GE90-100 72-00-00 QT define

GE90-100 (GEK109993) ENGINE MANUAL Revision No.
32 Dated 11/01/2015
ESM 72-00-00, INSPECTION 001
ENGINE ASSEMBLY - INSPECTION REQUIREMENTS FOR A LOW-MAINTENANCE WORKSCOPE OR QUICK-TURN ENGINE
* * * FOR ALL
TASK 72-00-00-200-001
1. General.
A. This procedure gives instructions to do an inspection of the engine. It also
defines inspection requirements for a low maintenance workscope or quick-
turn (Q/T) engines. A Q/T and low maintenance workscope is defined as one or
a combination of the conditions that follow:
(1) An engine that has a shop visit for designated service bulletin
activity. There may be more than one service bulletin applied at one
time.
(2) An engine that has limited maintenance activity that results in the
engine being continued time.
(3) Engines that are reworked as specified in TASK 72-00-00-800-802 (72-00-
00, Special Procedures 002) and TASK 72-00-00-800-804 (72-00-00, Special
Procedures 003) for high pressure compressor (HPC) top case or bottom
case removal.
(4) Engines defined as Q/T in a GE Product Support Engineering (PSE)
workscope or Service Bulletin.
NOTE:During these activities the engine will be considered to be continued
time. Continued time is defined as there being no maintenance action
that would result in what was to be the next scheduled shop visit of the
engine being extended.
Example: An engine has heavy maintenance activity (e.g. HPT overhaul) that
results in a scheduled shop visit following the accumulation of
approximately 3500 cycles. After 1000 cycles the engine has minor
maintenance activity in accordance with 72-00-00 low maintenance activity.
The engine is returned to service with the scheduled shop visit to occur in
2500 cycles. Thus, the original intended 3500 cycles between scheduled shop
visit for heavy maintenance is maintained.
B. Engine condition assessment should be accomplished prior to induction to
ensure workscope effectiveness:
(1) Verify that engine performance trends are satisfactory and that the
engine will have adequate performance margin for return to a service
condition.
(2) Verification that the engine has LLP stub life consistent with post
repair goals. Refer to TASK 05-11-00-200-001 (05-11-00, Life Limits
001).
(3) If possible, verify that all engine related fault messages within the
CMC fault history or in the FADEC non-volatile memory (NVM) have been
reviewed and appropriate maintenance action identified for the engine
and parts.
(4) During minor maintenance and quick turn activity soft life thresholds
for modules and accessories may be exceeded
NOTE:TASK 05-22-00-200-001 (05-22-00, Life Limits 001) defines the
manufacturer's engine scheduling and inspection information.
NOTE:Soft life thresholds are those life thresholds published in either the
GE90 Workscope Planning Guide, or the airline or operators approved
customized Repair Specification.
C. Parts and modules examined for the requirements of a low-maintenance
workscope or quick-turn engine must not be assembled to a different engine
GE PROPRIETARY INFORMATION - Not to be used, disclosed to others or reproduced
Date Printed: without the express written consent of GE. Technical data is considered ITAR and/or Page
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is strictly prohibited.
GE90-100 (GEK109993) ENGINE MANUAL Revision No. 32 Dated 11/01/2015
that does not get to the conditions specified as low-maintenance or quick-

turn.
2. Tools, Equipment, and Materials.
NOTE:You can use equivalent alternatives for tools, equipment, and consumable
materials.
A. Tools and Equipment.
(1) Special Tools. None.
(2) Standard Tools and Equipment. None
(3) Locally Manufactured Tools. None.
B. Consumable Materials. None.
C. Referenced Procedures.
ATA No. Description
05-11-00 Life Limits 001
70-42-00 Blending and Removal of High Metal Procedures
72-00-00 Special Procedures 002
72-00-00 Special Procedures 003
72-00-04 Inspection 001
D. Expendable Parts. None.
TASK 72-00-00-200-801
3. Visual Inspection.
Subtask 72-00-00-220-017
A. Borescope inspect as follows:

(1) Deleted.
(2) Borescope inspect the combustor section high pressure turbine section
stage one nozzle leading edge. Refer to AMM TASK 72-00-00-290-804-H01.
(3) Borescope inspect the stage one nozzle (all except leading edge). Refer
to AMM TASK 72-00-00-290-805-H01.
(4) Borescope inspect the high pressure turbine rotor section. Refer to AMM
TASK 72-00-00-290-806-H01.
(5) Deleted.
Subtask 72-00-00-220-018
B. Do a general visual inspection (GVI) of all visible engine parts.

