cracking when
penetrant inspection. Any color dye residues of halogen containing compounds
indications evident by white light visual remain on a part that is subsequently
inspection shall be considered valid subjected to elevated temperatures typical
indications even if not detectable by of welding, heat treating, or engine
ultraviolet light. operation. These parts must be thoroughly
cleaned with nonhalogen compounds after
• Excessive white light may interfere with exposure to any halogen containing
detection of a rejectable size indication. compound to prevent the cracking and
A test part having a known defect can be possible failure of parts.
used to evaluate effectiveness of white
light shielding. NOTE Indications of defects can be lost by
use of excessive solvent.
a. Parts must be cleaned of all traces of oil,
grease, carbon, and rust scale prior to c. Wipe off excess penetrant with a clean
penetrant application. cloth using a solvent.
11-39
GEK 98493 LM6000 PA
(1) Alternate. Remove excess penetrant b. Exercise extreme care during assembly
with a hydrophilic remover, provided or disassembly operations to prevent
it belongs to the same family as the entrance of pieces of safety wire, nuts,
penetrant used. Do not exceed 90 washers, or any other objects into the
seconds contact time. If remover is engine or assembly. If anything is
applied manually, do not scrub the dropped into the engine during assembly
surface of the part with the applicator. or disassembly, stop and remove the
Use applicator only to deliver fluid to object before proceeding.
the part surface.
c. Do not store tools or maintenance
WARNING Nonaquaeous developer is equipment on or against the engine.
mixed in a solvent base containing Account for and properly store all tools
acetone, isopropyl alcohol, and/or after use.
trichloroethane. Solvents are flammable
and toxic to skin, eyes, and respiratory d. Clean fittings of contamination before
tract. Skin, eye, and respiratory making or breaking connections.
protection is required. Avoid repeated or
prolonged contact. Avoid breathing WARNING Do not use external engine
vapors and use in a well-ventilated area. piping as a ladder or hand-hold while
performing maintenance. Serious damage
d. Apply either dry powder or NAWD as a or personal injury could result. Use only
fine thin coating at ambient temperature authorized work stands and platforms.
to a dry surface. Allow a minimum of
10 minutes for developer to absorb e. Handle all parts carefully. Lift heavy
penetrant before inspecting part. parts with proper lifting fixtures and a
hoist to prevent damage to parts and
e. Evaluate any indication to the required physical harm to personnel.
inspection standards.
f. Always use fiber or plastic blocks and
f. Remove all residues by spraying, hammers with plastic, rawhide, or nylon
wiping, or soaking with approved heads for driving operations.
solvents.
g. Tie related parts together when they are
11-3.25 Miscellaneous Procedures removed. Tag or mark parts for
identification.
CAUTION Use of motor-driven hydraulic
pumps to operate hydraulically actuated h. Coat parts, that are to be stored for any
special support equipment other than length of time, with an appropriate
torque multipliers is not recommended. preservative.
Equipment damage can result from
improper power application. i. When installing or removing body-
bound bolts, tap them straight through
a. Use hand-operated hydraulic pumps to the holes. Do not turn them.
operate hydraulically actuated special
support equipment such as pushers or j. Verify identification of all mating parts.
pullers, unless otherwise specified.
11-40
LM6000 PA GEK 98493
k. Observe tagged parts for proper location. q. Accessories, tubes, and hoses may have
oil or fuel in them at time of removal.
l. During assembly, align matchmarks on Drain these fluids from accessory being
all parts that were marked during removed and cap all connecting hoses or
disassembly. tubes.
m. Keep all protectors, plugs, and caps r. Lubricate all gears and splines with
installed until removal is required. engine lube oil before installing them,
unless otherwise specified.
n. Prior to final assembly, inspect all
cavities and openings for foreign s. Prior to the installation of any part, a
material. visual check should be made and any
obvious signs of handling damage or
o. Inspect all mating flanges for foreign abnormal wear should be noted and
material prior to final assembly. reported so that corrective action can be
Remove any high metal with a fine taken.
stone.
t. Always read the complete operation and
CAUTION Do not mix plated hardware be sure you understand it fully. It is
with unplated hardware. Do not use silver better to stop and ask than to continue
or cadmium-plated tools or hardware on and cause unnecessary work and/or
titanium parts. Plating contains small damage.
quantities of chlorine salts that are
harmful to titanium. u. Do not disassemble any component any
further than necessary to perform the
p. Three types of tools (common, required maintenance, even though
improvised, and special) are used to complete disassembly instructions may
perform maintenance. Common tools be given. Remove piping and electrical
are identified only when used in special leads only as required to perform
applications. Drawings for improvised maintenance tasks.
tools are incorporated in the text when
such tools are required. Special tools are v. Attaching hardware (bolts, nuts, plain
identified both by name and part number washers, brackets, clamps, etc.) is
when they are required. generally reusable. When possible, it is
recommended that attaching hardware be
WARNING Lubricating oil, MIL-L- left in place or temporarily reinstalled
23699, is toxic to skin, eyes, and until the replacement component is
respiratory tract. Skin and eye protection installed.
is required. Avoid repeated or prolonged
contact. Use in a well-ventilated area.
CAUTION Engine lubricating oil may

