ROUTINE

GE Industrial AeroDerivative
Gas Turbines
SERVICE BULLETIN LM2500-IND-0178
Revision 1
January 19, 2004

GE PROPRIETARY INFORMATION

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 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.
The information contained in this document may also be controlled by U.S. export control laws.
Unauthorized export or re-export is prohibited.

Copyright (2004) General Electric Company, U.S.A.

SUBJECT: 9th Stage Air Line Bracket Change

TRANSMITTAL INFORMATION

LM2500-IND-0178, SERVICE BULLETIN REVISION 1

This section transmits Revision 1 to LM2500-IND-0178, dated 19 January 2004.

The purpose of this revision is to revise:

(1) Paragraph I.D. Compliance

Remove Service Bulletin LM2500-IND-0178, dated 17 November 2003, in its entirety, and replace
with Service Bulletin LM2500-IND-0178, Revision 1, dated 19 January 2004.

The revision bars in the left margin indicate actual text changes. Revision bars are not used to
indicate format and sequence changes.

This Service Bulletin is reissued in its entirety.

ROUTINE
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LM2500-IND-0178
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January 19, 2004

I. PLANNING INFORMATION

A. Effectivity

(1) PRODUCTS: LM2500+ DLE Models

(2) ENGINE SERIAL NUMBERS:

LM2500+ DLE gas generators, serial numbers 636-050, 636-051, 636-101

through 636-106, 636-108, 642-101 through 642-147, 642-149 through
642-152, are affected by this Service Bulletin.

LM2500+ DLE gas turbines, serial numbers 559-051, 559-052, 559-101

through 559-116, are affected by this Service Bulletin.

B. Reason

(1) Objective:

This Service Bulletin introduces new 9th stage low pressure turbine (LPT)
cooling support brackets, and improved LPT cooling air manifolds.

(2) Condition/Event(s):

From the field there is evidence of cracking on some 9th stage LPT cooling air
manifolds and manifold brackets.

(3) Cause:

The cracking is believed to be caused by high resonant stress in the 9th stage
air manifold and manifold bracket.

(4) Improvement:

This change reduces the potential for 9th stage air manifold and manifold
bracket cracking, by the introduction of improved 9th stage LPT cooling
support brackets with increased material thickness along with changes
in bracket location

C. Description

This Service Bulletin provides instructions to replace existing LPT cooling air
manifolds and manifold brackets with new design parts.

D. Compliance

Category: Routine (R) Level: Field (F) Timing Code: 6

GE recommends compliance with this Service Bulletin at component part repair

or replacement.

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 LM2500-IND-0178
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E. Manpower

Approximately 4 man-hours are required to accomplish this Service Bulletin

F. Tooling

Special tooling is not required.

G. Material Requirements

(1) The following materials are required to accomplish this Service Bulletin:

Part Number Nomenclature Quantity

9134M25P33 Strap (1)
AS3237-07 Bolt, Machine (4)
J646P19D Bolt, Machine (2)
L42912G01 Manifold, Air-LPT (1)
L42913G01 Manifold, Air-LPT Cooling (1)
L51392G01 Bracket, Support-LPT Cooling (1)
L51393G01 Bracket, Support-LPT Cooling (1)
L51396G01 Bracket, Support-LPT Cooling (1)
L51397G01 Bracket, Support-LPT Cooling (1)
L51408G01 Bracket, LPT Cooling (1)
L51409P01 Bracket, LPT Cooling (1)
9608M08G52 Gasket (2)
9608M08G53 Gasket (2)
9608M08G55 Gasket (1)

The cost and delivery for this material will be quoted upon request or upon
receipt of purchase order submitted to the address on the next page:

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LM2500-IND-0178
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GE Marine and Industrial AeroDerivative Gas Turbines

Mail Drop S-133
One Neumann Way
PO Box 156301
Cincinnati, OH 45215-6301
U.S.A.

Attn: GE Customer Account Manager

Fax: (513) 552-5008

(2) The following consumable materials, which should be available locally, are
required to accomplish this Service Bulletin:

Part Number Nomenclature Quantity

GP460 Thread Lubricant (AR)
(GE Spec A50TF201)
or
MIL-T-5544
736L680G01 Safety Cable (AR)
R297P02 (ALT) Safety Wire (AR)