(1) Do a GVI of all parts removed. If you can see defects and are not
addressed in this GVI or an applicable service bulletin, refer to the
aircraft maintenance manual (AMM) module level inspections or piece part
level inspections in the priority order listed.
(2) Do a GVI of all parts not removed but that you can see because of
removal of other engine parts. If you can see defects and are not
addressed in this GVI or an applicable service bulletin, refer to the
AMM module level inspections or piece part level inspections in the
priority order listed.
(3) Do a GVI of all installed and removed control and accessory components
for access. If you can see defects and are not addressed in this GVI or
in an applicable service bulletin, module level inspections, piece part
inspections, or CMM in the priority order listed.
(4) Do a GVI of the visible parts of the fan hub assembly.
(a) Variable bypass valve (VBV) door seals and hood seals.
1 Tears, holes, frayed edges, and missing material. Any amount is
permitted.
(5) Do a GVI of the parts that you can see of the high pressure compressor
(HPC) forward stator.
(a) HPC interstage seal abradable (stage 1 and stage 2).
1 Groove wear in abradable material.
•Serviceable limit: any amount, only if the seals are installed
again in their original position and the seals are not rubbed
into the backing strip (parent material).
(b) Interstage seal (stage 2).
1 Missing abradable material at the end of the interstage seal.
•Serviceable limit: a maximum of 0.59 inch (15.0 mm)
circumferential for the width.
(c) Inner shroud (stage 1 and stage 2) (if the interstage seal is removed
for nonconformity only).
1 Wear on anti-rotation flange with bushing.
•Serviceable limit: any amount.
(d) Inner bushing (stage 1 and stage 2) (only if you get access to it).
1 Wear on the bushing flange face.
2 Unstuck bushing (stage 1 only).
•Serviceable limit: not serviceable.
(e) HPC stage 2 and stage 3 vanes.
1 For nicks, dents, and pits: refer to TASK 72-00-32-200-001 (72-
00-32, Inspection 001).
2 Distortion of the trailing edge at tip of stage 3 vane: any
amount.
(f) HPC forward case assembly.
1 Local scabs on the flow path surface: not serviceable.
2 Missing lever arm pin bushing.
•Serviceable limit: not serviceable.
(g) Partially exposed rotor.
1 Blisk and stage 2 blade tip rubs: any amount.

2 Blisk for erosion on the leading edges.
(h) VSV torsion bar (only if you get access to it).
1 For wear in the turnbuckles and VSV actuator on each clevis.
•Serviceable limit: no more than 0.02 inch (0.50 mm) in depth
after removal of high metal. Refer to TASK 70-42-00-350-002 (70-
42-00, Blending and Removal of High Metal Procedures).
(i) Stage 5-8 stator vane sectors. Refer to Figure 801 for more
guidelines.
1 Inner platform rail (j-hook) crack/missing material.
•Serviceable Limit: not serviceable.
2 Outer platform missing material.
3 Honeycomb cartridge material missing.
4 Honeycomb seal movement.
•Serviceable Limit: any amount.
5 Honeycomb seal groove depth.
•Serviceable Limit: any amount.
6 Tears and cracks on the leading edge and trailing edge of the
airfoil in area A. Refer to Figure 801.
(6) Do a GVI of the parts that you can see of the stage 1 HPT nozzle
assembly.
(a) Stage 1 HPT nozzle missing aft leaf seal clips (clips).
1 Any amount of missing clips or any amount of groups of missing
clips, a maximum of five adjacent clips is permitted. Any group
of four or more missing clips must be apart from other missing
clips by two remaining clips.
(b) Stage 1 HPT nozzle forward leaf seal.
1 Any amount of missing material is permitted.
2 Any amount of cracking is permitted.
(7) Do a GVI of the parts that you can see of the HPT stator.
(a) Stage 2 nozzle.
1 Damaged/worn stage 2 nozzle air guide tube sleeve collars: any
amount is permitted that includes through holes.
2 Any amount is permitted.
3 Cracking from the stage 2 nozzle borescope port.
•Serviceable limit: refer to TASK 72-00-52-200-001 (72-00-52
Inspection 001), Subtask 72-00-52-220-117 (paragraph 3.O.),
Subtask 72-00-52-220-118 (paragraph 3.O.(2)), and Subtask 72-00-
52-220-119 (paragraph 3.O.(3)).
(b) Stage 1 shroud hanger.
1 Leading edge cracking/oxidation: any amount of oxidation is

