LM6000 PA
GE Marine & Industrial Engines
CHAPTER 11
Maintenance Considerations
11-1. Purpose and Scope
This chapter covers basic maintenance and
inspection practices and procedures to be
followed during maintenance operations.
11-2. Levels of Maintenance
The workscope for level 1 corrective
maintenance allows replacement of external
parts, adjustments, and other work (preventive
and corrective) up to and including removal
and replacement of the entire engine.
The workscope for level 2 corrective
maintenance permits the replacement of major
engine sections (modules) and the
replacement or repair of certain internal parts.
Level 2 maintenance is performed on-site on a
noninstalled engine or on an installed engine
in the enclosure, as permitted by the enclosure
design. Maintenance is performed with the
engine horizontal. See Volume II.
11-3. Standard Maintenance
Practices
GEK 98493
Volume I
11-3.1 Points of Reference
The following points of reference are used
throughout this manual: forward, aft, right,
left, top, bottom, and clock position. These
points of reference are defined as follows:
Forward - the air intake end of the engine
Aft - the turbine end of the engine
Right - the right side of the engine when
viewed from the aft end and when the engine
is in the normal operating position (gearbox
down)
Left - the side opposite the right side
Top - the side of the engine that is up when
the engine is in the normal operating position
Bottom - the side of the engine on which the
gearboxes are mounted
Clock Positions - the positions of the
numbers on a clock face as seen from aft,
looking forward. The 12:00 o’clock position
is at the top, 3:00 o’clock is on the right side,
6:00 o’clock is at the bottom, and 9:00
o’clock is on the left side.
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Volume I
11-3.2 Maintenance Within
an Enclosure
WARNING
• The following steps must be performed
before entering the enclosure. These
conditions must be maintained while
inside the enclosure to prevent injury to
personnel.
• The fire extinguishing system must be
deactivated before personnel enter the
enclosure. Suffocation can occur if the
fire extinguishing system is activated.
CAUTION All hardware items have been
manufactured to English measurement
units. Use of substitute metric sizes is not
recommended and will void the warranty for
interfacing parts. Tools in metric sizes
should be furnished with suitable adapters to
mate with English measurement unit sizes
given. Limits, fits, and clearances may be
interpreted in either English or metric units,
as shown in the tables.
NOTE Most of the tasks outlined can be
done within the enclosure if the horizontal
maintenance option is selected, provided that
tooling is available. Deviations from the
procedures in the Volume II work packages
are permitted as necessary to adapt to the
needs dictated by the enclosure design,
provided that these deviations do not
compromise the intent of the instruction.
Some modular change-out may be done within
the enclosure and some outside, whichever is
more convenient. Consult the packager for
planning assistance when questions arise.
Observe all safety precautions listed below, as
well as those listed in Chapters 1 and 8.
a. Wear protective clothing, gloves, safety
glasses, etc. as required by the
maintenance to be performed.
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LM6000 PA
GE Marine & Industrial Engines
b. Ensure the engine will not be started while
personnel are inside the enclosure.
c. Post an observer at the exit while
maintenance is being performed inside the
enclosure.
WARNING Electrical power to system on
which maintenance is being performed
must be turned off to prevent arcing and
possible injury to personnel or damage to
components. Tag the switch “Out of
Service for Maintenance” to prevent
inadvertent activation.
d. Turn off all electrical power, liquid, and
air service to system on which
maintenance is to be performed. Allow
the engine to cool.
e. The following steps must be performed
upon exiting the enclosure after
completion of maintenance:
(1) Ensure no personnel are inside the
enclosure.
(2) Close the enclosure door.
(3) Remove tag and turn on electrical
power, and liquid and air services.
11-3.3 Electrical Bonding Straps
Electrical bonding strap contact surfaces shall
be prepared by removing all anoxic film,
grease, paint, lacquer, or other high-resistance
material from an area at least one and one-half
times the bonding surface contact area.
Bonds shall be installed and contact surfaces
sealed within 4 hours of cleaning. The area
shall then be painted to match the surrounding
area.
LM6000 PA GEK 98493
GE Marine & Industrial Engines Volume I

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

In these maintenance procedures, it is
assumed that all threaded parts on the engine
will be tightened to a specific torque value.
Special torque values, if required, will be
stated in the text; otherwise, standard torque
values should be used.
a. Torque values are expressed in lb in.
(pound-inches) or lb ft (pound-feet). One
pound-inch (or one pound-foot) is the
twisting force of one pound applied to a
twist-type fastener (such as a bolt or nut)
with 1 inch (or one foot) of leverage. This
twisting force is applied to the fastener to
secure the components.
wrench for the amount of torque being
applied. See table 11-1 for torque wrench
ranges and requirements.
CAUTION If torque should increase
significantly prior to final seating of any
threaded fastener, remove and inspect the
fastener for the cause of the torque increase.
c. Never over-torque any fastener. Torque
limits are provided in the text and in
tables 11-2 through 11-5; these limits
must be observed. Refer to paragraph
11-3.4.4 for application information.
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 N
m) 0 - 30 lb in. (0 - 3.4 N
m)
25 - 140 lb in. (2.8 - 15.8 N
m) 0 - 150 lb in. (0 - 16.8 N
m)
140 - 550 lb in. (15.8 - 62.1 N
m) 0 -600 lb in. (0 - 67.2 N
m)
30 - 140 lb ft (40.7 - 190 N
m) 0 - 150 lb ft (0 - 203 N
m)
140 - 240 lb ft (190 - 325 N
m) 0 - 250 lb ft (0 - 339 N
m)
240 - 1000 lb ft (325 - 1356 N
m) 0 - 1000 lb ft (0 - 1356 N
m)

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GEK 98493 LM6000 PA
Volume I GE Marine & Industrial Engines

Table 11-2 Torque Values for Steel Bolts, Nuts, and Self-Locking Nuts

Torque Value
Size Threads Per Inch lb in. N
m
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 N
m)
3/16 3 90-100 lb in. (10.2-11.3 N
m)
1/4 4 135-150 lb in. (15.3-16.9 N
m)
5/16 5 155-175 lb in. (17.5-19.8 N
m)
3/8 6 180-200 lb in. (20.3-22.6 N
m)
1/2 8 270-300 lb in. (30.5-33.9 N
m)
5/8 10 360-400 lb in. (40.7-45.2 N
m)
3/4 12 45-50 lb ft (61.0-67.8 N
m)
1 16 58-70 lb ft (78.6-94.9 N
m)
1-1/4 20 75-87 lb ft (102-118 N
m)
1-1/2 24 83-100 lb ft (113-136 N
m)

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LM6000 PA GEK 98493
GE Marine & Industrial Engines Volume I

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. N
m lb in. N
m
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 N
m 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.

