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CF34 TURBOFAN ENGINE

MAINTENANCE MANUAL
GE Aircraft Engines

LIFE LIMITS OF ROTATING ENGINE PARTS

1. General.

A. The FAA has approved service life-limit cycles (Airworthiness


Limitations) for rotating parts installed in the CF34-1A/-3A/-3A2
turbofan engines.

B. This chapter identifies engine parts that are life-limited as a result


of exposures to operating cycles or hours. It explains how to calculate
life-limit cycles to allow the operator to determine the number of
cycles at which a part must be removed from service.

C. Rotating parts of all turbine engines have some type of service limits.
Critical rotating parts are those parts whose sudden failure could
threaten the structural integrity of the engine. These parts, when
subjected to large repeated and/or alternating stresses, can fail
through fatigue. The material properties of a part are depleted by
fatigue as a function of the number of stress cycles the part
experiences. Stress cycles of turbine engine rotating parts result from
the transients of engine speed and temperatures occurring during normal
engine operation. Therefore, the life-limit cycles provide the operator
with a means of tracking the useful service life of a part so that the
part can be removed from service before possible fatigue failure. These
life-limits are usually expressed in terms of cycles, and can be
related almost directly to the number of stress cycles that occur
during engine operation. It is for this reason that the limits are in
terms of cycles.

D. Life limits of the critical rotating parts are established through


analysis and testing. Accumulated cycles are compared to the life
limits to determine if the affected hardware is still serviceable. No
component must be permitted to remain in service beyond its life-limit
cycles. Refer to paragraph 2.A. for the definition of a cycle.

E. There are two methods (refer to paragraph 2.E.) available for counting
life-limit cycles; a primary method and an alternate method:

(1) The primary method is simpler than the alternate method, and is
appropriate for most aircraft operators.

NOTE: High-utilization operators are defined as operators whose


mission requirements generate higher than normal touch-and-go
landings, missed approaches, or landings without an engine
shutdown.

(2) The alternate method is recommended for high-utilization


operators because it provides cycle counts more representative of
their type of aircraft usage.

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(3) The overall cycle counts using the alternate method will be lower
than the primary method cycle counts because the alternate method
differentiates between stresses experienced in different mission
operations. The primary method does not make this distinction as
it is of little benefit in general aircraft use.

F. GE Aircraft Engines has completed extensive testing of the engine and


its components to provide the basis for the establishment of life limit
cycles. GE Aircraft Engines will continue testing and will revise this
chapter when life-limit changes are justified and when substantiating
data has been approved by the FAA.

G. Life-limited parts must be removed from service before or as soon as


the life-limit of that part (as established by this chapter) has been
reached.

CAUTION: CERTAIN ROTATING PARTS ARE LIFE-LIMITED BASED ON THE SPECIFIC


APPLICATION FOR WHICH THE PART IS INTENDED. IN SOME CASES,
DIFFERENT LIFE LIMITS HAVE BEEN ESTABLISHED F0R IDENTICAL GE
LIFE-LIMITED PARTS FOR DIFFERENT APPLICATIONS (FOR EXAMPLE,
CF34-3A1 VS CF34-3B). ACCORDINGLY, THE FOLLOWING PRECAUTIONS AND
GUIDELINES MUST BE OBSERVED:
• USED LIFE-LIMITED PARTS MUST NOT BE RE-USED, UNLESS THE
HISTORY OF THAT PART IS KNOWN. THIS CHAPTER CONTAINS
INFORMATION FOR DETERMINING EQUIVALENT ACCUMULATED CYCLES VS
THE APPLICATION.
• IF THE APPLICATIONS IN WHICH THE PART HAS OPERATED AND THE
ACCUMULATED TOTAL NUMBER OF CYCLES ARE KNOWN, BUT THE NUMBER
OF CYCLES OPERATED IN EACH APPLICATION ARE NOT KNOWN, THEN
THE LOWEST LIFE LIMIT FOR A GIVEN PART MUST BE APPLIED (REFER
TO PARAGRAPH 2.B, METHOD II). IT IS THE RESPONSIBILITY OF THE
OPERATOR TO MAINTAIN ACCURATE RECORDS OF THE PART OPERATION.

2. Requirements.

A. Definitions.

A cycle is defined as a flight consisting of an engine start, takeoff,


and landing. Use of thrust reverser is not included in this cycle
count. Engine starts and shutdowns for operational checks, ground
maintenance, and taxiing do not count against life-limit cycles, unless
the engine is operated at takeoff fan speed. In that case, it counts as
one cycle. Other operational procedures that affect the life-limit
cycles of rotating parts are counted as follows:

(1) An air start is considered one cycle on rotating parts.

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GE Aircraft Engines

(2) When the thrust reverser is used and the throttle is advanced
beyond 70% N2, 1/6 cycle is added to the cycle count of each
rotating part. When the thrust reverser is used, but the throttle
is not advanced beyond 70% N2, no additional cycles are added.

(3) Whenever the throttle is used to set APR power, 2 cycles are
added to the cycle count of each rotating part.

(4) Each flight (takeoff and landing) counts as one cycle regardless
of whether or not the engines are shut down prior to the next
takeoff.

(5) A touch-and-go landing counts as one cycle for each rotating part
when using the primary cycle-counting method.

(6) A go-around counts as 2 cycles for each rotating part if APR


power is set using the throttle during the go-around. If APR
power is not set, the go-around counts as 1 cycle for each
rotating part. This applies for both the primary and the
alternate cycle-counting methods .

(7) If the alternate cycle-counting method is used, additional cycle


counting must be done. For each touch-and-go landing and for each
landing followed by a takeoff with no shutdown, record and
calculate these events as follows:

(a) The engine is divided into three sections for cyclic record
keeping purposes. Maintain a separate cycle count for each
of the following three sections:

Cycle Count for


Touch-and-Go, or
Section Components in Section Landing With No Shutdown

1 Fan, Compressor, and all 1.000


Low-Pressure Turbine (LPT)
Life-Limited parts, except
the Stage 4 Disk

2 All High-Pressure Turbine 0.250


Life-Limited parts

3 LPT Stage 4 Disk 0.525

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(b) In addition to the cycle counts calculated in step (a),


also count the following cycles for each of the three
sections (refer to Sample Calculations in paragraph E, step
(3)(b) for an example):
• ONE CYCLE PER FLIGHT FOR THE NORMAL MISSION.
• ONE CYCLE PER AIR START.
• ONE-SIXTH CYCLE (0.167) EACH TIME THE THRUST REVERSER IS
ACTIVATED ABOVE 70% N2.
• TWO CYCLES EACH TIME THE THROTTLE IS USED TO SET APR
POWER.

B. Calculating Cycle Count For Common CF34 Engine Parts That Are
Transferred Between Different CF34 Engine Models.

(1) The different CF34 engine models have a number of life-limited


parts that are common (have the same part number). Some of these
common parts also have the same life limits when transferred
between the different engine models. However, because the engine
model series experience different operating environments, the
life limits of some of the common parts may differ when used in
different CF34 models.

(2) When a common life-limited part is transferred from one CF34


engine model series to another, it will be necessary to calculate
equivalent accumulated cycles for the part, taking into account
the application (engine model) in which the part has operated, if
the life of the part differs between engine models. All
applicable information should be entered into the CF34 common
life-limited parts tracking form (refer to table 801). The
completed tracking form must be returned with the applicable
common parts when those parts are transferred between different
CF34 model series. The operator must get from GEAE, or from a GE
authorized CF34 overhaul facility, the life limits for each CF34
model applicable to the components service history.

(3) Two methods are available to establish the total life limit for
life-limited parts that are used in more than one CF34 engine
model:

CAUTION: METHOD II MUST BE APPLIED, UNLESS THE NUMBER OF CYCLES


OPERATED IN EACH ENGINE MODEL IS KNOWN AND DOCUMENTED.
IT IS THE RESPONSIBILITY OF THE OPERATOR TO MAINTAIN
ACCURATE RECORDS OF THE PART OPERATION.

(a) Method I:

If the number of cycles accumulated on one CF34 model is


accurately known and documented, the fraction of life
consumed can be calculated and used to determine the
remaining cyclic life in a different CF34 model.