H. Material Configuration Chart

Old Part Number Nomenclature Qty Action New Part Number Qty
682L572G06 Kit, Fuel System (1) RW 682L572G08 (1)
.J646P17D Bolt, Machine (120) QTC .J646P17D (118)
---------- Bolt, Machine (-) AD .J646P19D (2)
---------- Bracket, LPT (-) AD .L51409P01 (1)
Cooling
L50001G02 Assembly, Gas (1) RW L50001G04 (1)
Generator
.L51264G01 Manifold, Air LPT (1) RE .L42913G01 (1)
Cooling
.L51265G01 Manifold, Air LPT (1) RE .L42912G01 (1)
.L51242G01 Bracket, Support (1) RE .L51392G01 (1)
LPT Cooling

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 LM2500-IND-0178
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Old Part Number Nomenclature Qty Action New Part Number Qty
.L51267G01 Bracket, (1) RE .L51393G01 (1)
Support-LPT
Cooling
.L51220G01 Bracket, Support (1) RE .L51397G01 (1)
LPT Cooling
---------- Bracket, LPT (-) AD .L51408G01 (1)
Cooling
---------- Bolt, Machine (-) AD .AS3237-07 (4)
---------- Strap (-) AD .9134M25P125 (1)
.9134M25P125 Strap (3) QTC .9134M25P125 (1)
---------- Strap (-) AD .9134M25P125 (1)
.9134M25P33 Strap (3) QTC .9134M25P33 (1)
---------- Strap (-) AD .9134M25P33 (1)
---------- Strap (-) AD .9134M25P33 (1)
---------- Strap (-) AD .9134M25P33 (1)
L50001G01 Assembly, Gas (1) RW L50001G05 (1)
Generator
.L51264G01 Manifold, Air LPT (1) RE .L42913G01 (1)
Cooling
.L51265G01 Manifold, Air-LPT (1) RE .L42912G01 (1)
.L51242G01 Bracket, Support (1) RE .L51392G01 (1)
LPT Cooling
.L51267G01 Bracket, Support (1) RE .L51393G01 (1)
LPT Cooling
.L51220G01 Bracket, (1) RE .L51397G01 (1)
Support-LPT
Cooling
---------- Bracket, LPT (-) AD .L51408G01 (1)
Cooling
---------- Bolt, Machine (-) AD .AS3237-07 (4)
---------- Strap (-) AD .9134M25P125 (1)
.9134M25P125 Strap (3) QTC .9134M25P125 (1)
---------- Strap (-) AD .9134M25P125 (1)
.9134M25P33 Strap (3) QTC .9134M25P33 (1)

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LM2500-IND-0178
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Old Part Number Nomenclature Qty Action New Part Number Qty
---------- Strap (-) AD .9134M25P33 (1)
---------- Strap (-) AD .9134M25P33 (1)
---------- Strap (-) AD .9134M25P33 (1)
682L572G05 Kit, Fuel System (1) RW 682L572G09 (1)
.J646P17D Bolt, Machine (120) QTC .J646P17D (118)
---------- Bolt, Machine (-) AD .J646P19D (2)
---------- Bracket, LPT (-) AD .L51409P01 (1)
Cooling
682L572G02 Kit, Fuel System (1) RW 682L572G09 (1)
682L500G01 Kit, Joining (1) RM 682L500G01 (1)
.L51189G01 Bracket, Support (1) RE .L51396G01 (1)
LPT Cooling

OPERATION CODES
AD = Add
QTC = Quantity Change
RE = Replace
REF = Reference
RM = Remains
RW = Rework

I. Material Interchangeability

Physical interchangeability is affected in that the new hardware must be installed as

a complete set.

Functional interchangeability is not affected by this Service Bulletin.

J. Material Disposition

Scrap all replaced hardware.

K. Material Reidentification

Not applicable.

L. References

GEAE internal use only: CID: 705544

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 LM2500-IND-0178
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M. Previous Modifications

None.

II. ACCOMPLISHMENT INSTRUCTIONS

A. Remove LPT cooling air manifolds (11 and 18, figure 1) as follows:

(1) Remove bolts (2) and retaining strap (3) securing LPT cooling air manifold (1)
to LPT cooling air manifold bracket (4). Retain bolts and strap for reuse.

(2) Remove bolts (8) and retaining strap (9) securing LPT cooling air manifold (11)
to LPT cooling air manifold bracket (10). Retain bolts and strap for reuse.

(3) Remove bolts (5), gasket (6), and self-locking nuts (7). Discard gasket (6).
Retain bolts and nuts for reuse.

(4) Remove bolts (12), gaskets (13), and self-locking nuts (14). Discard LPT
cooling air manifold (11) and gaskets (13). Retain bolts and nuts for reuse.

(5) Remove bolts (15) and retaining strap (16) securing LPT cooling
air manifold (18) to LPT cooling air manifold bracket (17). Retain bolts and
strap for reuse.