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GEK 98493 LM6000 PA
Volume I GE Marine & Industrial Engines

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 N
m
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

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LM6000 PA
GE Marine & Industrial Engines
11-3.4.1 Tightening Procedures
CAUTION When chilling or heating an
engine part during assembly, do not torque
spanner nuts, locknuts, or retaining bolts
until the part has returned to room
temperature. The fastener may loosen as
the part cools or may be overstressed as the
part warms and expands.
a. If possible, tighten at a uniformly
increasing rate until the desired torque is
obtained. In cases where gaskets or
other parts cause a slow permanent set,
be sure to hold the torque at the desired
value until the material is seated.
b. Apply uniform torque to a series of bolts
that have different diameters and are
installed on one flange or in one area.
Torque shall be less than the final torque
required for the smallest diameter bolt.
This prevents shearing or breaking of
tight bolts due to force concentrations.
c. It is not desirable to tighten to the final
torque value during the first drawdown;
uneven tension can cause distortion or
overstressing of parts. Torque mating
parts by tightening the bolts or nuts
gradually until the parts are firmly
seated. Loosen each fastener by one-
quarter turn, then apply final tightening.
Tightening in a diametrically opposite
(staggered) sequence is desirable in most
cases (figure 11-1). Do not exceed
listed maximum torque values.
d. All bolts are installed with heads
forward and up with nuts aft and down,
unless otherwise specified.
GEK 98493
Volume I
e. Washers are installed beneath the part
that turns when tightening, unless
otherwise specified.
f. The torque wrenches listed in table 11-1
are recommended for use within the
indicated ranges. Larger wrenches have
too great a tolerance and can result in
inaccuracies.
g. Torque values specified in this manual
are actual values to be applied to
fasteners. Whenever an adapter
(crowfoot, spanner wrench, etc.) is used
with a torque wrench, torque must be
calculated per figure 11-2.
h. Inspect all nuts and bolts after tightening
to make sure they are seated. If any nut
or bolt is not seated after the required
torque has been applied, remove and
inspect for thread damage.
i. Lubricate tube/hose connector threads
and between the B-nut and ferrule of a
connector. Run B-nuts onto fittings by
hand to ensure that tubes and hoses are
aligned and threads are free of burrs.
Two wrenches must be used when
loosening or tightening B-nuts, one on
the fitting to which the tube or hose is
being connected to hold it stationary and
one on the B-nut for torquing. This not
only prevents twisting the tube, but also
prevents loosening or over-tightening the
fitting. When using an extension on a
torque wrench, calculate the correct
torque input before applying torque per
figure 11-2.
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GEK 98493 LM6000 PA
Volume I GE Marine & Industrial Engines

Figure 11-2 Torque Wrench Correction Factor Determination

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LM6000 PA GEK 98493
GE Marine & Industrial Engines Volume I

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. N
m
(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.

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GEK 98493 LM6000 PA
Volume I GE Marine & Industrial Engines

Figure 11-3 Universal Fittings Installation

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LM6000 PA
GE Marine & Industrial Engines
Figure 11-4 Tri-Wing Fastener Drive
11-3.5 Tri-Wing Fasteners
Tri-wing recessed-head fasteners are
available in a wide range of sizes, and each
size requires the use of a matched driver.
See figure 11-4. When properly used, the
tri-wing design permits a higher ratio of
torque to end-pressure than is possible with
slotted-head or cross-head designs,
minimizing burring and mutilation. The
following procedures should be used for tri-
wing fasteners.
GEK 98493
Volume I
11-3.5.1 Installation
a. Select the correct driver. The driver
number should match the recess number
of the fastener head as shown in figure
11-4. Table 11-7 lists a range of
standard fastener sizes with their
corresponding tri-wing recess identifi-
cation numbers.
b. Ensure the axis of the drive is aligned
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.
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GEK 98493 LM6000 PA
Volume I GE Marine & Industrial Engines

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.

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LM6000 PA
GE Marine & Industrial Engines
(2) Immediately following the marking
operations, all chemicals remaining on
the part shall be neutralized and
flushed, and, on corrodible materials,
a corrosion-preventive treatment
compatible with the base metal shall
be applied.
(3) When marking is applied to premium
quality material, as defined in the
applicable material specification, it
must be ensured that the marking
process is not capable of producing
any evidence of intergranular attack in
the base metal, when inspected at
400X magnification.
CAUTION Grease or lead (graphite)
pencils must not be used to mark
combustion-section or hot-section parts.
These materials plus heat can cause parts
material damage.
e. Lead- and sulfur-containing materials
should not be used for marking any
parts. Preferred materials are listed
below:
• Sharpie T.E.C.
• Chalk
• Dykem - red, yellow, black
• Ink - Justrite Slink Black; Marco S-
1141, black
• March Stencil Ink
• Carters Marks-A-Lot - black
• Carters Marks-A-Lot - blue
• Dixon - black
• Dixon - yellow
GEK 98493
Volume I
• Dykem Steel Blue DX100
• Soapstone
11-3.7 Safety-Wiring
Safety-wiring is the securing of two or more
parts with a wire installed in such a manner
that any tendency for a part to loosen will be
counteracted by additional tightening of the
wire. This is not a means for obtaining or
maintaining torque, but rather a safety
device used to prevent the disengagement of
parts. See figure 11-5 for general safety-
wiring practices.
NOTE
• Although not every possible combination
of safety-wiring is shown in figure 11-5,
all safety-wiring must, in general,
correspond to the examples shown.
• GE gas turbines use special locking
cables at some locations. When removed
for maintenance, these should be
replaced with equivalent cables or safety
wire using standard safety-wiring
procedures in this chapter.
11-3.7.1 Safety-Wiring General
Practices
The following rules for safety-wiring shall
be observed, unless specific instructions to
the contrary are given in the text.
• Safety wire shall consist of two strands
of wire twisted together (so called
double-twist method), where one twist is
defined as being produced by twisting
the strands through an arc of 180°,
equivalent to half a complete turn. Use
the single-strand method only when
specified.
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Figure 11-5 Safety-Wiring Practices (Sheet 1 of 2)

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GE Marine & Industrial Engines Volume I

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

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GEK 98493
Volume I
• Safety wire shall not be installed in a
manner to cause the wire to be subjected
to chafing, fatigue through vibration, or
additional tension other than the tension
imposed on the wire to prevent
loosening.
• In all cases, safety-wiring must be done
through the holes provided. If no wire
hole is provided, safety-wiring shall be
to a neighboring part in a manner not to
interfere with the function of the parts
and in accordance with the basic
principles described.
• The maximum span of safety wire
between tension points shall be 6 inches
(152 mm), unless otherwise specified.
Where multiple groups are safety-wired
either by the double-twist or the single-
strand method, the maximum number in
a series shall be determined by the
number of units that can be safety-wired
with a 24-inch (610 mm) length of wire.
When safety-wiring widely spaced
multiple groups with the double-twist
method, the maximum number in a
series shall be three units.
• Both 0.020-inch (0.51 mm) and 0.032-
inch (0.81 mm) safety wires are used
throughout the engine. The application
is determined by the size of the hole in
the unit to be safety-wired. Whenever
possible, use the 0.032 inch (0.813 mm)
safety wire. Only new safety wire shall
be used in each application.
• The safety wire shall be pulled taut while
being twisted, and shall have 9 to 12
twists per inch (25 mm) for 0.020 inch
(0.51 mm) diameter wire and 7 to 10
twists per inch for 0.032 inch (0.81 mm)
diameter wire.
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LM6000 PA
GE Marine & Industrial Engines
• Hose and electrical coupling nuts shall
be safety-wired in the same manner as
tube coupling nuts.
• Caution must be exercised while
twisting to keep the wire tight without
overstressing it or allowing it to become
nicked, kinked, or otherwise mutilated.
• Only existing safety wire should be
replaced; do not add safety wire which
was not previously in place or specified
in text.
• When removing safety wire, identify
safety-wiring holes on parts.
11-3.7.2 Safety Wire Installation
The following safety-wiring procedures are
to be used throughout the engine:
a. Insert the safety wire through the first
part and bend the upper end either over
the head of the part or around it. If bent
around it, the direction of wrap and twist
of the strands shall be such that the loop
around the part comes under the strand
protruding from the hole. Done this
way, the loop will not tend to slip
upward and become slack.
b. Twist the strands while taut until the
twisted portion is just short of the
nearest hole in the next part. The twisted
portion should be within 1/8 inch (3.2
mm) of the hole in each part.
c. If the free strand is to be bent around the
head of the second part, insert the upper
strand through the hole in this part, then
repeat the previous step. If the free
strand is to be bent over the unit, the
direction of twist is unimportant. If
there are more than two units in the
series, repeat the preceding steps.
LM6000 PA GEK 98493
GE Marine & Industrial Engines Volume I