First, calculate the fraction of life used for a part


installed in a given CF34 model, then calculate the
equivalent cycles since new (CSN) for the part installed in
a different CF34 model; use this procedure:

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1 Calculate the fraction of life used for a part


installed in initial CF34 model as follows:

Cycles accumulated
Fraction of life = on CF34 model 1
used LCF limit for
CF34 model 1

2 Use this fraction to calculate the equivalent CSN on


the part, if installed in another different CF34 model
(model 2)as follows:

Equivalent CSN = Fraction of X LCF limit for


for life used CF34 model 2
CF34 model 2

3 Determine the cycles remaining on the part installed in


CF34 model 2 as follows:

Cycles remaining = LCF limit _ Equivalent CSN


CF34 model 2 for CF34 for CF34 model
model 2 2

4 Example 1:

Consider a part with LCF limits in two different CF34


models as follows:

CF34 Model 1 LCF limit = 15,000 cycles


CF34 Model 2 LCF limit = 20,000 cycles

The part accumulates 6,000 cycles while installed in


one CF34 model (model 1), and then will be installed in
a different CF34 model (model 2). Calculate the
equivalent CSN for the part installed in CF34 model 2,
and determine how many LCF cycles remain, as follows:

Fraction of life used = 6,000 = 0.04


while installed in CF34 15,000
model 1

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GE Aircraft Engines

Equivalent CSN for


CF34 model 2 = 0.40 x 20,000 = 8,000 cycles

Cycles remaining on
the part installed = 20,000 - 8,000 = 12,000 cycles
in CF34 model 2

5 Example 2:

Consider a part with LCF limits in three different


CF34 models as follows:
Model 1 LCF limit = 12,000 cycles
Model 2 LCF limit = 27,000 cycles
Model 3 LCF limit = 20,000 cycles

The part accumulates 6,000 cycles while installed in


one CF34 model (model 1), in addition to 4,000 cycles
installed in a second CF34 model (model 2). The part is
planned to be installed in a third CF34 model
(model 3). Calculate the equivalent CSN for the part
installed in CF34 model 3, and determine how many LCF
cycles remain as follows:

Cycles accumulated Cycles accumulated


Fraction of = on CF34 model 1 + on CF34 model 2
life used LCF limit for LCF limit for
model 1 model 2

Fraction of
life used = 6,000 + 4,000 = 0.65
12,000 27,000

Equivalent
CSN for model 3 = 0.65 x 20,000 = 13,000 cycles

Cycles remaining for


the part installed
in CF34 model 3 = 20,000 - 13,000 = 7,000 cycles

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MAINTENANCE MANUAL
GE Aircraft Engines

(b) Method II:

If the applications in which the part has operated and the


total number of cycles accumulated are known, but the
number of cycles operated in each application are not
known, the lowest life limit for a given limit for a given
part must be applied (as shown below) when calculating
fraction of life consumed and cyclic life remaining. This
method requires maintaining only records of the total
number of cycles on the part in any CF34 model and the
engine models in which the part has been used.

1 Calculate the fraction of life used for a part


installed in initial CF34 model as follows:

Fraction of life used = Total cycles accumulated


Lowest published life of
all models in which the
part has operated

2 Use this fraction to calculate the equivalent CSN on


the part, if installed in another different CF34
(model 2) as follows:

Equivalent CSN for = Fraction of X LCF limit for


CF34 model 2 life used CF34 model 2

3 Determine the cycles remaining on the part installed in


CF34 model 2 as follows:

Cycles remaining = LCF limit for - Equivalent CSN


for CF34 model 2 CF34 model 2 for CF34 model 2

4 Example 3: Consider a part with lCF limits in two


different CF34 models as follows:
CF34 Model 1 LCF limit = 15,000 cycles
CF34 Model 2 LCF limit = 20,000 cycles

The part has accumulated 5,000 cycles total while


installed for some period of time on CF34 model 1, and
for some period of time on CF34 model 2. The part will
now be installed in CF34 model 2. Calculate the
equivalent CSN and cycles that remain for the part
installed in CF34 model 2.

The lowest published life on the part (15,000 cycles)


must be applied in the calculations because it is not
known exactly how many cycles the part accumulated
while installed in each engine model.

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GE Aircraft Engines

Fraction of life used = Total cycles accumulated


Lowest published life

Fraction of life used = 5,000 = 0.33


15,000

Equivalent CSN = 0.33 X 20,000 = 6,000 cycles


for CF34 model 2

Cycles remaining on
the part installed = 20,000 - 6,600 = 13,400 cycles
in CF34 model 2

C. Affected Components.

CAUTION: THE LIFE-LIMITED PARTS DEFINED IN THIS SECTION MUST NOT BE


OPERATED BEYOND THE ESTABLISHED LIMITS.

The engine components that are life-limited by this section are the
following:
• Fan Rotor Components (refer to 5-11-01).
• Compressor Rotor Components (refer to 5-11-02).
• High-Pressure Turbine Rotor Components (refer to 5-11-03).
• Low-Pressure Turbine Rotor Components (refer to 5-11-04).
• Additional Life Limits (Non-LCF) (refer to 5-11-05).

D. Cycles Recording.

(1) The operator is responsible for maintaining an accurate record of


cycles experienced during engine operation. The operator must
also monitor the status of the parts to ensure that none of the
parts listed in paragraph C exceed the established life-limit
cycles.

(2) The CF34 Turbofan Engine Service Record book provides forms for
recording the cycle history of the engine.

(3) The operator and/or the Service or Overhaul Facility is


responsible for making appropriate engine logbook entries to
reflect changes in components.

E. Sample Calculations for Primary and Alternate Life-Cycle Counting


Methods.

(1) Chapters 5-11-01 through 5-11-05 provide cycle limits which must
be used to establish the continued serviceability of components.
Step (2) shows an example of the primary life-cycle counting
method, and step (3) shows an example of the alternate life-cycle
counting method.

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MAINTENANCE MANUAL
GE Aircraft Engines

(2) Examples of primary life-cycle counting method:

(a) During a flight, the operator makes an air start on the


right-hand engine, lands using the thrust reverser, and
shuts down the engines. During the thrust reverser
operation, the throttles are advanced above 70% N2.

Cycle count right-hand engine: 1 normal mission


1 air start
1/6 thrust reverser
2-1/6 total

Cycle count left-hand engine: 1 normal mission


1/6 thrust reverser
1-1/6 total

(b) The operator starts the engines, takes off, and lands using
the thrust reverser followed by engine shutdown. The
operator makes a second takeoff and landing using the
thrust reverser, but does not shut down the engines. The
operator then makes a third takeoff and landing without
using the thrust reversers. The throttles were advanced
beyond 70% N2 during the thrust reverser operation. The
operator then makes a power assurance check at takeoff fan
speed.

Cycle count left-hand and right-hand engines:

Flight plus Reverser and Shutdown 1-1/6 cycles


Flight plus Reverser and no Shutdown 1-1/6 cycles
Flight with No Reverser and Shutdown 1 cycle
Power Assurance Check and Shutdown 1 cycle
4-1/3 cycles

(3) Examples of alternate life-cycle counting method:

(a) An operator starts the engines, takes off, and experiences


a missed approach and a touch-and-go before landing and
does not shut down the engines. The operator makes a second
takeoff, and during the flight makes an air start on the
right-hand engine. The operator then experiences two more
missed approaches and another touch-and-go before making a
second landing, and again does not shut down the engines.
The operator then makes a third takeoff, and during the
flight makes an air start on the left-hand engine. The
operator lands using the thrust reversers with throttle
advanced beyond 70% N2 and shuts down the engines.

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GE Aircraft Engines

(b) Refer to paragraph A, steps (7)(a) and (7)(b) for the


definitions, and calculate the cycle count as follows:

CYCLE COUNT FOR EACH SECTION


OF EACH ENGINE FOR EACH EVENT
TIMES QUANTITY OF EVENTS IN
THAT FLIGHT

Section 1 Section 2 Section 3

One Takeoff 0.000 0.000 0.000


Three Missed Approaches 3.000 0.750 1.575
Two Touch-and-Go 2.000 0.500 1.050
One Air Start 1.000 1.000 1.000
Two Landings Followed by a Takeoff
With No Shutdown Between 2.000 0.500 1.050
One Thrust Reverser Application
Above 70% N2 0.167 0.167 0.167
One Full Stop Landing with Shutdown 1.000 1.000 1.000
Totals for this Flight 9.167 3.917 5.842

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CF34 TURBOFAN ENGINE
MAINTENANCE MANUAL
GE Aircraft Engines

FAN ROTOR - LIFE-LIMITS

1. General.

A. This section contains the FAA approved life-limits for the fan rotor
components.

B. The life limit is determined by the total number of flight cycles


(refer to 5-11-00, TIME LIMITS for the definitions and calculations of
cycles).

C. The operator is responsible to make sure that the cycle-limited


components are not used beyond their established cycle limits.

CAUTION: IF YOU TRANSFER A LIFE-LIMITED PART FROM ONE CF34 MODEL TO


ANOTHER CF34 MODEL, REFER TO 5-11-00, TIME LIMITS, PARAGRAPH 2.B,
FOR CALCULATING CYCLE COUNT FOR COMMON CF34 ENGINE PARTS THAT ARE
TRANSFERRED BETWEEN CF34 ENGINE MODELS.