permitted. Any amount of radial cracks at the shroud hanger hook

is permitted. No circumferential cracking is permitted.
(c) The air guide tube retaining clips: replace with new parts (only if
you get access to it).
(d) Damage/worn air guide tubes (visually examined in location, only if
you get access to it): not permitted, replace air guide tube.
(e) Impingement ring (only if you get access to it).
1 Cracking: any amount is permitted.
2 Wear caused by nozzle contact: any amount is permitted.
3 Localized distortion: any amount is permitted.
4 Damaged/worn impingement ring of the air guide tube sleeve: any
amount is permitted, also through holes.
5 Missing material: permitted to a maximum of 0.150 inch (3.81 mm)
in diameter and missing material area of 0.200 inch (5.08 mm) x
0.300 inch (7.62 mm).
(f) HPT case (only if you get access to it).
1 Missing thermal barrier coating (TBC): any amount is permitted.
2 Internal surface wear caused by air guide tubes: any amount is
permitted.
3 Wear in ports because of the contact by cooling air check valves:
any amount is permitted.
(g) Stage 2 shroud hanger (only if you get access to it).
1 Anti-rotation slot cracking: any amount is permitted.
2 Corrosion/oxidation: any amount is permitted.
3 Baffle cracking: any amount is permitted if there is no missing
material.
4 Baffle dents or bulges: any amount permitted.
NOTE:Stage 1 and stage 2 HPT stator diameter measurements are not
necessary.
(h) Stage 2 shroud (only if you get access to it).
1 Rubs: any amount is permitted.
2 Missing material: none permitted.
3 Surface oxidation/corrosion/craze cracking: any amount.
a A hole through the shroud flowpath surface is not permitted.
4 Missing material from split line oxidation/corrosion: any amount.
a Exposed spline seal slot is permitted.
b Missing spline seal is permitted.
NOTE:The split line region is the end of each shroud to 0.10 inch (2.5
mm) from the end.
(8) Do a GVI of the parts that you can see of the HPT rotor.
(a) Corrosion all rotor hardware: any amount is permitted.
(b) Forward rotating seal teeth coating.
1 If you use the original combustor diffuser nozzle (CDN)/forward
outer seal (FOS)/honeycomb, use the forward rotating seal as is
again.