d. After wiring the last part, continue
twisting the wire to form a pigtail of
three to eight twists (1/4-1/2 inch [6-13
mm] long) and cut off the excess wire.
Bend the pigtail inward toward the part
in such a manner as to prevent it from
becoming a hazard to personnel.
WARNING Use extreme caution in
monitoring the safe and complete removal
of all excess safety wire. Care must be
taken when cutting off the ends of
installed wire to ensure complete retrieval
in order to prevent injury 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.

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• The hand operated crimping tool
operates in one direction only and has a
cycle end dead stop to tell the operator
when the ferrule is fully crimped. The
crimping pressure of the tool is set by
the manufacturer. If necessary, the
crimping pressure can be adjusted with
standard hand tools. The Snap-On tool
has a spring-loaded crimp rod to hold the
ferrule in place during the crimping
procedure. Cable tension is done
automatically by the internal retraction
mechanism.
• Where possible, install the safety cable
so it does not touch other parts.
• Make sure the cable is not damaged or
bent when installing safety cable through
the holes in the fastener or part. Frayed
cable assemblies are not permitted.
• Install the safety cable through existing
holes only.
• Unless specified differently in the
packager’s manual:
The maximum length of the safety cable
between safety cabled parts is 6.0 inches
(152.4 mm).
No more than three bolts can be safely
tied with one safety cable.
Safety cable can not be used on titanium
fasteners.
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GE Marine & Industrial Engines
11-3.8.2 Crimping Tool Verification
Do a pulloff load test as necessary to make
sure the crimp done by the crimping tool
meets the necessary requirements. GE
Aircraft Engines recommends the pulloff
load test be done at the beginning, middle,
and end of each shift. Refer to
manufacturer’s instructions for pulloff load
test procedure.
11-3.8.3 Safety Cable Installation
a. Do a visual inspection of the holes to be
safety cabled to find all damage. If the
hole is damaged, replace the part, or if
possible, use another hole to safety
cable.
NOTE Keep the safety cable as straight as
possible when you safety cable the fasteners
or parts together.
b. Put the end of the cable without the
cable end fitting into the hole in the part.
Pull the cable through the hole until the
cable end fitting is against the part.
c. Insert the end of the cable through the
second part. Choose the hole in the part
that permits the cable to be as straight as
possible. Pull the cable through the
second part. If three parts must be safety
cabled, do the same procedure for the
third part.
LM6000 PA
GE Marine & Industrial Engines
NOTE On a two bolt pattern, do not cable
in a negative pull direction. Make sure the
cable has a positive or neutral pull.
d. Put the end of the safety cable coming
out of the last part to be safety cabled
through a ferrule in the ferrule magazine.
Pull the safety cable through the ferrule
and use the safety cable to pull the
ferrule out of the ferrule magazine.
e. Put the end of the safety cable through
the crimping head of the crimping tool.
Make sure the large hole in the crimping
head is on the same side as the ferrule.
Move the crimping tool along the safety
cable until the crimping head is against
the ferrule. Pull back on the retraction
knob. Put the ferrule in the crimping
head and release the retraction knob.
Make sure the ferrule is fully in the
crimping head.
CAUTION Do not put too much tension
on the safety cable. The crimping tool will
automatically set the tension. Too much
tension will break the safety cable.
f. Pull the safety cable to the tension post
on the crimping tool. Wrap the cable
completely around the post. Make sure
the cable is in the groove at the top of
the post. Pull the cable toward the drive
handle until the cable goes behind the
locking ball.
g. Hold the crimping tool perpendicular to
the cable in the bolt head. Make sure the
ferrule is tightly against the bolt head.
Lightly pull on the end of the safety
cable to remove slack.
GEK 98493
Volume I
h. Push the start cycle button and turn the
drive handle clockwise. At the start of
the cycle, the tension block will move
backwards. This movement backwards
provides the cable tension. When the
drive handle is turned, release the start
cycle button. Turn the drive handle until
it stops (approximately two full turns).
i. Pull up on the safety cable end to
remove it from the tension block.
j. Pull back on the retraction knob and
remove the crimping tool from the
crimped ferrule and the remaining safety
cable.
k. Cut the unused safety cable even with
the crimped ferrule. Use the side
cushioned cutters. Discard the unused
safety cable.
l. Visually inspect safety cable for kinks,
frayed wires, or improper crimps.
Remove and replace safety cable if a
problem exists.
m. Push against the safety cable with light
finger pressure halfway between the
safety cabled parts. If the cable feels
loose, do a dimensional check to make
sure the safety cable is serviceable as
follows (see figure 11-6):
(1) Measure the distance between the
safety cabled parts. Write this
measurement down as Dimension A.
If three parts are safety cabled
together, measure the distance
between each of the parts and add the
two measurements together to get
Dimension A.
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GEK 98493
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(2) Push against the safety cable with
light finger pressure halfway between
two safety cabled parts. Measure the
distance the safety cable moves
laterally. Write this measurement
down as Dimension C.
(3) Compare the dimensions that were
written down to the limits given in
figure 11-6.
CAUTION Do not try to break the safety
cable. If the safety cable must be removed,
cut the safety cable to avoid damage to the
holes in the parts.
n. If the safety cable is not in the limits
given in figure 11-6, cut the safety cable
with wire cutters and remove the
installed safety cable. Install new safety
cable.
11-3.9 Correction of Leaks
CAUTION Do not over-torque threaded
fasteners as a method of correcting leaking
connections. Over-torquing could result in
part failure.
a. Disassemble the connection.
b. Discard the seal, gasket, or packing, if
present.
c. Inspect mating surfaces for
contamination, scratches, dents, or other
surface defects.
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.
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GE Marine & Industrial Engines
11-3.10 Unpacking and Repacking
The following general instructions apply
during unpacking and repacking to minimize
possible part damage and contamination.
a. Initially, remove only that portion of the
packing material necessary to mount the
part. Where possible, remove the
remainder of the packing material,
including protective caps and plugs, one
at a time as each connection (fluid, air,
or electrical) is made.
b. Retain protective caps and plugs and
reusable packing components for
repacking purposes.
c. Install a cap or plug on each connection
(fluid, air, or electrical) as it is
disconnected.
d. When possible, repack the part for
storage or shipment, using the same
packing material in which the
replacement part was received.
e. When original packing components are
not available, use locally available
packing materials and containers to pack
the part. Make sure all ports, openings,
connections, and mating surfaces are
capped or covered, and that the part is
protected from potential handling or
environmental damage.
f. Bearings shall be handled per paragraph
11-3.20 in this chapter.
LM6000 PA GEK 98493
GE Marine & Industrial Engines Volume I