2. Life Limits of Fan Rotor Components. Refer figure 801.

LOCATION
(REF. FIG. COMPONENT CURRENTLY APPROVED
801) NOMENCLATURE PART NUMBER LIFE-LIMIT CYCLES

CF34-1A CF34-3A/-3A2

1 Fan Disk 5921T54G01 9,000 9,000


5922T01G03 13,200 13,200
5922T01G04 22,700 22,700
5922T01G05 22,700 22,700
6020T62G04 9,000 9,000
6020T62G05 9,000 9,000
*6078T00G01 9,000 9,000
*6078T57G02 6,000 6,000
*6078T57G03 6,000 6,000
6078T57G04 24,300 24,300
6078T57G05 24,300 24,300

2 Fan Forward Shaft 6017T63P04 38,280 38,280


6017T63P05 38,280 38,280
6078T51P01 15,000 15,000
6078T51P02 15,000 15,000
6078T51P03 15,000 15,000

3 Fan Drive Shaft 6036T78P02 15,000 15,000

* Fan disk can be reworked to “0” time after reaching current limits (refer to
REI-13392, latest revision) at certified overhaul shops only.

5-11-01
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Page 801
Sep 15/02
GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.
CF34 TURBOFAN ENGINE
MAINTENANCE MANUAL
GE Aircraft Engines

Fan Rotor - Life Limited Components


Figure 801

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GE Aircraft Engines

COMPRESSOR ROTOR - LIFE LIMITS

1. General.

A. This section contains the FAA-approved life limits for the compressor
rotor components.

B. The life limit is determined by the total number of flight cycles


(refer to 5-11-00, TIME LIMITS for the definitions and the calculations
of cycles).

C. The operator is responsible to make sure that the cycle-limited


components are not used beyond their cycle limits.

CAUTION: IF YOU TRANSFER A LIFE-LIMITED PART FROM ONE CF34 MODEL TO


ANOTHER CF34 MODEL, REFER TO 5-11-00, TIME LIMITS, PARAGRAPH 2.B,
FOR CALCULATING CYCLE COUNT FOR COMMON CF34 ENGINE PARTS THAT ARE
TRANSFERRED BETWEEN CF34 ENGINE MODELS.

2. Life Limits of Compressor Rotor Components. Refer to figure 801.

LOCATION
(REF. FIG. COMPONENT CURRENTLY APPROVED
801) NOMENCLATURE PART NUMBER LIFE-LIMIT CYCLES

CF34-1A CF34-3A/-3A2

1 Stage 1 Disk 6040T79G01 6,000 6,000


6087T00G01 15,000 15,000
6087T00G02 15,000 15,000

2 Forward Shaft 5037T01P03 12,300 11,740


5037T01P04 12,300 11,740

3 Stage 2 Disk 6036T91P01 15,000 15,000


6036T91P02 15,000 15,000

4 Forward Spool 6036T75P02 6,000 6,000


6036T75P03 6,000 6,000
6078T56P01 *12,000 *12,000
6078T56P03 27,000 27,000
6078T56P04 27,000 27,000
6078T56P05 6,000 6,000

* Retire all forward spools PN 6078T56P01


at scheduled 6,000-hour overhaul or, if
6000-hour overhaul has been completed,
at next exposure at or before 12,000 cycles.

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GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.
CF34 TURBOFAN ENGINE
MAINTENANCE MANUAL
GE Aircraft Engines

Compressor Rotor - Life Limited Components


Figure 801

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LOCATION
(REF. FIG. COMPONENT CURRENTLY APPROVED
801) NOMENCLATURE PART NUMBER LIFE-LIMIT CYCLES

CF34-1A CF34-3A/-3A2

5 Rear Spool 5087T46P01 22,000 22,000


5087T46P02 22,000 22,000
6037T83P03 6,000 6,000
6037T83P04 6,000 6,000
6087T02P01 6,000 6,000
6 Rear Shaft CDP 4019T38P01 15,080 14,400
Seal

7 Rear Shaft 6016T83P01 6,000 6,000


6087T03P01 6,000 6,000
6087T03P02 6,000 6,000
6087T03P03 23,000 23,000

8 Stage 9 Disk 6016T43P03 6,000 6,000


6087T01P01 6,000 6,000
6087T01P02 23,000 23,000
6087T01P03 23,000 23,000

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CF34 TURBOFAN ENGINE
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GE Aircraft Engines

HIGH-PRESSURE TURBINE ROTOR - LIFE LIMITS

1. General.

A. This section contains the FAA-approved life limits for the high-
pressure turbine (HPT) rotor components.

B. The life limit is determined by the total number of flight cycles


(refer to 5-11-00, TIME LIMITS for the definitions and the calculations
of cycles).

C. The operator is responsible to make sure that the cycle-limited


components are not used beyond their established cycle limits.

CAUTION: IF YOU TRANSFER A LIFE-LIMITED PART FROM ONE CF34 MODEL TO


ANOTHER CF34 MODEL, REFER TO 5-11-00, TIME LIMITS, PARAGRAPH 2.B,
FOR CALCULATING CYCLE COUNT FOR COMMON CF34 ENGINE PARTS THAT ARE
TRANSFERRED BETWEEN CF34 ENGINE MODELS.

2. Life Limits of High-Pressure Turbine Rotor Components. Refer to figure 801.

LOCATION
(REF. FIG. COMPONENT CURRENTLY APPROVED
801) NOMENCLATURE PART NUMBER LIFE-LIMIT CYCLES

CF34-1A CF34-3A/-3A2

1 Seal, Balance 5025T33P02 7,200 7,200


Piston Air 3921T56P01 7,200 7,200
5025T33P03 7,200 7,200
3921T58P01 7,200 7,200
5025T33P04 7,200 7,200
5025T33P06 7,200 7,200
6078T90P01 6,000 6,000

2 Shaft, HPT Rotor 6017T00P04 6,000 6,000


6017T00P05 6,000 6,000
6920T61P01 6,000 6,000

3 Plate, Stage 1 3921T52P01 6,000 6,000


Front Cooling 4027T15P02 6,000 6,000
4027T15P03 6,000 6,000

4 Disk, Stage 1 6031T89P01 4,358 4,358


Turbine 3921T50P01 6,000 6,000
6031T89P02 6,000 6,000
6031T89P03 6,000 6,000
6078T93P01 6,000 6,000
6078T93P02 6,000 6,000

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LOCATION
(REF. FIG. COMPONENT CURRENTLY APPROVED
801) NOMENCLATURE PART NUMBER LIFE-LIMIT CYCLES

CF34-1A CF34-3A/-3A2

5 Plate, Stage 1 5041T70P01 Refer to Refer to


Aft Cooling 5-11-05 5-11-05

5041T70P03 6,000 6,000

6 Plate, Stage 2 3921T54P01 6,000 6,000


Rear Cooling 5023T97P02 6,000 6,000
5023T97P03 6,000 6,000

7 Disk, Stage 2 6031T90P01 3,256 3,256


Turbine 3921T51P01 6,000 6,000
6031T90P02 6,000 6,000
6031T90P03 6,000 6,000
6078T94P01 6,000 6,000
6078T94P02 6,000 6,000

8 Plate, Stage 2 3921T53P01 6,000 6,000


Front Cooling 5042T29P01 6,000 6,000
5042T29P02 6,000 6,000

9 Coupling, Outer 5041T67P02 6,000 6,000


Torque 3921T61P01 6,000 6,000

10 Coupling, Inner 5041T66P02 6,000 6,000


Torque 3921T55P01 6,000 6,000
5079T02P01 6,000 6,000

NOTE: Cycle limits apply to all PN 5041T66P02 and PN 3921T55P01 inner torque
couplings, except for the serial numbers listed below which are limited
to 4,230 cycles.

GAT3189B GAT3232F GAT3665H GAT5705B


GAT3191B GAT3233F GAT3666H GAT5725B
GAT3193B GAT3234F GAT3667H GAT5728B
GAT3194B GAT3235F GAT3668H GAT8842G
GAT3196B GAT3236F GAT3669H GAT8843G
GAT3197B GAT3237F GAT3670H GAT8844G
GAT3226F GAT3238F GAT3671H GAT8845G
GAT3227F GAT3239F GAT3672H GAT8846G
GAT3228F GAT3240F GAT3673H GAT8847G
GAT3229F GAT3660H GAT3674H GAT8849G
GAT3230F GAT3663H GAT3675H GAT8850G
GAT3231F GAT3664H GAT3676H GAT8851G

5-11-03
TIME LIMITS
Page 803
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CF34 TURBOFAN ENGINE
MAINTENANCE MANUAL
GE Aircraft Engines

LOW-PRESSURE TURBINE ROTOR - LIFE LIMITS


1. General.

A. This section contains the FAA-approved life limits for the low-pressure
turbine (LPT) rotor components.

B. The life limit is determined by the total number of flight cycles


(refer to 5-11-00, TIME LIMITS for the definitions and the calculations
of cycles).