2 If you replace the original CDN/FOS/honeycomb with a new one or

if you install a different assembly, use the original forward
seal again if it meets the criteria for missing coating. Refer to
TASK 72-00-53-200-001 (72-00-53, Inspection 001), Subtask 72-00-
53-220-057 (paragraph 3.C.(3)).
3 Seal tooth cracking is not permitted.
(c) Interstage seal teeth coating (only if you get access to it).
1 Dented or damaged seal teeth: refer to TASK 72-00-53-200-001 (72-
2 Interstage seal teeth coating.
a If you use the original stage 2 nozzles, use the interstage
seal as is again.
b If you replace the original stage 2 HPT nozzles with new stage
2 HPT nozzles or if you install a different stage 2 HPT nozzle
assembly, then use the original interstage seal again if the
original interstage seal meets inspection criteria for missing
coating. Refer to TASK 72-00-53-200-001 (72-00-53, Inspection
001), Subtask 72-00-53-220-219 (paragraph 3.AL.(3)), and
Subtask 72-00-53-220-220 (paragraph 3.AL.(4)).
4 Missing corrosion coating: any amount is permitted.
(d) Aft rotating seal teeth coating (only if you get access to it).
1 Dented or damaged seal teeth: refer to TASK 72-00-53-200-001 (72-
2 Missing seal teeth coating: any amount is permitted.
(e) Stage 2 blade retainer (only if you get access to it or it is
removed).
1 Oxidation or discoloration: any amount is permitted.
2 Cracking: is not permitted.
(f) Stage 2 disk (only if you get access to it).
1 Dovetail dents: any amount if there is no visual sign of
cracking.
(g) Stage 2 blades (only if you get access to it).
1 Any amount of dovetail dents is permitted if the blade is
installed again in the same stage 2 disk slot.
(h) Stage 1 and stage 2 blade tip diameter measurement is not necessary.
(9) Do a GVI of the parts that you can see of the turbine center frame
(TCF).
(a) TCF case heat shield rivets.
1 Loose or missing rivets: a maximum of four for each heat shield.
(b) Flowpath oxidation.
1 Flowpath oxidation is permitted for module-level TCF assembly.
(c) Loose material inside TCF: any amount is permitted.
(d) Flow path fairings and panels for thermal distress: none permitted.
(e) Stage 1 LPT nozzle.

1 Corrosion: any amount is permitted.

2 Dents/impact damage: any amount is permitted if there is no
missing material or cracking.
(f) Stage 1 nozzle retainer.
1 Cracking: any amount is permitted.
2 Distortion: any amount less than 0.25 inch (6.4 mm) from TCF aft
flange is permitted.
(g) Forward brush seal.
1 Damper panel rivets for looseness: any amount is permitted.
2 Damper panel missing rivets: none permitted.
3 Damper panel cracks: none permitted.
4 Stationary LPT damper forward flange mounting bolts: broken bolts
and/or missing captive nuts are permitted at four locations in
total, if each nonconformity location is apart by a minimum of
three serviceable bolts.
5 The brush seal bristles: refer to TASK 72-54-21-200-001 (72-54-
21, Inspection 001), Subtask 72-54-21-220-051 (paragraph 4.A.).
Replace the brush seal if it is unserviceable.
(h) Rear inner seal tip for rubs: any amount is permitted, if there is no
cracking.
(i) Loose scavenge oil tube heat shield: any amount is permitted.
(j) Air adapters (strut cap).
1 Internal wear: any amount is permitted.
2 Missing or broken check valve flappers: replace the check valve.
(10)Do a GVI of the parts that you can see of the LPT/TRF module.
(a) Stage 1 LPT blade.
1 The stage 1 blade forward angel wing ID surface for:
a Rubs: for maximum serviceable limit. Refer to TASK 72-00-04-
200-001 (72-00-04, Inspection 001), Subtask 72-00-04-220-005
(paragraph 4.K.).
b Deleted.
2 The stage 1 blade forward angel wing OD surface for.
a Rubs: for maximum serviceable limit. Refer to TASK 72-00-04-
200-001 (72-00-04, Inspection 001), Subtask 72-00-04-220-019
(paragraph 4.L.).
(b) Stage 1-6 shrouds.
1 Cracks in the shroud anti-rotation tab braze joint: for maximum
serviceable limits, maximum repairable limits, and repair method.
Refer to TASK 72-56-04-200-001 (72-56-04 Inspection 001), Subtask
72-56-04-220-069 (paragraph 4.G.).
2 Bent edges: any amount is permitted if it does not prevent
correct assembly.
(c) Stage 2-5 nozzle segments.
1 If you find cracks, do an inspection for maximum serviceable
limits, maximum repairable limits, and repair method. Refer to
TASK 72-56-05-200-001 (72-56-05, Inspection 001).
2 Any amount of corrosion is permitted.
3 Nick and dents, do an inspection for maximum serviceable limits,