Figure 11-6. Safety Cable Flex Limits

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Volume I
11-3.11 Jackscrews
a. When using jackscrews to remove
components, do not bend flanges or strip
threads. Lubricate jackscrews with
engine lube oil before installing. Turn
jackscrews inward evenly and in small
increments. Always check for and
remove burrs or rough edges before
using jackscrews. If regular bolts are
used as jackscrews, the tips must be
blunt and polished. Do not allow
components to fall free as jackscrews are
tightened.
b. Jackscrew holes are often in flanges that
are only thick enough for three or four
threads. The ends of most standard bolts
are chamfered, and the first couple of
threads are missing or incomplete.
These should not be used as jackscrews
without modification, since only one or
two threads will engage and the threads
in the flange are likely to strip.
c. Jackscrews, frequently designed as
special tools and identified as such, are
not chamfered and full thread
engagement will occur. If specially
manufactured jackscrews are not
available and must be manufactured
locally, be sure that the ends are ground
to remove the chamfer and the
incomplete thread so that the maximum
number of threads may be engaged.
11-3.12 Protective Closures and
Caps
a. Preventing foreign material from lodging
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.
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b. Wrap precision parts and cap or plug all
openings and connections. It is most
important that all engine parts be kept
clean and free of corrosion. All
instructions that specify special handling
of parts must be followed without
exception.
c. Accessories, tubes, and hoses may
contain fuel or oil at the time of removal.
Drain these fluids from the accessory
being removed and cap all connecting
hoses or tubes. Do not use tape.
d. Do not remove plugs, caps, etc., until the
part is ready for assembly. Check both
seating surfaces for removal of plugs,
etc. prior to assembly.
11-3.13 Universal Fittings
Universal fittings should be installed
according to the procedures described below
(figure 11-3).
Pipe fitting
a. Inspect the fitting visually.
b. Clean if necessary.
c. Lubricate mating fittings.
d. Install the fitting, screwing it down to
within one-half turn of final position.
e. Remove the fitting, clean, inspect, and
lubricate the male thread.
f. Reinstall the fitting and screw it down to
its final position.
LM6000 PA
GE Marine & Industrial Engines
Union
a. Lubricate the packing and roll it over the
threads into the groove in the union.
b. Screw the union into the boss until the
packing contacts the surface of the boss.
c. Tighten the union to the proper torque
value.
Bulkhead fitting
a. Lubricate the fitting end. Screw the nut
onto the fitting until the washer face of
the nut is aligned with the upper corner
of the seal groove.
b. Lubricate the packing and roll it over the
threads into the groove in the fitting so
that it contacts the nut.
c. Screw the fitting and nut simultaneously
into the boss until the seal contacts the
chamfer at the face of the boss and the
nut contacts the boss.
d. Position the fitting either by turning in as
much as three-quarters of a turn (270°
clockwise) or turning out as much as
one-quarter turn (90° counterclockwise).
Attach the line to the fitting and check
the alignment of the fitting. Tighten the
nut to the proper torque.
Fittings with backup rings
a. Lubricate the male threads of the fitting,
the backup ring, and the packing.
b. Screw the nut onto the fitting, with the
counterbore side facing the fitting end.
c. Put the backup ring on the fitting and
seat it in the counterbore of the nut, with
its convex side facing the fitting end.
GEK 98493
Volume I
d. Roll the packing over the threads into
the groove in the fitting.
e. Adjust the nut so the backup ring forces
the packing firmly against the lower
threaded portion of the fitting.
f. Screw the fitting and nut simultaneously
into the boss until the packing contacts
the chamfer at the face of the boss.
g. Hold the nut and turn the fitting one-
and-a-half turns into the boss. The
fitting may be positioned further by one
additional turn.
h. Attach the line to the fitting and check
the alignment of the fitting.
i. Hold the fitting and tighten the nut to the
proper torque.
11-3.14 Cleanliness
Cleanliness is important for equipment life
and proper operation. The major cause of
premature engine removal is foreign object
damage (FOD).
a. The enclosure must be kept clean and
free of dirt and loose objects. It is
recommended that small FOD containers
be kept in the work area or in tool boxes.
b. All parts shall be inspected for
cleanliness before being installed.
c. Gaskets and packing shall be free from
dirt, lint, and/or grit.
d. Mating flanges, tube flanges, and
couplings shall be wiped clean to make
sure that a good seal will be obtained.
e. Hands and gloves must be clean when
handling machined surfaces.
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f. The engine shall not be used as a shelf
for holding tools or parts while
maintenance is being performed.
g. After performing any maintenance, the
work area shall be thoroughly inspected
for loose parts, rags, tools, and other
materials. The area shall be cleaned to
remove grit, dust, chips, safety wire, and
other small objects.
11-3.15 Gaskets and Packing
a. Gaskets, packing, key washers, and
cotter pins shall not be reused, unless
otherwise specified.
b. Gaskets and packing shall be lightly
lubricated with engine lube oil prior to
installation, unless otherwise specified.
Ensure parts are properly seated. When
a fitting with a jamnut and packing is
used, see figure 11-3 for the proper
installation procedure. See figure 11-7
for packing used with flexible sleeve
type fittings.
11-3.16 Tubes
When installing tubes, the following
precautions and instructions apply. See
figure 11-7.
a. As tubes are installed, tighten all end
fittings and clamps finger-tight. After a
complete system is installed, torque
clamps first and then end-fittings.
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GE Marine & Industrial Engines
• Maintain a minimum clearance of
0.125 inch (3.2 mm) between tubes
and adjacent parts.
• Tubes and manifolds must fit within
0.063 inch (1.6 mm) radius in a free
state during assembly or be replaced.
• Coupling nuts shall thread freely by
hand.
• Mating flanges on tubes shall seal
flush within 0.005 inch (0.13 mm).
• The distance between faces of
mating surfaces or flanges shall not
exceed 0.063 inch (1.6 mm).
• If tubes are reworked, the bend radii
shall not be less than twice the tube
diameter and the bend angle shall not
be changed by more than 3 degrees.
No kinks or wrinkles are permitted.
• Do not bend tubes at fitting or weld
areas.
• Original bends in a tube may be bent
in the same direction, but reverse
bending is not allowed.
• Bend tubes in existing straight
sections, if possible.
Use bending tools on any tube 1 inch or
more in diameter to prevent the tube from
collapsing.
LM6000 PA GEK 98493
GE Marine & Industrial Engines Volume I

Figure 11-7 Flexible Coupling Assembly

11-25
GEK 98493 LM6000 PA
Volume I GE Marine & Industrial Engines

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.