C. The operator is responsible to make sure that the cycle-limited


components are not used beyond their established cycle limits.

CAUTION: IF YOU TRANSFER A LIFE-LIMITED PART FROM ONE CF34 MODEL TO


ANOTHER CF34 MODEL, REFER TO 5-11-00, TIME LIMITS, PARAGRAPH 2.B,
FOR CALCULATING CYCLE COUNT FOR COMMON CF34 ENGINE PARTS THAT ARE
TRANSFERRED BETWEEN CF34 ENGINE MODELS.

2. Life Limits of Low-Pressure Turbine Rotor Components. Refer to figure 801.

LOCATION
(REF. FIG. COMPONENT CURRENTLY APPROVED
801) NOMENCLATURE PART NUMBER LIFE-LIMIT CYCLES

CF34-1A CF34-3A/-3A2

1 Turbine Rear Shaft 6030T72P02 39,000 39,000


4922T19P01 38,280 34,490

2 Stage 3 Disk 5026T16P01 3,828 3,440


4922T14P01 6,000 6,000
5026T16P02 6,000 6,000
6078T91P01 15,000 15,000
6078T91P02 15,000 15,000

3 Stage 3 and 4 Seal 5023T59P02 33,000 29,730


4922T20P01 33,000 29,730

4 Stage 4 Disk 5026T17P02 4,330 4,330


4922T15P01 6,000 6,000
5026T17P03 6,000 6,000
6078T02P01 15,000 15,000
6078T02P03 17,000 17,000
6078T02P04 17,000 17,000

5 Stage 6 Disk 5023T45P03 8,816 7,940


4922T17P01 8,816 7,940
5023T45P04 8,816 7,940
6078T89P01 15,000 15,000
6078T89P03 15,000 15,000

5-11-04
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Page 801
Sep 1/04
GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.
CF34 TURBOFAN ENGINE
MAINTENANCE MANUAL
GE Aircraft Engines

Low-Pressure Turbine Rotor - Life Limited Components


Figure 801

5-11-04
TIME LIMITS
Page 802
Sep 15/99
CF34 TURBOFAN ENGINE
MAINTENANCE MANUAL
GE Aircraft Engines

LOCATION
(REF. FIG. COMPONENT CURRENTLY APPROVED
801) NOMENCLATURE PART NUMBER LIFE-LIMIT CYCLES

CF34-1A CF34-3A/-3A2

6 Stage 5 and 6 Seal 5023T64P02 33,000 29,730


4922T22P01 33,000 29,730

7 Stage 5 Disk 5024T53P01 5,830 5,830


4922T16P01 6,000 6,000
5024T53P02 6,000 6,000
6078T92P01 15,000 15,000
6078T92P02 15,000 15,000

8 Drive Cone 5023T40P01 15,000 15,000


4922T18P01 15,000 15,000
5023T40P03 15,000 15,000

9 Stage 4 and 5 Seal 5023T67P01 33,000 29,730


4922T21P01 33,000 29,730

5-11-04
TIME LIMITS
Page 803
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GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.
CF34 TURBOFAN ENGINE
GE Aircraft Engines MAINTENANCE MANUAL

ADDITIONAL LIFE LIMITS (NON-LCF)

1. General.

This section contains additional life limits for specific non-LCF components.

2. Life Limits.

ITEM REQUIREMENT MAXIMUM INTERVAL METHOD

* * * * * FOR CF34-1A * * * * *

HPT Stage 1 Blades:

NOTE: Refer to SB 72-34 (latest revision) for the maximum interval that apply to stage 1 blades that
are installed in specific engine serial numbers.

x PN 6040T72P04 Replace 3000 hours Send the HPT rotor to


x PN 6040T72P07 Replace 3000 hours an authorized service
x PN 6040T72P08 Replace 3000 hours or overhaul facility.
x PN 6040T72P09 Replace 3000 hours
x PN 6040T72P10 Replace 3000 hours
x PN 6078T19 No Limit --- -----

* * * * * FOR CF34-3A/3A2 * * * * *

HPT Stage 1 Blades:

x PN 6040T72P07 Replace 1000 hours Send HPT rotor to an


x PN 6040T72P08 Replace 1000 hours authorized service or
x PN 6040T72P09 Replace 1000 hours overhaul facility.
x PN 6040T72P10 Replace 2000 hours
x PN 6078T19 No Limit --- -----

5-11-05
TIME LIMITS
Page 801
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CF34 TURBOFAN ENGINE
GE Aircraft Engines MAINTENANCE MANUAL

ITEM REQUIREMENT MAXIMUM INTERVAL METHOD

* * * * * FOR ALL * * * * *

HPT Stage 1 Aft Replace 3000 hours Send the HPT rotor to an
Cooling Plate PN authorized service or overhaul
5041T70P01. facility.

HPT Stage 2 Studs Replace 6000 hours Send the HPT rotor to an
(only when authorized service or overhaul
SB 72-5 is facility.
accomplished).

No. 5 Bearing Carbon Replace 3000 hours Refer to 72-40-00,


Seal Preformed (refer to NOTE) REMOVAL/INSTALLATION.
Packing (KALREZ).

NOTE: The No. 5 bearing carbon seal preformed packing must be replaced at the next 3000 hours (HSI)
inspection, and then at every 3000 hours (HSI) thereafter. If Service Bulletin 72-53 has been
complied with, refer to 5-21-00, Table 803, item Q., NOTE 6 for instructions.

Combustion Liner (PN Replace 750 cycles maximum Refer to 72-40-00,


6063T15G01 and G04 (refer to NOTE) REMOVAL/INSTALLATION.
only) (low-emission,
Type I).

NOTE: Combustion liner PN 6063T15G01 and G04, that are installed in CF34-3A engines SN 350336
through 350504 (low-emission Type I), must be replaced between 600 and 750 cycles maximum
until Service Bulletin (CF34) 72-26 is complied with.

HPT Stator Stage 2 Replace 3000 hours Refer to 72-50-00,


Nozzle (refer to NOTE) REMOVAL/INSTALLATION.
Retaining Ring
Sector.

NOTE: The stage 2 nozzle retaining ring sectors must be replaced at the next 3000 hours (HSI)
inspection, and then at every 3000 hours (HSI) thereafter, unless Service Bulletin 72-77 has
been complied with. If Service Bulletin 72-53 has been complied with, refer to 5-21-00, Table
803, item Q., NOTE 6 for instructions.

5-11-05
TIME LIMITS
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CF34 TURBOFAN ENGINE
MAINTENANCE MANUAL
GE Aircraft Engines

LIST OF EFFECTIVE PAGES

CHAPTER/ CHAPTER/
SECTION PAGE DATE SECTION PAGE DATE

List of
Effective
Pages *1 Sep 1/04

Table of
Contents 1 Sep 30/98

5-11-00 801 thru 811 Sep 30/98

5-11-01 801 Sep 15/02


802 Sep 30/98

5-11-02 *801 Sep 1/04


802 Sep 30/98
*803 Sep 1/04

5-11-03 801 thru 803 Sep 15/00

5-11-04 *801 Sep 1/04


802 Sep 15/99
*803 Sep 1/04

5-11-05 801 Sep 15/99


*802 Sep 1/04

* Asterisk indicates pages added, changed, or deleted by this revision.

5-11-00
LIST OF EFFECTIVE PAGES
Page 1
Sep 1/04
GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.
CF34 TURBOFAN ENGINE
MAINTENANCE MANUAL
GE Aircraft Engines

TABLE OF CONTENTS

CHAPTER/
SUBJECT SECTION PAGE

LIFE LIMITS OF ENGINE ROTATING PARTS

Life Limits of Engine Rotating Parts 5-11-00 801


General 801
Requirements 802
Definitions 802
Calculating Cycle Count For Common CF34 Engine
Parts That Are Transferred Between Different
CF34 Engine Models. 804
Method I 804
Method II 808
Affected Components 809
Cycles Recording 809
Sample Calculations for Primary and Alternate
Life-Cycle Counting Method 809
Primary Life-Cycle Counting Method 810
Alternate Life-Cycle Counting Method 810

Fan Rotor - Life Limits 5-11-01 801


General 801
Life Limits of the Fan Rotor Components 801

Compressor Rotor - Life Limits 5-11-02 801


General 801
Life Limits of the Compressor Rotor Components 802

High-Pressure Turbine Rotor - Life Limits 5-11-03 801


General 801
Life Limits of the High-Pressure Turbine Rotor
Components 801

Low-Pressure Turbine Rotor - Life Limits 5-11-04 801


General 801
Life Limits of the Low-Pressure Rotor Components 801

Additional Life Limits (Non-LCF) 5-11-05 801


General 801
Life Limits 801

5-11-00
TABLE OF CONTENTS
Page 1
Sep 30/98
CF34 TURBOFAN ENGINE
MAINTENANCE MANUAL
GE Aircraft Engines

SCHEDULED MAINTENANCE PROGRAM

1. General.

A. This section contains the scheduled inspection checks for the CF34-1A/
-3A/-3A2 engines.

B. The scheduled Inspection and Servicing Requirements (refer to table


801), or manufacturer's recommendations, consists of installed-engine
repetitive visual and borescope inspections of the engine's external
and internal components, specific maintenance checks and tasks, a
performance trend monitoring program, and compliance with life limits
as specified in Chapter/Section 5-11-00, compliance with all the
manufacturer's Service Bulletins, as well as removal of the engine
hot section for Hot Section Inspection (HSI).