(6) Remove bolts (22) and retaining strap (23) securing LPT cooling
air manifold (18) to LPT cooling air manifold bracket (24). Retain bolts and
strap for reuse.

(7) Remove bolts (19), gaskets (20), and self-locking nuts (21). Discard LPT
cooling air manifold (18) and gaskets (20). Retain bolts and nuts for reuse.

B. Replace LPT cooling air manifold bracket as follows:

(1) Remove bolts (2, figure 2) and self-locking nuts (3) securing LPT
cooling air manifold bracket (1) to forward side of HPC aft flange.
Discard bracket (1). Retain bolts and nuts for reuse.

(2) Lightly coat threads and friction face of bolts, PN 9673M86P03 (2),
removed in previous step with thread lubricant. Using bolts (2),
bolthead forward and self-locking nuts (3) secure new LPT cooling
support bracket, PN L51396G01 (4), to forward side of HPC aft flange.
Tighten nuts (3) to 380-420 lb in. (43.0-47.5 N.m) of torque.

C. Replace LPT cooling air manifold bracket as follows:

(1) Remove bolts (2, figure 3) and self-locking nuts (3) securing LPT cooling air
manifold bracket (1) to aft side of CRF forward flange. Discard bracket (1).
Retain bolts and nuts for reuse.

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LM2500-IND-0178
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Left Side 9th Stage LPT Cooling Air Manifold Removal/Installation

Figure 1

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 LM2500-IND-0178
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HPC Aft Flange LPT Cooling Air Manifold Bracket Removal/Installation

Figure 2

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CRF Forward Flange LPT Cooling Air Manifold Bracket Removal/Installation

Figure 3

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 LM2500-IND-0178
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(2) Lightly coat threads and friction face of bolts, PN AS3580-5-26 (2),
removed in previous step with thread lubricant. Using bolts (2),
bolthead forward and self-locking nuts (3) secure new LPT cooling
support bracket, PN L51392G01 (4), to aft side of CRF forward flange.
Tighten nuts to 209-231 lb in. (23.6-26.1 N·m) of torque.

D. Replace LPT cooling air manifold bracket as follows:

(1) Remove bolts (2, figure 4) securing LPT cooling air manifold bracket (1) to
aft side of extended flange bracket (3). Discard bracket (1). Retain bolts
for reuse.

(2) Lightly coat threads and friction face of bolts, PN MS9557-23 (2), removed
in previous step with thread lubricant. Using bolts (2), bolthead aft, secure
new LPT cooling support bracket, PN L51393G01 (4), to aft side of extended
flange bracket (3). Tighten bolts finger-tight.

E. Replace bracket as follows:

(1) Remove bolts (2, figure 5) and self-locking nuts (3) securing bracket (1) to
forward side of CRF aft flange. Discard bracket (1). Retain bolts and nuts
for reuse.

(2) Lightly coat threads and friction face of bolts, PN J815P054A (2), removed
in previous step with thread lubricant. Using bolts (2), bolthead forward
and self-locking nuts (3) secure new LPT cooling support bracket,
PN L51397G01 (4), to forward side of CRF aft flange. Tighten bolts finger-tight.

F. Install LPT cooling bracket as follows:

NOTE
Fuel hose assemblies run clockwise (CW). The No.1 location is the first fuel hose
assembly to the right of 12:00 o’clock position, aft looking forward.

(1) Locate fuel hose assembly 26 and 27, (figure 6).

(2) Remove bolts (2, Detail A) from fuel hose assembly 26 and 27. Discard bolts.

(3) Lightly coat threads and friction face of new bolts, PN J646P19D (2),
with thread lubricant. Using bolts (2) install new LPT cooling bracket,
PN L51409P01 (1), between Fuel hose assembly 26 and 27. Ensure tab of
bracket (1) is aft. Tighten bolts finger-tight.

G. Install LPT cooling bracket as follows (figure 7):

(1) Lightly coat threads and friction face of new bolts, PN AS3237-07 (2),
with thread lubricant. Using bolts (2) install new LPT cooling bracket,
PN L51408G01 (3), to LPT cooling bracket (1). Tighten bolts finger-tight.