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LM6000 PA GEK 98493
GE Marine & Industrial Engines Volume I

Figure 11-8. Hose Assemblies Installation

11-27
GEK 98493 LM6000 PA
Volume I GE Marine & Industrial Engines

Figure 11-9. Factory Preformed Hoses

Figure 11-10. Routing and Clamping Techniques

11-28
LM6000 PA
GE Marine & Industrial Engines
Figure 11-11. Cushion Clamps Installation
11-3.19 Electrical Cables and
Connectors
During electrical cable installation, adjust
the cable through the clamps to get the
smoothest and largest radius. Sharp bends,
twists, and kinks must be avoided.
Minimum clearance between the electrical
cable and any component other than hoses or
other electrical cables is 0.125 inch (3.18
mm).
A seal ring is located in the coupling nut of
each electrical connector. Inspect to ensure
the seal is present and serviceable before
attaching the connector. Replace
unserviceable seals as follows:
a. Remove the unserviceable seal.
b. Engage the new seal over the barrel of
the connector.
GEK 98493
Volume I
CAUTION Do not allow the seal to tip
and flatten. An incorrectly installed seal
could affect the usefulness of the seal
and/or connector.
c. Push the seal to its seated position
against the internal shoulder in the
connector using a mating connector or
blunt screwdriver.
CAUTION Do not force the connectors
together. If the pins are not aligned, they
will be bent or distorted and will not make
contact.
d. Inspect electrical connector pins for
straightness before connecting. Insert
the mating cable connector, hand-tighten
the retaining nut, push the mating parts
together until seated, and tighten the
retaining nut as required.
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Volume I
e. If the connector is a locking connector,
engage the connector and wiggle the
backshell while tightening the coupling
ring hand-tight. A clicking sound is
produced during tightening of the
connector. Ensure that the full coupling
color band on the receptacle is not
visible and that the backshell has no
movement.
f. Electrical connectors on flexible
harnesses and leads shall be hand-
tightened beyond finger-tight (20°
maximum) until connecting parts are in
solid contact without damage. Safety-
wire the connectors only when specified
in the procedure.
g. Do not sharply bend, kink, or twist rigid
leads. When tightening the connection,
always hold both mating connectors to
prevent damage to the leads.
11-3.20 Bearing Handling
CAUTION Ball and roller bearings
require special care to prevent corrosion.
Bearings must not be handled with bare
hands nor with any device that might cause
contamination. Clean rubber or nylon
gloves or a protective hand cream shall be
used at all times when handling bearings.
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11-3.20.1 Preservation
WARNING Lubricating oil, MIL-L-
6085, is flammable and toxic to skin, eyes,
and respiratory tract. Skin, eye, and
respiratory protection is required.
At the point where bearings are accessible in
the disassembly cycle, the bearings shall be
thoroughly covered with lubricating oil,
MIL-C-6085.
Use of engine lubricating oil as a lubricant
or preservative is specifically prohibited.
Personnel handling bearings must wear
either synthetic rubber or nylon-mesh gloves
with polyethylene palms and fingers.
WARNING Corrosion preventive, MIL-
C-11796, is flammable and toxic to skin,
eyes, and respiratory tract. Skin, eye, and
respiratory protection is required.
Bearings returned to storage shall be
preserved with corrosion preventive,
MIL-C-11796, Class 3, and wrapped in
barrier paper, MIL-B-121, Grade A, Type 2,
Class 2, glossy side toward bearing.
After installation, bearings shall be returned
to room temperature and be preserved with
lubricating oil, MIL-C-6085.
LM6000 PA
GE Marine & Industrial Engines
11-3.20.2 Heating and Chilling
WARNING
• Corrosion preventive, MIL-C-6529, is
toxic to skin, eyes, and respiratory
tract. Skin, eye, and respiratory
protection is required.
• Dry ice, BB-C-104, is extremely cold
and can cause serious low-
temperature burns. Wear insulated
gloves when handling material.
• Wear insulated gloves to prevent
injury when handling hot parts.
• When using compressed air for
cleaning, cooling, or drying, do not
exceed 30 psig. Wear eye protection
and do not direct compressed air at
self or others.
CAUTION
• Immediately after installing or
removing a chilled bearing, use a heat
gun to restore the bearing and any
adjacent cold area to room temperature
so that condensation of moisture will be
minimized. Check carefully for
evidence of moisture and continue
heating until the bearing is completely
dry. Apply corrosion preventive, MIL-
C-6529, Type III, at once to the bearing
after complete drying.
• When heat is required to relieve shrink
fits of bearings, use heat guns or ovens.
Do not use direct-heat sources to apply
the heat and do not heat the bearings to
a temperature higher than 350°F
(175°C). Apply corrosion preventive,
MIL-C-6529, Type III, to the bearings
before heating and after they have
cooled to room temperature.
GEK 98493
Volume I
NOTE Heating and chilling are defined as
any temperature 10°F (6°C) or more above
or below room temperature.
a. When it is necessary to chill a bearing in
dry ice, coat the bearing thoroughly with
corrosion preventive, MIL-C-6529, Type
III, and place in a plastic bag prior to
chill.
b. Immediately after installation of a
chilled bearing, apply heat with a heat
gun until bearing and adjacent parts are
brought to room temperature. Remove
any moisture using clean, dry shop air,
and coat the bearing with corrosion
preventive, MIL-C-6529, Type III.
c. Heat bearings using ovens or heat guns.
No direct heat source, such as a blow
torch, may be used. When the bearing
returns to room temperature, coat with
corrosion preventive, MIL-C-6529, Type
III.
11-3.21 Spray Shields
Spray shields shall be positioned on tubing
so as to prevent fluid from spraying on the
engine if a leak occurs at the shielded area of
a tube.
11-3.22 Blending
NOTE Refer to specific engine manual
section or service bulletin for blend limits
for the piece part under review. Use the
limits in this procedure only when no
specific limits are specified for the
component in the engine manual or
appropriate service bulletin.
Blending is a repair procedure that is used to
remove stress concentrations caused by
nicks, scratches, or other sharp-edged
damage marks on critical parts. Removal of
the material surrounding the stress
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concentration, so that the sharp edges are
blended into smooth contour, relieves the
stress concentration and permits further use
of the part by lessening the danger of
cracking.
Blending is also used to remove sharp edges
resulting from machining, drilling, etc., and
to restore the original contour and/or surface
finish to parts that have been repaired by
welding, brazing, etc.
11-3.22.1 Blending General
Practices
The following rules for blending shall be
observed, unless specific instructions to the
contrary are given in the text:
CAUTION Do not repair titanium parts
with tools, such as grinding wheels, files,