C. The scheduled inspection checks and servicing requirements set forth


in this Chapter represents the plans and the recommendations by GE
Aircraft Engines. The specified time intervals are based upon engines
being operated at all times within approved operating limits and main-
tained in accordance with GE Aircraft Engines published instructions,
including compliance with the recommended inspection intervals.

D. The replacement intervals for life-limited parts (refer to Chapter/


Section 5-11-00) shall take precedence over all maintenance actions
contained in this Chapter. The inspection and maintenance intervals
recommended herein are subject to the cycle life or hourly parts limits
as described in Chapter/Section 5-11-00.

E. During the removal of engine components, and prior to the installation


of any component, inspect all the components that are removed, or
port ions of the components that are exposed. Inspect the components
and the exposed areas in accordance with the published inspection
criteria in the applicable sections in this manual.

2. Special Tools and Fixtures.

The special tools and fixtures recommended by GE Aircraft Engines are


listed in table 801. Equivalent substitutes can be used.

TABLE 801. SPECIAL TOOLS AND FIXTURES

TOOL NUMBER NOMENCLATURE

11-10792 Kit, Igniter Plug Gage


(Unison Industries
7575 Baymeadows Way
Jacksonville, FL 32256
USA

5-21-00
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GE Aircraft Engines

3. Consumable Materials.

The consumable materials listed in table 802 are recommended for use when
doing scheduled maintenance procedures in this section. Equivalent substi-
tutes can be used for listed items.

TABLE 802. CONSUMABLE MATERIALS

DESCRIPTION MANUFACTURER

Oil, Penetrating (LPS-1) LPS Research Lab, Inc.


2050 Cotner Ave.
Los Angeles, CA 90025 USA
Oil, Penetrating (WD-40) WD-40 Company
P.O. Box 80607
San Diego, CA 92138
USA

4. Scheduled Inspection Checks.

A. Preliminary Instructions.

(1) The inspection time categories in table 803 are divided into six
inspection intervals: Preflight or Postflight, 100-hour, 300-
hour, 600-hour, 1200-hour, and 3000-hour inspection intervals.
The checks in these intervals indicate the minimum inspection
requirements for satisfactory inspection compliance.

(2) Visually inspect the engine components for the appropriate


Inspection Time Categories.

(3) When the condition of an engine part can not be determined, refer
to the inspection limits that apply to the individual part, in
the applicable inspection table in this manual.

(4) The oil filter must be inspected for contamination (refer to


79-00-00, INSPECTION) when:

 There has been an indication of oil impending bypass.


 The oil filter or the engine has reached its time category
interval.
 The engine has been overhauled.

B. Daily Checks (Preflight or Postflight).

(1) Use a flashlight and visually inspect the engine inlet and
exhaust areas (with the duct covers removed) for the conditions
listed in table 803.

(2) Inspect the ground surface area and any aircraft surfaces in the
immediate vicinity of the engine inlets for foreign debris.

5-21-00
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C. Periodic Inspections.

(1) A thorough visual inspection of the engine is required at regular


intervals and at complete overhaul scheduled for 6000 hours.

(2) Borescope-inspect (refer to 72-00-00, INSPECTION) the compressor


section, and clean (refer to 72-00-00, CLEANING) the compressor
for performance recovery.

(3) Visually inspect the engine components for the appropriate


Inspec- tion Time Categories.

D. Mid-Point (3000-Hour) Hot Section Inspection Interval.

(1) Inspect the engine components listed in table 803 for the inspec-
tion time category at 3000 hours. Disassemble the engine to the
extent that the combustion liner can be inspected (remove only
the engine components necessary to access the combustion liner,
and be sure that all turbine parts are matchmarked before you
remove them).

(2) After you remove the necessary airframe QEC parts, disassemble
the engine in the sequence given in table 804 (refer to the
paragraph titled "On-Aircraft Maintenance and Inspection of Hot
Section" in 72-00-00, SPECIAL MAINTENANCE PRACTICES), for the
procedures to inspect the Hot Section components.

NOTE:  The swirler assemblies are replaced when the combustion


liner is reworked.
 The combustion liner PN 6052T10G01 (SN GGMDP906) and up, do
not require rework.

(3) Inspect the combustion liner, exposed carbon seals, and seal
runners (refer to 72-40-00 and 72-50-00, INSPECTION).

(4) Do the following for these combustion liners:

 If the combustion liner is PN 6036T69G05 or PN 6052T10G01,


return it to an authorized GE Aircraft Engines overhaul facil-
ity for rework. Do not return combustion liner PN 6052T10G01
with SN GGMDP906 and up (this liner does not require rework).
 Combustion liner PN 6036T69G05 must be reworked to PN
5921T51G01.
 Combustion liner PN 6052T10G01 (other than SN GGMDP906 and up)
must be reworked to PN 5921T51G02.

(5) Inspect the transition case for missing hard coat on the slots
and inspect the transition outer liner for missing hard coat on
the lugs (refer to 72-50-00, INSPECTION). Inspect the removed
parts as required in the sections of this manual.

5-21-00
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GE Aircraft Engines

NOTE: It is not necessary to disassemble the major engine subassem-


blies (such as the LPT rotor and stator assemblies, or the HPT
turbine rotor and stator assemblies).

(6) Visually inspect all the exposed engine components and the
exposed internal components that are visible, as required by the
applica- ble inspection tables.

(7) Clean the damaged Components; then repair them or replace them,
if the condition indicates.

(8) Re-assemble the engine according to the instructions in the


appli- cable chapters referenced in table 804.

(9) Functionally-check the engine (refer to the table titled "CHECKS


REQUIRED AFTER MAINTENANCE" in 72-00-00, TESTING for the checks
to be done); then, do an Engine Break-In Run (refer to 72-00-00,
TESTING).

TABLE 803. INSPECTION AND SERVICING REQUIREMENTS

INSPECTION TIME CATEGORIES

3000
Hours
Preflight (Refer
ENGINE COMPONENT or 100 300 600 1200 to
AND INSPECTION Postflight Hours Hours Hours Hours Para D)

A. Check the inlet duct for:

(1) Deterioration, damage, X


and loose rivets.

(2) Integrity of acoustical X


panels.

(3) Presence of foreign X


objects.

B. Check (refer to Note 1 at


the end of this table) the
external hoses and tubes,
electrical connectors,
ports, flanges, clamps, and
brackets for:

(1) Security. X

(2) Damage (visually). X

5-21-00
CF34 ENGINE MAINTENANCE PROGRAM
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CF34 TURBOFAN ENGINE
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GE Aircraft Engines

TABLE 803. INSPECTION AND SERVICING REQUIREMENTS (Cont)

INSPECTION TIME CATEGORIES

3000
Hours
Preflight (Refer
ENGINE COMPONENT or 100 300 600 1200 to
AND INSPECTION Postflight Hours Hours Hours Hours Para D)

(3) Evidence of leakage from X


external hoses or tubes.

(4) Chafing (visually). X

C. Check (refer to Note 1 at the


end of this table) under the
cowl for evidence of leakage
(fuel, oil, air) from:

(1) Surfaces beneath the X


engine.

(2) Engine surfaces and X


accessories.

(3) Fuel heater.* X

* Remove the cap from the bleed air tube, and check for any evidence of
fuel accumulation (not allowed). If fuel is found in the air tube,
replace the fuel heater (73-00-00, REMOVAL/INSTALLATION). Re-install
the cap; if the cap is silver-plated, torque the cap to 85-90 lb in.
(9.6-10.2 N•m); if the cap is not silver-plated, torque the cap to
135-150 lb in. (15.3-16.9 N•m).

D. Check the oil system for


contamination as follows:

NOTE: A leak check (refer to 72-00-00, TESTING) must be done after any compo-
nent of the oil system is disconnected or removed.

(1) Remove, inspect, and X


replace the oil filter
element (79-00-00,
INSPECTION) (also, refer
to Note 1 at the end of
this table).