maximum repairable limits, and repair method. Refer to TASK 72-
56-05-200-001 (72-56-05, Inspection 001).
(d) Do a GVI of the TRF.
1 FPI of the TRF case at the rear mount lug location is not
necessary for quick-turn engines. Refer to TASK 72-00-04-200-001
(72-00-04, Inspection 001), Subtask 72-00-04-230-001 (paragraph
3.A.).
2 Heat shield for cracking: any amount is permitted.
(e) Fan mid shaft.
1 Missing paint and coating: touchup the paint, do an inspection
for maximum serviceable limits, maximum repairable limits, and
repair method. Refer to TASK 72-00-04-200-001 (72-00-04,
Inspection 001), Subtask 72-00-04-220-212 (paragraph 4.AD.).
2 Corrosion on the No. 4 aft seal mounting flange: any amount is
permitted.
3 Oil and coke deposits in the shaft internal diameter (ID): any
amount is permitted.
(f) Do a GVI of the LPT case.
1 The shroud support rings for nicks, scores, scratches, or
fretting: any amount is permitted.
2 The nozzle lockpins of the shroud support rings for wear: any
amount is permitted.
(g) Rotating air seals seal teeth.
1 Chipped or missing aluminum oxide coating: any amount is
permitted if you install it again with the original stationary
seal during assembly.
NOTE:Continued removal of parts (disassembly) is not necessary if the parts
that you can see are in a serviceable condition by visual inspection.
NOTE:A GVI is an inspection check. This is a visual examination of engines,
engine systems, subsystems, components, and/or parts to find structural
failure, deterioration, or damage. The check function determines if
corrective maintenance is necessary. For example, items such as engine
exterior surfaces, rotor and stator assemblies, blades and vanes,
control systems, linkages, accessory components, tubing, electrical
wiring and connections, safety wiring, fasteners, clamps, etc., are
inspected to verify the existence of proper conditions and acceptability
for continued service. Checks are usually done with the engine in the
static state. The check function for the engine is similar to the
periodic visual inspections done on engine airframe combinations.
NOTE:During low maintenance and or Q/T activity, components identified in
TASK 05-21-00-200-001 (05-21-00, Life Limits 001) that become piece part
must have the mandatory inspections performed, unless a service bulletin
applicable to the maintenance performed defines that the mandatory
inspection does not need to be accomplished.

* * * FOR ALL
Figure 801 (Sheet 1) Vane Sectors, Stages 5 thru 8 Inspection Areas

* * * FOR ALL
Figure 801 (Sheet 2) Vane Sectors, Stages 5 thru 8 Inspection Areas

Subtask 72-00-00-220-019
C. Do a general visual inspection of the main fuel pump retention studs.
(1) Inspect retention studs and nuts for security.
Maximum Not serviceable
serviceable
limit:
Maximum Not repairable
repairable
limit:
Repair method: Replace the broken studs. Refer to TASK 72-64-01-300-801
(72-64-01, Repair 003)
TASK 72-00-00-200-802
4. Specific Inspection Procedure for Heavy Maintenance Engines (not applicable to
low workscope or Q/T engines).
Subtask 72-00-00-210-006
A. Do a ground continuity test of the core electrical harnesses at all full
engine shop visits as follows:
(1) Do a ground continuity test of the W721 (05-060, 73-22-80), W722 (05-
110, 73-22-80), W723 (05-150, 73-22-80), W724 (05-190, 73-22-80), W727
(05-280, 73-22-80), W728 (05-290, 73-22-80), W729 (05-320, 73-22-80),
W731 (05-350, 73-22-80), W732 (05-380, 73-22-80), W737 (05-230, 73-22-
80), W738 (05-270, 73-22-80) and W739 (05-410, 73-22-80) electrical
harnesses. Refer to CMM 73-22-98 (GEK 110008).
Subtask 72-00-00-210-007
B. Do a ground continuity test of the fan electrical harnesses at all full
engine shop visits as follows:
(1) Do a ground continuity test of the W701 (01-010, 73-22-80), W702 (01-
150, 73-22-80), W703 (01-030, 73-22-80), W704 (01-110, 73-22-80), W707
(01-150, 73-22-80), W708 (01-130, 73-22-80), W709 (01-070, 73-22-80) and
W719 (01-170, 73-22-80) electrical harnesses. Refer to CMM 73-22-97 (GEK
110009).
Subtask 72-00-00-220-049
C. Engine Accessories installed or removed from the engine.