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LM2500-IND-0178
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CRF Aft Outer Case Forward Flange LPT Cooling Air Manifold Bracket Removal/Installation
Figure 4

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 LM2500-IND-0178
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CRF Aft Flange LPT Cooling Air Manifold Bracket Removal/Installation

Figure 5

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LM2500-IND-0178
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Fuel System Kit 682L572, LPT Cooling Bracket Installation

Figure 6

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 LM2500-IND-0178
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LPT Cooling Bracket and Hardware Installation

Figure 7

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H. Install LPT cooling air manifold (11 and 18, figure 1) as follows:

(1) Position new LPT cooling air manifold, PN L42912G01 (18), in same position
as manifold removed in step A. (7). Lightly coat threads and friction face of
bolts, PN AS3237-16 (19), with thread lubricant. Using bolts (19), self-locking
nuts (21), removed in step A. (7), and new gaskets, PN 9608M08G52 (20),
secure aft flange of manifold (18), two places. Tighten bolts finger-tight.

(2) Position new LPT cooling air manifold, PN L42913G01 (11), in same position
as manifold removed in step A.(4). Lightly coat threads and friction face of
bolts, PN AS3237-16 (12) and AS3238-14 (5) with thread lubricant. Using
bolts (12), self-locking nuts (14), removed in step A.(4), and new gaskets,
PN 9608M08G53 (13), secure aft flange of manifold (11), two places. Using
bolts (5), self-locking nuts (7), removed in step A.(3), and new gasket,
PN 9608M08G55 (6), secure forward flange of manifold (11). Tighten all
bolts finger-tight.

(3) Lightly coat threads and friction face of bolts, PN AS3237-10 (22), with thread
lubricant. Using bolts (22), and retaining strap, PN 9134M25P125 (23),
removed in step A.(6), lightly secure LPT cooling manifold (18), to LPT cooling
support bracket installed in step E.(2). Tighten bolts finger-tight.

(4) Lightly coat threads and friction face of bolts, PN AS3237-10 (15), with thread
lubricant. Using bolts (15), and retaining strap, PN 9134M25P125 (16),
removed in step A.(5), lightly secure LPT cooling manifold (18), to LPT cooling
support bracket installed in step D.(2). Tighten bolts finger-tight.

(5) Lightly coat threads and friction face of new bolts, PN AS3237-07 (4, figure 7),
with thread lubricant. Using bolts (4), and new retaining strap,
PN 9134M25P33 (5), lightly secure LPT cooling air manifold (6), to LPT
cooling bracket (3), installed in step G.(1). Tighten bolts finger-tight.

(6) Lightly coat threads and friction face of bolts, PN AS3237-10 (8, figure 1), with
thread lubricant. Using bolts (8), and retaining strap, PN 9134M25P33 (9),
removed in step A.(2), lightly secure LPT cooling manifold (11), to LPT cooling
support bracket installed in step C.(2). Tighten bolts finger-tight.

(7) Lightly coat threads and friction face of bolts, PN AS3237-10 (2), with thread
lubricant. Using bolts (2), and retaining strap, PN 9134M25P125 (3), removed
in step A.(1), lightly secure LPT cooling manifold (1), to LPT cooling support
bracket installed in step B.(2). Tighten bolts finger-tight.

(8) Tighten self-locking nuts (14 and 21) to 55-70 lb in. (6.2-7.9 N.m) of torque.

(9) Tighten self-locking nuts (7) to 100-130 lb in. (11.3-14.7 N.m) of torque.

(10) Tighten self-locking nuts (3, figure 3) to 210-230 lb in. (23.7-26.0 N.m)
of torque.

(11) Tighten bolts (2, figure 4) to 62-68 lb in. (7.0-7.7 N.m) of torque.

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(12) Tighten self-locking nuts (3, figure 5) to 162-178 lb in. (18.3-20.1 N.m)
of torque.

(13) Tighten bolts (2, figure 6) as follows:

(a) Tighten bolts to 100 lb in. (11.3 N.m) of torque.

(b) Tighten bolts to 20 lb ft. (27.1 N.m) of torque.

(c) Tighten bolts to 32-35 lb ft. (43.4-47.5 N.m) of torque.

(d) Safety-wire bolt to existing bolt on fuel hose assembly.

(e) Ensure safety-wire is not applied from one fuel hose assembly to
another fuel hose assembly.

(14) Tighten bolts (2, figure 7) to 55-70 lb in. (6.3-7.9 N.m) of torque.

(15) Tighten bolts (2, 8, 15, and 22, figure 1) to 55-70 lb in. (6.3-7.9 N.m) of torque.

(16) Tighten bolts (4, figure 7) to 55-70 lb in. (6.3-7.9 N.m) of torque.

III. COMPLIANCE RECORD

Compliance with this Service Bulletin must be entered in local records. The attached
Service Bulletin Compliance Record form must be completed and returned to the address
indicated on the compliance form.

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LM2500-IND-0178
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9th Stage Air Line Bracket Change

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