5-21-00
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CF34 TURBOFAN ENGINE
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GE Aircraft Engines

TABLE 803. INSPECTION AND SERVICING REQUIREMENTS (Cont)

INSPECTION TIME CATEGORIES

3000
Hours
Preflight (Refer
ENGINE COMPONENT or 100 300 600 1200 to
AND INSPECTION Postflight Hours Hours Hours Hours Para D)

NOTE:  The chip detector in the accessory gearbox (AGB) should be inspected
when metal is found in the oil filter. If the AGB chip detector appears
normal, or the metal in the oil filter is non-ferrous (not attracted by
a magnet), then the Integrated Drive Generator (IDG) and the garlock
seal should be removed to inspect the axis-BB drive bearing.
 Replace the oil filter after the first 100 hours of operation; then at
600 hours, and then every 600 hours thereafter.

(2) Do a continuity check of X


all the magnetic chip
detectors (refer to 72-
00-00, INSPECTION). If
the continuity check
fails, inspect the chip
detectors for metallic
particles (refer to 72-
00-00, INSPECTION).

(2A)Do an insulation X
resistance check of the
magnetic chip detector
(refer to 79-00-00,
INSPECTION).

(3) Check the oil level X


(maintain the oil level
by actuating the
aircraft oil
replenishing system).*
* Oil may seep from the oil tank into the gearbox when the engine is
inactive and can give a false indication of a low oil level. Check the
oil level within 30 minutes after engine shutdown.

5-21-00
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CF34 TURBOFAN ENGINE
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GE Aircraft Engines

TABLE 803. INSPECTION AND SERVICING REQUIREMENTS (Cont)

INSPECTION TIME CATEGORIES

3000
Hours
Preflight (Refer
ENGINE COMPONENT or 100 300 600 1200 to
AND INSPECTION Postflight Hours Hours Hours Hours Para D)

(4)Sample oil (refer to X


72-00-00,
SERVICING).* Visually
inspect the drained
oil for presence of
metallic particles.
Visually check the
oil level in the
engine oil tank for
evidence of
overservicing and
fuel contamination.
* If the acid level is more than 1.5 mg KOH/g, change the oil at the next
convenient time.

5-21-00
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GE Aircraft Engines

TABLE 803. INSPECTION AND SERVICING REQUIREMENTS (Cont)

INSPECTION TIME CATEGORIES

3000
Hours
Preflight (Refer
ENGINE COMPONENT or 100 300 600 1200 to
AND INSPECTION Postflight Hours Hours Hours Hours Para D)

(5) Visually inspect all X


the oil system
components for leaks
during the Ground
Idle Run in 72-00-00,
TESTING.

(6) Do an oil filter X


bypass sensor
indication test
(refer to 72-00-00,
TESTING).

(7) Visual inspection of X


the C-sump scavenge
screen fittings
(refer to SEI-581,
79-00-00, figure 3,
items 55A and 245) in
the lube and scavenge
pump for accumulation
of coked oil build-
up. If a 3000-hour
HSI inspection has
already been
completed, do this
inspection at the
next scheduled 3000-
hour inspection.

E. Check the fuel system


(refer to 73-00-00) as
follows:

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GE Aircraft Engines

TABLE 803. INSPECTION AND SERVICING REQUIREMENTS (Cont)

INSPECTION TIME CATEGORIES

3000
Hours
Preflight (Refer
ENGINE COMPONENT or 100 300 600 1200 to
AND INSPECTION Postflight Hours Hours Hours Hours Para D)

NOTE: If any components of the fuel system is disconnected or replaced, a leak


check must be done (refer to 72-00-00, TESTING).

(1) Replace the fuel filter X


element.*
* The fuel filter element is the disposable type, and must be replaced
every 600 hours or when the element is contaminated. If the element is
contaminated, inspect and clean the fuel system (refer to 73-00-00,
CLEANING).

(2) Check for the fuel X


filter for a popped
bypass indication button
(refer to 73-00-00,
CLEANING for corrective
action).

(3) Inspect the fuel filter X


bracket for cracks.

(4) Visually inspect all X


fuel system components
for leaks during the
Ground Idle Run in
72-00-00, TESTING.

(5) Visually inspect (refer X


to 79-00-00, INSPECTION)
the housing of the oil
cooler for chafing
(caused by the loop
clamp on the C-sump aft
scavenge hose).

(6) General visual X


inspection of the fuel
pump and the main fuel
control assembly.

F. Check the visible areas


of the fan rotor, engine
inlet, and front frame
(refer to 72-20-00,
INSPECTION) for the
usable limits):

5-21-00
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GE Aircraft Engines

TABLE 803. INSPECTION AND SERVICING REQUIREMENTS (Cont)

INSPECTION TIME CATEGORIES

3000
Hours
Preflight (Refer
ENGINE COMPONENT or 100 300 600 1200 to
AND INSPECTION Postflight Hours Hours Hours Hours Para D)

(1) Fan spinner for:

(a) Cracks. X

(b) Dents. X

(c) Looseness. X

(2) Fan rotor for free X


rotation (use your
hands to turn the
rotor).

(3) Fan vanes for dents X


and cracks, and for
loose or missing
nuts.

(4) Fan rotor blades for:

(a) Unserviceable blade X


tip rubs (as evidenced
by tip discoloration).

(b) Nicks and dents. X

(c) Security and X


cracks.

(d) Missing lubricant


on the blade tangs
(re-apply for
cause only).

(5) Fan disk for X


protruding bushings.*

(6) Aluminum components X


of the fan casing for
cracks and dents.

* Only needed when N1 vibrations are above


the normal operating range. The bushings
should not be felt when you move a
straightedge across the face of the disk.

5-21-00
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GE Aircraft Engines

TABLE 803. INSPECTION AND SERVICING REQUIREMENTS (Cont)

INSPECTION TIME CATEGORIES

3000
Hours
Preflight (Refer
ENGINE COMPONENT or 100 300 600 1200 to
AND INSPECTION Postflight Hours Hours Hours Hours Para D)

(7) Abradable rub strip for X


unserviceable rubs.*

(8) Forward engine mount for X


security and cracks.

(9) Front frame for cracks X


around the AGB mount
pads.

(10)Ignition exciter for X


security and damage
(refer to 74-00-00,
INSPECTION).

(11)Visually inspect the X


water drain, in the
blade removal port,
for blockage.

G. Check the compressor


rotor and the stator
assemblies (refer to
72-30-00, INSPECTION
for the limits) for:

(1) Nicks, dents, and curled X


tips on the rotor blades
that are visible through
the borescope.

(2) Cracks on rotor blades X


that are visible through
the borescope.

(3) Dents and cracks in X


visible areas of the
compressor casings.

* A continuous circumferential rub more than


75% or more of the rub strip is evidence of
a possible separation of the fan blade tang.

5-21-00
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GE Aircraft Engines

TABLE 803. INSPECTION AND SERVICING REQUIREMENTS (Cont)

INSPECTION TIME CATEGORIES

3000
Hours
Preflight (Refer
ENGINE COMPONENT or 100 300 600 1200 to
AND INSPECTION Postflight Hours Hours Hours Hours Para D)

(4) Variable vanes for:

(a) Nicks and dents. X

(b) Cracks and excessive X


movement.

(5) Missing lock tabs from X


visible variable vane
outer shank nuts.

(6) Rubs between variable X


vanes and shrouds that
are visible through the
borescope.

(7) Distorted variable vane X


actuator ring.

(8) Loose variable geometry X


system caused by worn
bushings in rod end,
actuator rings, and
torque shaft forward
bearing for migration.

(9) Inspect the variable X


geometry feedback cable
and the VG actuator
attachment points for
security.

(10) Disengaged or bent X


variable vane Lever
arms or turnbuckles.*

* If you see any disengaged or bent lever arms or turnbuckles, the


engine must be sent to an authorized GE Aircraft Engines overhaul shop.

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GE Aircraft Engines

TABLE 803. INSPECTION AND SERVICING REQUIREMENTS (Cont)

INSPECTION TIME CATEGORIES

3000
Hours
Preflight (Refer
ENGINE COMPONENT or 100 300 600 1200 to
AND INSPECTION Postflight Hours Hours Hours Hours Para D)

WARNING: PENETRATING OIL

DO NOT LET PENETRATING OIL STAY ON YOUR SKIN. PENETRATING OIL IS


DANGEROUS TO YOUR SKIN AND EYES. DO NOT BREATHE THE FUMES FROM THIS
OIL. MAKE SURE YOU HAVE A GOOD FLOW OF AIR. THE FUMES CAN GIVE YOU
A HEADACHE AND CAN MAKE YOU DIZZY AND SICK.

CAUTION: THE VG LINKAGE ROD-END BEARINGS MUST BE LUBRICATED EVERY 300 HOURS
WITH PENETRATING OIL WD-40 OR LUBRICANT LPS-1 (OR EQUIVALENT) ON THE
TURNBUCKLES AND THE CLEVIS ADAPTER AT 24 LOCATIONS.

(11) Lubricate the surfaces X


of the VG rod end
bearings (refer to
figure 801, view A
for the location) with
penetrating oil WD-40
or lubricant LPS-1.