soften paint or stain clothing. Clean spilled
oil from painted surfaces.
11-41
GEK 98493 LM6000 PA
w. Parts or assemblies designated as (4) If tube ends do not align within the
matched sets elsewhere in this manual or above limits, readjust mounting until
by the parts list shall be maintained as a proper alignment is attained.
matched set throughout the maintenance
cycle. Set numbers, part numbers, and b. Ensure flange faces are free of dirt,
serial numbers shall be protected during grease, corrosion, distortion,
cleaning or repair to prevent removal. deformation, and scratches.
When identification is removed, or is no
longer legible, the item shall be re- c. Use protective flange caps on the ends of
marked per the original marking method all ducts until the installation progresses
and location for the part. to the point where removal of the cap is
essential to continuing with the
x. When discrepancies are found during installation.
maintenance, refer to inspection tables
for limits and corrective action. d. Use care during the installation of ducts
and tubes to ensure mating and
Petrolatum, Fed Specification VV-P-236, alignment of flanges. A poorly fitted
shall be used as an assembly aid for tight- joint requires excessive torque on the T-
fitting parts, bearings, and packing, unless bolt to close the joint and imposes
otherwise specified. structural loads on the V-band clamp.
Adjacent support clamps or brackets
NOTE Mobile Assembly Fluid 403C may should remain loose until installation of
be used in place of soft petrolatum. the coupling has been completed. When
connections are by V-band couplings,
11-3.26 V-Band (Coupling) Clamps the weight of the components should be
fully supported during the fit-up and
11-3.26.1 Preinstallation Checks installation of the couplings.
a. Check alignment of tube ends, e. When reinstalling a used coupling, check
unrestrained, to the following maximum it for twist or distortion. Visually check
limits prior to installing V-band clamps: the V-section for spreading at the open
ends or other signs of distortion. Check
(1) Parallelism: no angle (centerlines of
spot welds or rivets for condition and
tubes or fittings parallel).
security. The corner radii should be
(2) Offset between fittings or tube carefully checked for tool marks and
centerlines: no more than 0.060 inch cracks. V-band couplings in poor
(1.52 mm) circumferential, axial, or condition should be replaced.
combined.
f. Check the threads on the T-bolt for wear
(3) Gaps: no more than 0.060 inch and condition. If there is any sign of
(0.15 mm) space between fitting seats. wear, galling, or deformation, install a
new T-bolt or coupling clamp.
11-42
LM6000 PA GEK 98493
g. Check the T-bolt for straightness; CAUTION Coupling T-bolt nuts shall not
however, if it is bent it will be necessary be reused. Do not substitute any other
to determine if the bend is intentional. coupling nut for the type nut supplied with
Some small diameter couplings have the coupling. The correct nut (ESNA
curved T-bolts. Check the applicable Z1200J series) is identified by the letter “J”
illustrated parts breakdown for part stamped on a wrench flat. Failure to
identification. If in doubt, install a new comply may result in duct joint failure.
T-bolt or coupling clamp.
a. Place the V-band clamp over one of tube
h. Check the trunnion and latch for ends far enough to clear flange.
freedom of movement or other
overloading. b. Install gasket, if required, and mate both
flanges.
i. Avoid twisting, spreading, or bending of
the coupling when positioning the c. Relocate clamp over both flanges and
coupling on the joint. press clamp closed.
j. When gaskets are used in the joint, d. Install nut. Ensure T-bolt is properly
exercise care in handling to avoid nicks seated, and tighten nut to approximately
and burrs on the gasket surfaces. one-half of required torque marked on
Whenever a joint is disassembled after strap.
service operations, a new gasket should
be used when reassembling to ensure e. Tap clamp lightly around circumference
maximum sealing efficiency. Exercise with a rubber mallet to equally distribute
care to ensure that the gasket is properly load.
seated.
f. Alternate tightening and tapping until
11-3.26.2 Installation torque stabilizes at the specified value.
Avoid overtorquing.
The following procedures should be
followed to ensure proper V-band clamp g. Inspect clamp for even seating.
installation:
h. See figure 11-15 for safety wiring the
CAUTION Do not use pliers on V-band V-band clamp. Use 0.041-0.051 inch
clamps to force alignment of tube ends (NOVN) (1.0-1.3 mm) safety-wire.
while engaging V-band bolts and nuts.
Residual stress in the tubes and nicks,
scratches, or deformation in the clamps,
can cause premature failure of these parts.
11-43
GEK 98493 LM6000 PA
Figure 11-15 V-Band Clamps and Safety-Wiring Techniques
11-44