stones, or emery cloth, that have been used
to repair other types of metal. Damage to
parent metal could occur.
• Defects more than 0.25 inch (6.4 mm)
apart shall be blended separately. Those
less than 0.25 inch (6.4 mm) apart
(except splines) shall be blended
together. Splines that are closer together
than 0.25 inch (6.4 mm) and defects
shall be repaired separately.
• The finish on the blended area must be
as close as possible to the original finish
of the part.
11-3.22.2 Hand Blending
Sharp edges can be blended out using
abrasive stones or papers, files, or crocus
cloth. Coarse grades of abrasives or files
may be used for fast metal removal, but the
parts must then be given a smooth surface
finish with fine grades of abrasives or crocus
cloth.
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WARNING Particles from grinding or
sanding abradable material could be
harmful to eyes and respiratory tract.
Eye and respiratory protection is
required.
NOTE Refer to the inspection and repair
limits for specific instructions on blending
limits applicable to each part of the engine.
a. When blending compressor rotor blades,
stator vanes, turbine blades, and similar
parts, blend in a radial direction in
relation to the engine. Avoid removing
metal from leading and trailing edges of
airfoil sections in such a way that the
edges become thin or sharp; blend so as
to maintain approximately the original
contour.
b. When blending a cylindrical part, blend
in a circumferential direction, not along
the axis of the part.
c. The finish on the blended area shall be
as close to the original finish as possible.
d. When blending on a part involving a
radius, keep the radius as specified in the
repair section. If the radius is not
specified, keep it as close as possible to
the original contour. Refer to a similar
part, if necessary, to determine original
radius.
e. Etch reworked area per paragraph
11-3.23 and inspect by spot fluorescent-
penetrant method, per paragraph
11-3.24, after blending
11-3.22.3 Power Blending
Blending on most parts may be done by
using a power-driven polishing wheel or
rubber-bonded abrasive points, and any
special instructions for the individual part
must be followed.
LM6000 PA
GE Marine & Industrial Engines
WARNING Particles from grinding or
sanding abradable material could be
harmful to eyes and respiratory tract.
Eye and respiratory protection is
required.
CAUTION Power blending of airfoil
sections may be done only when specified
by individual part instructions. When doing
power blending, be sure to avoid building
up excessive heat and resulting thermal
stresses in the part.
NOTE After power blending of a titanium
part is completed, hand-blend the same area
approximately 0.002 inch (0.05 mm) deeper
to remove any residual stresses in the
surface material.
a. Rough out defects using coarse grades of
resilient flexible abrasive impregnated
wheels, brushes, or points. Use fine or
extra fine grades to finish the blend
areas.
b. Follow the requirements described-in
paragraph 11-3.22.2 when doing power
blending.
c. Etch reworked area per paragraph
11-3.23 and inspect by spot fluorescent-
penetrant method, per paragraph
11-3.24, after blending.
11-3.22.4 Component Specific
Requirements
NOTE Requirements in specific engine
manual section or appropriate service
bulletin take precedence over the following
procedures. The requirements in this
section should be used with engine manual
or service bulletin criteria or when no
criteria are specified.
GEK 98493
Volume I
a. Blending Airfoils.
(l) The types of airfoil damage described
below may be repaired by hand
blending or by power blending.
Always refer to applicable part
inspection paragraph for a description
of airfoil defect limits as follows:
(a) Nick
A V-shaped depression in
the airfoil made by a sharp-edge
object pushing the metal inward.
(b) Pit – A round sharp-edged hole
with a rounded bottom caused by
corrosion.
(c) Scratch – A V-shaped line or fur-
row in the airfoil such as would be
made by dragging a sharp object
across the surface.
(d) Dent – A smooth rounded depress-
ion in the airfoil made by impact
with a rounded object. If there is
any noticeable sharp discontinuity
in the depression, it should be
considered as a nick. Waviness of
leading or trailing edges is to be
treated as a dent.
(e) Erosion
A sand- or shot-blasting
effect on the leading edges or the
leading portion of the concave side
caused by sand or dust going
through the engine.
(f) Torn Metal
A separation or pull-
ing apart of material by force,
leaving jagged edges.
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(2) Hand-blending of airfoils may be done
as specified below:
(a) Blending is done to remove stress
caused by nicks, pits, and scratches
to prevent blade failure. Remove
high metal and straighten dents
(where permitted) to restore the
airfoil shape as closely as possible
to its' original aerodynamic contour.
(b) Blending shall be finished with fine
stone or crocus cloth. Coarser tools
may be used for initial removal of
material. Finish blending in a
direction along the length of the
blade or vane and remove all
evidence of marks across the airfoil
that may have been made during
initial blending.
(c) Defects more than 0.25 inch
(6.4 mm) apart shall be blended
separately; those 0.25 inch
(6.4 mm) or less apart may be
blended together. All blends must
have a minimum radius of 0.25 inch
(6.4 mm). The total reduction in
chord width may be taken on either
side or divided between the sides.
The amount of rework is controlled
by the minimum chord width limit.
The minimum allowable chord is
given for root and tip of airfoil, the
minimum chord at other points is
proportional. To minimize the
possibility of an engine stall, keep
the shape of the blended airfoil
leading edge as close as possible to
the original contour (see Figure
11-12).
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LM6000 PA
GE Marine & Industrial Engines
(d) Blending limits are given as depth
dimensions to make it easier to see
how much can be repaired.
Experience has shown that depth
limits are used for most rework.
However, the minimum chord limit
is the most important dimension; it
should be checked in borderline
cases or where previous rework is
evident in the same area. For
convenience, the depth limits and
minimum chord limits are given in
both decimals and fractions. In
borderline cases where depth limits
and minimum chord limits conflict
with one another, use the decimal
minimum chord dimension to
decide if the part is usable.
(e) Defect limits are given as depth
dimensions since this is the
dimension that affects strength.
However, accurate depth
measurements require special
equipment not normally available.
Comparing the depth of a defect
with the thickness of a leaf of
thickness gage or with the thickness
of a piece of safety wire is a reason-
ably accurate way of measuring
depth (see Figure 11-13).
(f) Swab etch reworked area per
paragraph 11-3.23 and spot-
fluorescent-penetrant inspect per
paragraph 11-3.24. Brush or swab
on penetrant where air passages are
present to prevent excessive
penetrant entrapment.
LM6000 PA GEK 98493
GE Marine & Industrial Engines Volume I