(12) Overall condition of X


the variable geometry
system.

H. Check the combustion section


(refer to 72-40-00, INSPEC-
TION) for:

(1) Security of the fuel X


manifold connections.

(2) Cracks in combustion X


chamber frame (visible
areas).

(3) Nicks, dents, scratches, X


wear, or carbon buildup
on the fuel injectors
that are visible through
the borescope (refer to
73-00-00, INSPECTION).

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GE Aircraft Engines

Variable Geometry Actuating System - Inspection


Figure 801

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GE Aircraft Engines

TABLE 803. INSPECTION AND SERVICING REQUIREMENTS (Cont)

INSPECTION TIME CATEGORIES

3000
Hours
Preflight (Refer
ENGINE COMPONENT or 100 300 600 1200 to
AND INSPECTION Postflight Hours Hours Hours Hours Para D)

(4) Detailed visual inspec- X


tion of the fuel injec-
tor heat shields (refer
to 73-00-00, INSPEC-
TION).

(5) Hot spots, bulges, and X


cracks on the combustion
liner during the bores-
cope inspection.

(6) Detailed visual inspec- X


tion of the stages 1 and
2 nozzle assemblies.

(7) Visible wear on the X


primary swirlers (refer
to 72-40-00, INSPEC-
TION).

(8) Centering of the fuel


injectors in swirlers
(refer to 72-4O-00,
INSPECTION) at:

(a) Borescope inspec- X


tion.

(b) Detailed visual X


inspection of the
swirlers after the
removal of the
injectors.

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GE Aircraft Engines

TABLE 803. INSPECTION AND SERVICING REQUIREMENTS (Cont)

INSPECTION TIME CATEGORIES

3000
Hours
Preflight (Refer
ENGINE COMPONENT or 100 300 600 1200 to
AND INSPECTION Postflight Hours Hours Hours Hours Para D)

I. Check the accessory drive


section (refer to 72-60-00,
INSPECTION) for:

(1) Security of the acces- X


sory gearbox brackets
and the brackets on the
front frame.

(2) Security of the compo- X


nents that are installed
on the gearbox.

SB 72-11

(3) Borescope inspection X


(refer to 72-00-00,
INSPECTION) of the PTO
carbon sleeve (G01 and
G06 assemblies only) for
forward movement.

(4) Detailed inspection of X


the accessory gearbox
mounts.

J. Check the condition and the X


security of the isolators on
the control amplifier (refer
to 74-00-00, INSPECTION).

K. Check the HPT and LPT


turbine sections (refer
to 72-50-00, INSPECTION)
for:

(1) Cracks, bulges, and hot X


spots on the casings.

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GE Aircraft Engines

TABLE 803. INSPECTION AND SERVICING REQUIREMENTS (Cont)

INSPECTION TIME CATEGORIES

3000
Hours
Preflight (Refer
ENGINE COMPONENT or 100 300 600 1200 to
AND INSPECTION Postflight Hours Hours Hours Hours Para D)

(2) Operational defects on X


the LPT exposed areas of
the turbine nozzles.

(3) Condition of thermo- X


couple harness (must
meet all serviceable
requirements in
74-00-00, INSPECTION).

(4) Borescope inspection X


(refer to 72-00-00,
INSPECTION) of the stage
1 nozzle and the HPT
stage 1 blades.

(5) Borescope inspection of X


the outer transition
liner on engines
SN 350489 and below that
have not been modified
to SB 72-38.

(6) Visual inspection of the X


stage 6 turbine blades
for FOD.

(7) Security of the exhaust X


centerbody.

(8) Igniter plugs (must meet X X


all the serviceable CF34-1A/-3A CF34-3A2
requirements in 74-00-00 only only
INSPECTION); also, refer
to the note.

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GE Aircraft Engines

TABLE 803. INSPECTION AND SERVICING REQUIREMENTS (Cont)

INSPECTION TIME CATEGORIES

3000
Hours
Preflight (Refer
ENGINE COMPONENT or 100 300 600 1200 to
AND INSPECTION Postflight Hours Hours Hours Hours Para D)

NOTE:  For CF34-1A/-3A engines, it is recommended that one igniter plug be


replaced every 300 hours. If both igniter plugs are within the
inspection limits in 74-00-00, INSPECTION, then replace the igniter
plug that has been in service longer. If neither igniter plug meets
the inspection requirements, replace both igniter plugs.
 For CF34-3A2 engines, the igniter plugs must be inspected with the
igniter plug gage PN 11-10792.

(9) Detailed visual X


inspection of the HPT
stages 1 and 2 shrouds.

(10) Inspect the LPT stator X


assembly.*

* If the LPT stator assembly is PN 6020T15G14, it must be returned to


an authorized overhaul facility for tack welding of the pin and clip
assemblies; then, after the rework, the assembly must re-identified
from PN 6020T15G14 to G24.

(11) Inspect the C-sump X


scavenge tube (at the 6
o'clock position) and
the groove for internal
coking; clean as
required (must be
within the serviceable
limits in 72-50-00,
INSPECTION).

L. Do a Power Assurance Check X


(refer to TESTING).

M. Waterwash the compressor X


(refer to 72-00-00,
CLEANING) .*

* Engines with a high rate of landings (especially in locations where there


is airborne soot, dirt, or salt) may require additional cleaning intervals.
Generally, if there is a performance deterioration, noted by an increase
in ITT (change margin) of 15 C (27 F) (as determined by the Power Assurance
curves in 72-00-00, TESTING), the engine will require cleaning (refer to
72-00-00, CLEANING).

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MAINTENANCE MANUAL
GE Aircraft Engines

TABLE 803. INSPECTION AND SERVICING REQUIREMENTS (Cont)


INSPECTION TIME CATEGORIES

3000
Hours
Preflight (Refer
ENGINE COMPONENT or 100 300 600 1200 to
AND INSPECTION Postflight Hours Hours Hours Hours Para D)

* * * * * FOR ENGINES NOT MODIFIED TO SB 75-0002 * * * * *

N. Do a B-Sump Pressure X
Measurement (refer to
72-00-00, SPECIAL
MAINTENANCE PRACTICES).**

** If any oil system component is disconnected or removed, a leak check must


be done (refer to 72-00-00, TESTING).

* * * * * FOR ALL * * * * *

O. At each engine
visit/exposure to any
authorized GEAE overhaul
shop, do a visual inspection
of the screens inside the C-
sump scavenge fitting (ports
No. 3 and No. 4) and the
screens inside the B-sump
scavenge fitting (ports No.
5 and No. 6) for evidence of
coked oil build-up. Clean
all evidence/traces of coked
oil build-up (refer to
SEI-582, 72-09-01, SPECIAL
PROCEDURE 02).

P. Do a mid-point inspection
(refer to para D).
Borescope-inspect (refer to
72-00-00, INSPECTION) the
Compressor, and disassemble
the engine to the extent to
inspect all the hot section
components, including the
combustion liner (refer to
72-00-00, SPECIAL
MAINTENANCE PRACTICES - On-
Aircraft Maintenance and
Inspection of Hot Section);
also, refer to Notes 2 and 3
at the end of this table.
Also, refer to item O.

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CF34 TURBOFAN ENGINE
MAINTENANCE MANUAL
GE Aircraft Engines

TABLE 803. INSPECTION AND SERVICING REQUIREMENTS (Cont)


INSPECTION TIME CATEGORIES

3000
Hours
Preflight (Refer
ENGINE COMPONENT or 100 300 600 1200 to
AND INSPECTION Postflight Hours Hours Hours Hours Para D)

Q. Do an engine overhaul
every 6000 hours (refer
to SEI-582); also, refer
to Notes 1 through 6 at
the end of this table.
Also, refer to item O.

NOTE: 1. An additional 10%, or 45 hours, whichever is less (per interval), is


allowed to provide operators with scheduling flexibility beyond the
fixed limits established above.

2. For the basic engine, the mid-point inspection interval (3000 hours),
or overhaul (6000 hours), is determined by the hours. Cycle lives,
referenced in Chapter 5-11-00, must not be exceeded prior to reaching
the hourly inspection limit.

3. All cycle limits are given in Chapter 5-11-00.

4. A complete borescope inspection of the engine must be done every


3000 hours or 10 years TSN/TSO (Time Since Overhaul), whichever occurs
first (refer to 72-00-00, INSPECTION for the borescope inspections;
except, do not borescope-inspect the PTO assembly, and the inspections
for Troubleshooting Purposes do not apply).

5. The overhaul of accessories, at the time of engine overhaul, is


recommended by GE Aircraft Engines. However, this is an option
of the operator.