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LM6000 PA GEK 98493

GE Marine & Industrial Engines Volume I

11-1. Purpose and Scope 11-3.1 Points of Reference

WARNING c. Post an observer at the exit while

a. Wear protective clothing, gloves, safety

11-3.4 Torque b. It is important to use the correct torque

Table 11-1 Torque Wrench Ranges and Requirements

Torque Range Torque Wrench Capacity

Table 11-3 Torque Values for Engine Plugs and Unions

Hose Aluminum Female Steel Female Sealing

Dash No. Threads Torque

Figure 11-1 Tightening Sequence for Threaded Fasteners

11-3.4.1 Tightening Procedures e. Washers are installed beneath the part

a. If possible, tighten at a uniformly g. Torque values specified in this manual

Figure 11-2 Torque Wrench Correction Factor Determination

11-3.4.2 Running Torque 11-3.4.4 Standard Torque

Prior to retightening, examine the fastener

Figure 11-3 Universal Fittings Installation

Figure 11-4 Tri-Wing Fastener Drive

11-3.5 Tri-Wing Fasteners 11-3.5.1 Installation

Table 11-7 Tri-Wing Drivers and Standard- 11-3.6 Marking of Parts

(2) Immediately following the marking • Dykem Steel Blue DX100

e. Lead- and sulfur-containing materials • GE gas turbines use special locking

• Chalk 11-3.7.1 Safety-Wiring General

• March Stencil Ink • Safety wire shall consist of two strands

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

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

• The hand operated crimping tool 11-3.8.2 Crimping Tool Verification

11-3.9 Correction of Leaks d. When possible, repack the part for

e. Replace nonserviceable parts and

Figure 11-6. Safety Cable Flex Limits

11-3.11 Jackscrews b. Wrap precision parts and cap or plug all

c. Jackscrews, frequently designed as Pipe fitting

Union d. Roll the packing over the threads into

f. The engine shall not be used as a shelf • Maintain a minimum clearance of

11-3.15 Gaskets and Packing • Mating flanges on tubes shall seal

Figure 11-7 Flexible Coupling Assembly

11-3.17 Hoses b. Fluid fittings shall be tightened

Figure 11-8. Hose Assemblies Installation

Figure 11-9. Factory Preformed Hoses

Figure 11-10. Routing and Clamping Techniques

Figure 11-11. Cushion Clamps Installation

e. If the connector is a locking connector, 11-3.20.1 Preservation

• Corrosion preventive, MIL-C-6529, is a. When it is necessary to chill a bearing in

WARNING Particles from grinding or a. Blending Airfoils.

Figure 11-12. Airfoil Leading Edge Blending

Figure 11-13. Airfoil Defect Measurement

(3) Power-blending of rotor blades, close as practical to the original finish

Figure 11-14. Blending and High Metal Removal

11-3.24 Spot-Fluorescent-Penetrant (3) Ultraviolet lamp to detect fluorescent

(2) Hydrophilic Removers: ZR10A or b. Apply penetrant oil with soft-bristle

CAUTION Engine lubricating oil may

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

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