Figure 11-12. Airfoil Leading Edge Blending

Figure 11-13. Airfoil Defect Measurement

11-35
GEK 98493
Volume I
(3) Power-blending of rotor blades,
variable vanes, and vane segments
may be done as follows:
(a) To avoid damaging the airfoil, use
masking tape and mask off the
airfoil next to the rework area.
(b) Use coarse grade, silicon-carbide
impregnated rubber wheels and
points for the initial benching of the
blades and vanes.
NOTE During finish blending of defects,
make a radius on both the leading and
trailing edges of the airfoil. To do this,
apply light pressure with the rubberized
abrasive wheel, and let the cushion action of
the wheel do both the blending of the radius
and the buffing of the defect.
(c) Finish blending the defects, using
the fine and extra fine grade of
rubberized abrasive wheels.
Remove only enough material to
repair the defect.
(d) Swab etch reworked areas per
paragraph 11-3.23 and spot-
fluorescent-penetrant inspect per
paragraph 11-3.24.
(e) Place the repaired blades and vanes
in separate containers to prevent
damage during handling.
(f) Carefully inspect the blades and
vanes.
b. Blending Minor Indications in Tubing.
(l) Use a fine abrasive stone, a small file,
emery cloth, or crocus cloth for
blending.
(2) Blend around the circumference of the
tubing. The finished blend shall be as
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LM6000 PA
GE Marine & Industrial Engines
close as practical to the original finish
of the part.
c. Removing High Metal. High metal is
caused by the displacement of metal
above a surface. It is found around
defects like nicks and scratches.
Remove high metal as follows:
(l) Use a fine abrasive stone, a small file,
emery cloth, or crocus cloth to remove
high metal.
(2) Remove only the material that is
projecting above the original surface
contour (see Figure 11-14).
(3) Swab etch reworked area per
paragraph 11-3.23 and spot-
fluorescent-penetrant inspect per
paragraph 11-3.24.
11-3.23 Swab Etching Procedure
This procedure describes the materials and
process for swab etching used as a
preliminary step before fluorescent-
penetrant inspection. Etching solutions are
used as described herein or with exceptions
as specified for individual parts in the Shop
Manual.
WARNING Etching solution contains
acid and is highly toxic to skin, eyes, and
respiratory tract. Skin and eye
protection, and vapor control are
required. Avoid all contact.
CAUTION Refer to the Material Safety
Data Sheets (MSDS) for storage and
handling instructions for etchant solution.
Etchant solutions can become hazardous to
personnel if not handled appropriately.
a. All surfaces to be etched must be free
from oil, grease, scale, or other
extraneous material.
LM6000 PA
GE Marine & Industrial Engines
Figure 11-14. Blending and High Metal Removal
b. Pour a small quantity of stock solution
into a clean plastic beaker or dish. This
quantity will be the working solution,
and is not to be returned to the stock
bottle.
c. Saturate a cotton swab with the working
solution, and swab the surface to be
etched for 60-90 seconds, all Classes,
except Class G. Class G etching time is
3-4 minutes. (Refer to MSDS for
classification of etchant being used.)
Keep the etching solution within defined
boundaries of the area to be etched.
Masking may be required to contain
etchant to areas for etching.
GEK 98493
Volume I
NOTE Keep fresh solution in contact with
the metal surface at all times by dipping the
swab into the working solution periodically.
Rub the swab continuously over the surface
of the metal being etched, to prevent the
formation of an inert sludge.
d. After etching, blot up etching solution
from the metal surface with a clean
paper towel or cloth.
e. Gently wipe the etched area at least three
times with a cloth or paper towel
saturated with clean water. Blot dry
with clean cloth or paper towel.
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GEK 98493
Volume I
CAUTION Do not pour working solution
back into stock container. Although the
small quantities involved do not ordinarily
constitute an environmental hazard, flush
away discarded solutions with several
volumes of water to ensure adequate
dilution.
f. Discard used working solution, rinse,
and dry plastic container for future use.
11-3.24 Spot-Fluorescent-Penetrant
Inspection
The spot-fluorescent-penetrant inspection
process is intended for inspections at remote
locations. It is a localized process, limited
to small specific areas for inspection. It is
not intended as a substitute for normal
inspection. It is convenient to use for
inspection of welded or other localized
repair areas.
Personnel performing this inspection must
be certified in accordance with MIL-STD-
410, American Society of Non-Destructive
Testing (ASNT-TC-IA), Air Transport
Association Specification No. 105 (ATA
105), or locally approved certification
program.
Any training which may be provided by GE
for a technique requiring the performance of
this inspection method does not imply that
the personnel who receive that training have
met the requirements for inspector
certification in accordance with MIL-STD-
410, ASNT-TC-IA, or ATA 105.
11-3.24.1 Spot-Fluorescent-
Penetrant Inspection Equipment/
Materials
a. Equipment required:
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LM6000 PA
GE Marine & Industrial Engines
(1) Inspection booth, darkroom, or black
cloth hood (for remote locations) to
prevent excessive admission of white
light.
(2) Compressed air supply for drying
parts. Air supply must have filters to
remove oil and moisture which can
contaminate parts or inspection
materials.
(3) Ultraviolet lamp to detect fluorescent
indications. The ultraviolet (black)
light source used for the detection of
fluorescent indications shall have an
intensity no less than 1,000
microwatts per sq. centimeter when
measured at 15 inches. (381.0 mm).
The black light should be checked on
a weekly basis or before use,
whichever is less frequent.
(4) White light lamp for visual inspection
of parts.
(5) Time piece for timing operations.
(6) Tools for inspection personnel:
(a) Three power and 10 power
magnifying lenses
(b) Cotton swabs or small fine hair art
brush to apply solvents for
evaluating questionable indications
b. Materials required:
NOTE Qualified Products listed in MIL-I-
25135 QPL (Qualified Products List) as
Level 3, Method D, are considered
acceptable alternates to the products listed.
(1) Post-Emulsification Fluorescent-
Penetrant Oils: ZL22A, B, or C,
ZL27 or ZL27A (Magnaflux
Corporation)
LM6000 PA
GE Marine & Industrial Engines
(2) Hydrophilic Removers: ZR10A or
ZR10B (Magnaflux Corporation)
(3) Dry Powders: ZP4A or ZP4B
(Magnaflux Corporation)
(4) Non-Aqueous Wet Developers
(NAWD): ZP9B, C, E, F, or D499C
(Magnaflux Corporation)
(5) Halogen-free solvents: Isopropyl
Alcohol (TT-I-735) or Acetone (O-A-
51)
11-3.24.2 Spot-Fluorescent-
Penetrant Inspection Procedure
This procedure is to be used wherever the
shop manual calls out specific classes using
either waterwashable or post-emulsifiable
penetrant systems.
NOTE
• If visible color dye penetrant has been
used on parts which are to be
subsequently inspected with fluorescent
penetrants, the contamination by the dye
may prevent reliable fluorescent
penetrant inspection. Any color dye
indications evident by white light visual
inspection shall be considered valid
indications even if not detectable by
ultraviolet light.
• Excessive white light may interfere with
detection of a rejectable size indication.
A test part having a known defect can be
used to evaluate effectiveness of white
light shielding.
a. Parts must be cleaned of all traces of oil,
grease, carbon, and rust scale prior to
penetrant application.
GEK 98493
Volume I
b. Apply penetrant oil with soft-bristle
brush, cotton swab, or spray application.
Allow a minimum of 30 minutes for
penetration.
WARNING Acetone, O-A-51 and
Isopropyl Alcohol, TT-I-735 are explosive
when subjected to high temperature,
source of ignition, high pressure, or other
chemicals. Flammable near sparks, open
flames, welding areas, hot surfaces, other
sources of ignition, or while smoking.
Inhalation, contact, or ingestion may
cause irritation or burning of respiratory
system, eyes, face, skin, or digestive
system. Personal protective equipment
required when handling or using this
material. May lead to allergic sensitivity
in some individuals. Thermal
decomposition may release toxic by-
products. Provide local exhaust or
general dilution ventilation to meet
published exposure limits. If these are
not available, use respirator having niosh
approval for the materials released.
CAUTION Titanium alloy parts are
subject to stress corrosion cracking when
residues of halogen containing compounds
remain on a part that is subsequently
subjected to elevated temperatures typical
of welding, heat treating, or engine
operation. These parts must be thoroughly
cleaned with nonhalogen compounds after
exposure to any halogen containing
compound to prevent the cracking and
possible failure of parts.
NOTE Indications of defects can be lost by
use of excessive solvent.
c. Wipe off excess penetrant with a clean
cloth using a solvent.
11-39
GEK 98493
Volume I
(1) Alternate. Remove excess penetrant
with a hydrophilic remover, provided
it belongs to the same family as the
penetrant used. Do not exceed 90
seconds contact time. If remover is
applied manually, do not scrub the
surface of the part with the applicator.
Use applicator only to deliver fluid to
the part surface.
WARNING Nonaquaeous developer is
mixed in a solvent base containing