6. GE Aircraft Engines will permit a one time extension of the Hot


Section Inspection Interval after you (the operator) complete
SB 72-53. Operators who comply with SB 72-53 before or concurrent
with Hot Section Inspection (2000-3000 hours TSN), and accomplish
a Hot Section Inspection while complying with SB 72-53, will be
permitted to operate the engine to its 6000-hour overhaul point
without performing a second Hot Section Inspection before overhaul.
If the engine has more than 3000 hours, SB 72-53 does not apply and
you must obey the Hot Section Inspection Intervals in this Chapter.

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GE Aircraft Engines

TABLE 804. HOT SECTION REMOVAL/INSPECTION REQUIREMENTS

Removal/Installation Inspection
Item Procedures Procedures

A. Low-pressure turbine assembly 72-00-00, SPECIAL 72-50-00,


(without fan drive shaft). MAINTENANCE PRACTICES INSPECTION

B. High-pressure turbine 72-00-00, SPECIAL 72-50-00,


stator/rotor assembly. MAINTENANCE PRACTICES INSPECTION

NOTE: Because the combustion liner, the stages 1 and 2 turbine nozzles, and
the stages 1 and 2 HPT shrouds are more susceptible to hot section
distress than other engine parts, they are used as indicators of abnormal
distress. Therefore, during inspection of the hot section, if the
combustion liner, the stages 1 and 2 turbine nozzles, and the stages 1
and 2 HPT shrouds are abnormally distressed, also inspect the fuel
injectors in the area of distress (refer to 73-00-00, INSPECTION).

C. Stage 1 turbine nozzle. 72-00-00, SPECIAL 72-40-00,


MAINTENANCE PRACTICES INSPECTION

5. CF34-1A/-3A/-3A2 Engine Maintenance Program - Shop Level Mandatory


Inspection Requirements.

A. This procedure is used to identify specific piece-parts that require


mandatory inspections that must be accomplished at each piece-part
exposure in a GEAE authorized overhaul facility, using the applicable
Chapters referenced in table 805 for the inspection requirements.

B. Piece-part exposure is defined as follows:

(1) For engines that utilize the “On Condition” maintenance


requirements:

The part is considered completely disassembled when done in


accordance with the disassembly instructions in the GEAE engine
authorized overhaul Shop Manual and:

The part has accumulated more than 100 cycles in service since
the last piece-part opportunity inspection and the part is
returned to the overhaul facility, provided that the part was not
damaged or related to the cause for its removal from the engine.

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(2) For engines that utilize the “Hard Time” maintenance


requirements:

The part is considered completely disassembled when done in


accordance with the disassembly instructions used in the “Minor
Maintenance” or “Overhaul” instructions in the GEAE engine
authorized Maintenance or Shop Manual, and:

The part has accumulated more than 100 cycles in service since
the last piece-part opportunity inspection and the part is
returned to the overhaul facility, provided that the part was not
damaged or related to the cause for its removal from the engine.

C. Refer to table 805 for the mandatory inspection requirements.

TABLE 805. MANDATORY INSPECTION REQUIREMENTS

MANUAL
PART NAME/PART NUMBER CHAPTER/SECTION/SUBJECT MANDATORY INSPECTION

Fan Disk (all) SEI-582 All areas (FPI) 1


72-21-00, INSPECTION Bores (ECI) 2

Stage 1 HPT Rotor Disk SEI-582 All areas (FPI) 1


(PN 6031T89, PN 6078T93, 72-52-00, INSPECTION Bore (ECI) 2
and all reworked PN Boltholes (ECI) 2
rotor disks) Air Holes (ECI) 2

Stage 2 HPT Rotor Disk SEI-582 All areas (FPI) 1


(PN 6031T90, PN 6078T94, 72-52-00, INSPECTION Bore (ECI) 2
and all reworked PN Boltholes (ECI) 2
rotor disks) Air Holes (ECI) 2

HPT Rotor Outer Torque SEI-582 All areas (FPI) 1


Coupling PN 5041T67 72-52-00, INSPECTION Bore (ECI) 2
and all reworked PN
outer torque couplings)
1
FPI = Fluorescent Penetrant Inspection Method
2
ECI = Eddy Current Inspection Method

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6. CF34-1A/-3A/-3A2 Engine Maintenance Program - Shop Level Requirements.

A. During the disassembly of any engine component, and before the


installation of any component, inspect all the components that are
removed, or portions of the components that are exposed. Inspect the
components and exposed areas referred to in the published inspection
criteria in the applicable section in this manual.

B. The replacement intervals for life-limited parts (refer to


Chapter/Section 5-11-00) must take precedence over all maintenance
actions contained in the Engine Maintenance Program - Shop Level
Requirements. The inspection and maintenance intervals herein are
subject to the cycle life or hourly parts limits as described in
Chapter/Section 5-11-00.

C. Table 806 contains important time- or cycle-driven shop level


maintenance actions which are recommended to be done if the engine is
removed from the aircraft for any cause. Based upon engine
refurbishment findings, GE Aircraft Engines will work with operators to
recommend additional preventative refurbishment action that must be
considered.

D. Go to Table 806.

TABLE 806. CF34-1A/-3A/-3A2 ENGINE MAINTENANCE PROGRAM - SHOP LEVEL


REQUIREMENTS

Inspection/ Inspection/Maintenance
Maintenance Interval Requirements Reference

Inspection of the
fan blade
retaining pin
holes for:

NOTE: If the cycle since new (CSN) of a used fan blade is not known, use this
criteria:

 For fan blade serial numbers that are within an operator's fleet,
assign to the fan blade the highest CSN of any engine in the
operator's fleet.
 If the blade is not originally owned by the operator, use the
highest CSN engine in the CF34 fleet (this information can be
obtained from GEAE Product Support Engineering by contacting your
technical representative).

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TABLE 806. CF34-1A/-3A/-3A2 ENGINE MAINTENANCE PROGRAM - SHOP LEVEL


REQUIREMENTS (Cont)

Inspection/ Inspection/Maintenance
Maintenance Interval Requirements Reference

(1) Fan blades At 15,000 cycles If the fan blades will SEI-582,
without (but not to exceed not be reworked, by 72-00-00,
bushings. 15,000 cycles), installation of the fan SPECIAL
and every 3,000 blade retaining pin PROCEDURES.
cycles after the hole bushing, do an Inspect per
15,000 cycle Eddy Current Inspection 72-21-00,
inspection (refer (ECI) of all three INSPECTION,
to the holes of each fan Table 804.
NOTE for blade.
establishing
cycles).
or
If the fan blades will SEI-582,
be reworked, by 72-21-00,
installation of the fan INSPECTION,
blade retaining pin hole Table 804.
bushing, send the fan
blades to a GEAE
approved repair source.

(2) Fan blades At 18,000 cycles Remove the blades from 72-00-00,
with since rework by service and scrap the SPECIAL
bushings bushing part. MAINTENANCE
(PN installation (but PRACTICES.
4923T56). not to exceed
18,000 cycles).
Cycles must be
established from
the time of
initial bushing
installation.

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GE Aircraft Engines

REVISION NO. 29, DATED SEP 1/04

CHAPTER/SECTION DESCRIPTION OF CHANGE PAGE (S)

5-11-02 Added forward spool PN 6078T56P05 and 801


TIME LIMITS its life limits in paragraph 2.

5-11-02 Revised the life limits for rear spool 803


TIME LIMITS PN 5087T46P01/P02 and stage 9 disk PN
6087T01P03.

5-11-04 Added new life limits for stages 3, 4, 801, 803


TIME LIMITS 5, and 6 disks.

5-11-05 Added a NOTE to clarify the life limits 802


TIME LIMITS of the No. 5 bearing carbon seal
preformed packing in paragraph 2.

5-11-00
HIGHLIGHTS
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LIST OF EFFECTIVE PAGES

CHAPTER/ CHAPTER/
SECTION PAGE DATE SECTION PAGE DATE

List of
Effective
Pages *1 Sep 1/04

Table of
Contents 1 Apr 1/03

5-21-00 801 thru 805 Jun 30/97


806 Sep 15/00
806A/806B Sep 15/00
807 Sep 15/00
808 thru 809 Sep 15/99
810 Sep 30/98
811 thru 816 Jun 30/97
817 thru 818 Sep 15/01
*819 Sep 1/04
820 thru 821 Sep 15/00
822 thru 823 Apr 1/03

* Asterisk indicates pages added, changed, or deleted by this revision.

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Page 1
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TABLE OF CONTENTS

CHAPTER/
SUBJECT SECTION PAGE

SCHEDULED MAINTENANCE PROGRAM 5-21-00

General 801
Special Tools and Fixtures 801
Consumable Materials 802
Scheduled Inspection Checks 802
Preliminary Instructions 802
Daily Checks (Preflight or Postflight) 802
Periodic Inspections 803
Mid-Point (3000-Hour) Hot Section Inspection
Interval 803
CF34-1A/-3A/-3A2 Engine Maintenance Program -
Shop Level Mandatory Inspection Requirements 820

5-21-00
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Page 1
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