(1) Do a general visual inspection (GVI) of control and accessory
components, either installed or removed for access. If defects are
observed, refer to the applicable Component Maintenance Manual (CMM) for
serviceability limits.
NOTE:A GVI is an inspection check. This is a visual examination of
engines, engine systems, subsystems, components, and/or parts to
find structural failure, deterioration, or damage. The check
function determines if corrective maintenance is necessary. For
example, items such as engine exterior surfaces, rotor and stator
assemblies, blades and vanes, control systems, linkages, accessory
components, tubing, electrical wiring and connections, safety
wiring, fasteners, clamps, etc., are inspected to verify the
existence of proper conditions and acceptability for continued
service. Checks are usually done with the accessories in the static
state. The check function for the engine is similar to the periodic
visual inspections done on engine airframe combinations.
TASK 72-00-00-200-803
5. Inspection of Temperature Sensor.
Subtask 72-00-00-220-054
A. Do a visual inspection to the oil temperature sensors (15-410, 79-00-00, 45-
060, 79-00-00, 45-150, 79-00-00, 45-260, 79-00-00, and 45-370, 79-00-00)
for:
NOTE:The sensor must be replaced if the above visual inspection check fails.
NOTE:Wear or frettage of the sensor is permitted if no cracks occur.
NOTE:Damage to the flange is permitted if the sensor can be installed into
the engine tubes.
NOTE:Damage to the connector threads is permitted if the sensor can be
connected to the engine electrical harnesses.
(1) Cracks in connector to housing weld.
(2) Cracks in sheath to housing and end cap to sheath braze joints.
(3) Sensor sheath bent.
(4) Connector pad or O-ring torn or missing.

(5) Connector pins bent.

(6) Damaged connector threads.
TASK 72-00-00-200-804
6. Inspection of the Starter Air Valve.
Subtask 72-00-00-220-071
A. Do a visual inspection to the Starter Air Valve (01-060, 80-11-50) for:
NOTE:The Starter Air Valve must be replaced if the above visual inspection check
fails.
NOTE:Wear or frettage of the Starter Air Valve Restrictor housing is permitted
up to 1.50 inches (38.1 mm) in length and 0.100 inch (2.54 mm) in depth.
NOTE:Damage to the connector threads is permitted if the sensor can be connected
to the engine electrical harnesses.
(1) Cracks in housing.
(2) Connector pins damaged or bent.
(3) Damaged connector threads that prevents connection to the engine
electrical harnesses.

* * * FOR ALL
Figure 802 Starter Air Valve - Assembled View


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GE90-100 (GEK109993) ENGINE MANUAL Revision No.

that does not get to the conditions specified as low-maintenance or quick-

A. Borescope inspect as follows:

B. Do a general visual inspection (GVI) of all visible engine parts.

GE PROPRIETARY INFORMATION - Not to be used, disclosed to others or reproduced

1 Blisk and stage 2 blade tip rubs: any amount.

GE PROPRIETARY INFORMATION - Not to be used, disclosed to others or reproduced

permitted. Any amount of radial cracks at the shroud hanger hook

GE PROPRIETARY INFORMATION - Not to be used, disclosed to others or reproduced

2 If you replace the original CDN/FOS/honeycomb with a new one or

GE PROPRIETARY INFORMATION - Not to be used, disclosed to others or reproduced

1 Corrosion: any amount is permitted.

3 Nick and dents, do an inspection for maximum serviceable limits,

GE PROPRIETARY INFORMATION - Not to be used, disclosed to others or reproduced

Figure 801 (Sheet 1) Vane Sectors, Stages 5 thru 8 Inspection Areas

GE PROPRIETARY INFORMATION - Not to be used, disclosed to others or reproduced

Figure 801 (Sheet 2) Vane Sectors, Stages 5 thru 8 Inspection Areas

C. Engine Accessories installed or removed from the engine.

GE PROPRIETARY INFORMATION - Not to be used, disclosed to others or reproduced

(5) Connector pins bent.

GE PROPRIETARY INFORMATION - Not to be used, disclosed to others or reproduced

Figure 802 Starter Air Valve - Assembled View

GE PROPRIETARY INFORMATION - Not to be used, disclosed to others or reproduced

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