acetone, isopropyl alcohol, and/or
trichloroethane. Solvents are flammable
and toxic to skin, eyes, and respiratory
tract. Skin, eye, and respiratory
protection is required. Avoid repeated or
prolonged contact. Avoid breathing
vapors and use in a well-ventilated area.
d. Apply either dry powder or NAWD as a
fine thin coating at ambient temperature
to a dry surface. Allow a minimum of
10 minutes for developer to absorb
penetrant before inspecting part.
e. Evaluate any indication to the required
inspection standards.
f. Remove all residues by spraying,
wiping, or soaking with approved
solvents.
11-3.25 Miscellaneous Procedures
CAUTION Use of motor-driven hydraulic
pumps to operate hydraulically actuated
special support equipment other than
torque multipliers is not recommended.
Equipment damage can result from
improper power application.
a. Use hand-operated hydraulic pumps to
operate hydraulically actuated special
support equipment such as pushers or
pullers, unless otherwise specified.
11-40
LM6000 PA
GE Marine & Industrial Engines
b. Exercise extreme care during assembly
or disassembly operations to prevent
entrance of pieces of safety wire, nuts,
washers, or any other objects into the
engine or assembly. If anything is
dropped into the engine during assembly
or disassembly, stop and remove the
object before proceeding.
c. Do not store tools or maintenance
equipment on or against the engine.
Account for and properly store all tools
after use.
d. Clean fittings of contamination before
making or breaking connections.
WARNING Do not use external engine
piping as a ladder or hand-hold while
performing maintenance. Serious damage
or personal injury could result. Use only
authorized work stands and platforms.
e. Handle all parts carefully. Lift heavy
parts with proper lifting fixtures and a
hoist to prevent damage to parts and
physical harm to personnel.
f. Always use fiber or plastic blocks and
hammers with plastic, rawhide, or nylon
heads for driving operations.
g. Tie related parts together when they are
removed. Tag or mark parts for
identification.
h. Coat parts, that are to be stored for any
length of time, with an appropriate
preservative.
i. When installing or removing body-
bound bolts, tap them straight through
the holes. Do not turn them.
j. Verify identification of all mating parts.
LM6000 PA
GE Marine & Industrial Engines
k. Observe tagged parts for proper location.
l. During assembly, align matchmarks on
all parts that were marked during
disassembly.
m. Keep all protectors, plugs, and caps
installed until removal is required.
n. Prior to final assembly, inspect all
cavities and openings for foreign
material.
o. Inspect all mating flanges for foreign
material prior to final assembly.
Remove any high metal with a fine
stone.
CAUTION Do not mix plated hardware
with unplated hardware. Do not use silver
or cadmium-plated tools or hardware on
titanium parts. Plating contains small
quantities of chlorine salts that are
harmful to titanium.
p. Three types of tools (common,
improvised, and special) are used to
perform maintenance. Common tools
are identified only when used in special
applications. Drawings for improvised
tools are incorporated in the text when
such tools are required. Special tools are
identified both by name and part number
when they are required.
WARNING Lubricating oil, MIL-L-
23699, is toxic to skin, eyes, and
respiratory tract. Skin and eye protection
is required. Avoid repeated or prolonged
contact. Use in a well-ventilated area.
CAUTION Engine lubricating oil may
soften paint or stain clothing. Clean spilled
oil from painted surfaces.
GEK 98493
Volume I
q. Accessories, tubes, and hoses may have
oil or fuel in them at time of removal.
Drain these fluids from accessory being
removed and cap all connecting hoses or
tubes.
r. Lubricate all gears and splines with
engine lube oil before installing them,
unless otherwise specified.
s. Prior to the installation of any part, a
visual check should be made and any
obvious signs of handling damage or
abnormal wear should be noted and
reported so that corrective action can be
taken.
t. Always read the complete operation and
be sure you understand it fully. It is
better to stop and ask than to continue
and cause unnecessary work and/or
damage.
u. Do not disassemble any component any
further than necessary to perform the
required maintenance, even though
complete disassembly instructions may
be given. Remove piping and electrical
leads only as required to perform
maintenance tasks.
v. Attaching hardware (bolts, nuts, plain
washers, brackets, clamps, etc.) is
generally reusable. When possible, it is
recommended that attaching hardware be
left in place or temporarily reinstalled
until the replacement component is
installed.
11-41
GEK 98493
Volume I
w. Parts or assemblies designated as
matched sets elsewhere in this manual or
by the parts list shall be maintained as a
matched set throughout the maintenance
cycle. Set numbers, part numbers, and
serial numbers shall be protected during
cleaning or repair to prevent removal.
When identification is removed, or is no
longer legible, the item shall be re-
marked per the original marking method
and location for the part.
x. When discrepancies are found during
maintenance, refer to inspection tables
for limits and corrective action.
Petrolatum, Fed Specification VV-P-236,
shall be used as an assembly aid for tight-
fitting parts, bearings, and packing, unless
otherwise specified.
NOTE Mobile Assembly Fluid 403C may
be used in place of soft petrolatum.
11-3.26 V-Band (Coupling) Clamps
11-3.26.1 Preinstallation Checks
a. Check alignment of tube ends,
unrestrained, to the following maximum
limits prior to installing V-band clamps:
(1) Parallelism: no angle (centerlines of
tubes or fittings parallel).
(2) Offset between fittings or tube
centerlines: no more than 0.060 inch
(1.52 mm) circumferential, axial, or
combined.
(3) Gaps: no more than 0.060 inch
(0.15 mm) space between fitting seats.
11-42
LM6000 PA
GE Marine & Industrial Engines
(4) If tube ends do not align within the
above limits, readjust mounting until
proper alignment is attained.
b. Ensure flange faces are free of dirt,
grease, corrosion, distortion,
deformation, and scratches.
c. Use protective flange caps on the ends of
all ducts until the installation progresses
to the point where removal of the cap is
essential to continuing with the
installation.
d. Use care during the installation of ducts
and tubes to ensure mating and
alignment of flanges. A poorly fitted
joint requires excessive torque on the T-
bolt to close the joint and imposes
structural loads on the V-band clamp.
Adjacent support clamps or brackets
should remain loose until installation of
the coupling has been completed. When
connections are by V-band couplings,
the weight of the components should be
fully supported during the fit-up and
installation of the couplings.
e. When reinstalling a used coupling, check
it for twist or distortion. Visually check
the V-section for spreading at the open
ends or other signs of distortion. Check
spot welds or rivets for condition and
security. The corner radii should be
carefully checked for tool marks and
cracks. V-band couplings in poor
condition should be replaced.
f. Check the threads on the T-bolt for wear
and condition. If there is any sign of
wear, galling, or deformation, install a
new T-bolt or coupling clamp.
LM6000 PA
GE Marine & Industrial Engines
g. Check the T-bolt for straightness;
however, if it is bent it will be necessary
to determine if the bend is intentional.
Some small diameter couplings have
curved T-bolts. Check the applicable
illustrated parts breakdown for part
identification. If in doubt, install a new
T-bolt or coupling clamp.
h. Check the trunnion and latch for
freedom of movement or other
overloading.
i. Avoid twisting, spreading, or bending of
the coupling when positioning the
coupling on the joint.
j. When gaskets are used in the joint,
exercise care in handling to avoid nicks
and burrs on the gasket surfaces.
Whenever a joint is disassembled after
service operations, a new gasket should
be used when reassembling to ensure
maximum sealing efficiency. Exercise
care to ensure that the gasket is properly
seated.
11-3.26.2 Installation
The following procedures should be
followed to ensure proper V-band clamp
installation:
CAUTION Do not use pliers on V-band
clamps to force alignment of tube ends
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.
GEK 98493
Volume I
CAUTION Coupling T-bolt nuts shall not
be reused. Do not substitute any other
coupling nut for the type nut supplied with
the coupling. The correct nut (ESNA
Z1200J series) is identified by the letter “J”
stamped on a wrench flat. Failure to
comply may result in duct joint failure.
a. Place the V-band clamp over one of tube
ends far enough to clear flange.
b. Install gasket, if required, and mate both
flanges.
c. Relocate clamp over both flanges and
press clamp closed.
d. Install nut. Ensure T-bolt is properly
seated, and tighten nut to approximately
one-half of required torque marked on
strap.
e. Tap clamp lightly around circumference
with a rubber mallet to equally distribute
load.
f. Alternate tightening and tapping until
torque stabilizes at the specified value.
Avoid overtorquing.
g. Inspect clamp for even seating.
h. See figure 11-15 for safety wiring the
V-band clamp. Use 0.041-0.051 inch
(NOVN) (1.0-1.3 mm) safety-wire.
11-43
GEK 98493 LM6000 PA
Volume I GE Marine & Industrial Engines

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

11-44