Fan Removal

GEK 109976 SEP 05

110B & 115B

FAN STATOR REMOVAL/INSTALLATION

GE Aircraft Engine PROPRIETARY

GE90

GE AIRCRAFT ENGINES

BOEING 777

eCUSTOMER TECHNICAL EDUCATION CENTER

1. Introduction

GE AIRCRAFT ENGINES GE90 TRAINING MANUAL

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GE PROPRIETARY INFORMATION

Page 1-1Sep 05B777/GE90-110B, -115B 71-00-05

GE90 Fan Stator Removal/Installation

gDocument: GEK 109976

Issued: Sep 05

Published by:Customer Training Services

GE Aircraft EnginesCustomer Technical Education Center

123 Merchant StreetCincinnati, Ohio 45246


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Page 1-2Sep 05B777/GE90-110B, -115B 71-00-05

THIS PAGE INTENTIONALLY LEFT BLANK


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This publication is for TRAINING PURPOSES ONLY. This information is accurate at the time of compilation; however, noupdate service will be furnished to maintain accuracy. For authorized maintenance practices and specifications, consult thepertinent Maintenance Publication.

This product is considered GE Aircraft Engines technical data information and therefore is exported under U.S. GovernmentExport License Regulations. It is issued to the user under specific conditions that; the contained data, or it's product may notbe resold, diverted, transferred, trans-shipped, re-exported, or used in any other country without prior written approval of theU.S. Government.

Proprietary Information NoticeThe information contained in this document is disclosed in confidence. It is the property of GE and shall not be used (exceptfor evaluation), disclosed to others, or reproduced without the expressed written consent of GE. If consent is given forreproduction in whole or in part, this notice shall appear on any such reproduction, in whole or in part. The foregoing is subjectto any rights the U.S. Government may have acquired as such information.

Copyright 2005 GE Aircraft Engines


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Page 1-4Sep 05B777/GE90-110B, -115B 71-00-05



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Page 1-5Sep 05B777/GE90-110B, -115B 71-00-05

TABLE OF CONTENTS

Section Topic Revised Page Numbers

1. IntroductionTable of Contents ........................................................................ Sep/05 ................................ 1 - 5Acronyms and Abbreviations ..................................................... Sep/05 ................................ 6 - 7Engine General ............................................................................ Sep/05 ................................ 8 - 9Fan Stator Module Removal/Installation Introduction .............. Sep/05 ............................ 10 - 12

2. Fan Stator Module Removal/Installation - Equipment .................... Sep/05 .............................. 1 - 18

3. Fan Stator Module Removal/Installation - Engine Preparation ..... Sep/05 .............................. 1 - 56

4. Fan Stator Module R & I - 9C6030 Transfer System ....................... Sep/05 .............................. 1 - 14

5. Replacement Engine Test ................................................................ Sep/05 ................................ 1 - 4


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Page 1-7Sep 05B777/GE90-110B, -115B 71-00-05

ALF Aft Looking ForwardAMM Aircraft Maintenance ManualCTEC Customer Technical Education CenterEAI Engine Anti-IceEBU Engine Buildup UnitEDP Engine Driven PumpEEC Electronic Engine Control (also FADEC)FHF Fan Hub FrameFLA Forward Looking AftFADEC Full Authority Digital Engine Control (also

EEC)GEAE GE Aircraft EnginesHMU HydroMechanical UnitHPT High Pressure TurbineIDG Integrated Drive GeneratorLH Left HandLPT Low Pressure TurbineMFP Main Fuel PumpOGV Outlet Guide Vane(s)PRSOV Pressure Regulating Shut Off ValveRH Right HandR&I Removal & InstallationQEC Quick Engine ChangeVBV Variable Bleed ValveVSV Variable Stator Vanes

ABBREVIATIONS & ACRONYMS


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Page 1-8Sep 05B777/GE90-110B, -115B 71-00-0572-00-00

ENGINE GENERAL

The GE90 has been designed to power the BOEING 777and future airplanes. With an initial thrust of 76,000 lbs ithas a growth capability up to 115,000 lbs ( and more ).

The GE90 is an ultrahigh bypass (9:1), variable stator,axial-flow turbofan propulsion system designed to meethigh thrust commercial jet engine requirements ofadvanced aircraft manufactured during the mid 1990's andbeyond.

The 75K to 115K+ lbs thrust family of engines is designedto provide 10% improvement in specific fuel consumption(SFC), and 33% lower emissions over previouscommercial turbofan engines. In addition, its reducednoise level permits operation at the most noise sensitiveairports in the world.

The specific fuel consumption (SFC) improvement isachieved through a higher efficiency engine cycle. Ahigher overall pressure ratio than current engines giveshigher thermal efficiencies, while the higher bypass ratio(BPR) provides improved propulsion efficiency.

The GE90 is designed for ease of maintainability and highoverall system reliability. Many of the components werederived from proven designs on existing engines. Thisderivative heritage provides a sound foundation for thecomponents and systems of the GE90.

Type of engine: Turbofan engine

Arrangement: Two spool axial airflow

Rotation: (both rotors) Clockwise (AFT lookingForward)

Compressors:- Fan: Single stage- Booster: Four stages- High pressure compressor: Nine stages

Combustion chamber: Dual-dome annular

Turbines:- High pressure turbine: Two stages- Low pressure turbine: Six stages

Dimensions:- Engine (no EBU or inlet):- Nominal length: 287.36 inches (7.300 m)- Nominal width: 134.86 inches (3.425 m)- Nominal weight (dry): 18,291 lbs (8314 kg)

- Powerplant (with EBU and inlet):- Nominal length: 323.24 inches (8.210 m)- Nominal width: 166.46 inches (4.228 m)- Nominal weight (dry): 18,982 lbs (8628 kg)


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Page 1-9Sep 05B777/GE90-110B, -115B 71-00-0572-00-00

GE90 PROPULSION SYSTEM

FAN

DIA

MET

ER =

128

IN. (

3.52

4 M

)

POW

ER P

LAN

T H

EIG

HT

= 16

6.46

IN. (

4.22

8 M

)

SPARE ENGINE LENGTH = 190.84 IN. (4.847 M)

POWERPLANT OVERALL LENGTH = 323.24 IN. (8.210 M)

INSTALLABLE SPARE ENGINE LENGTH = 287.36 IN. (7.300 M)

FAN

STA

TOR

DIA

MET

ER =

134

.86

IN. (

3.42

5 M

)

2


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Page 1-10Sep 05B777/GE90-110B, -115B 71-00-05

FAN STATOR MODULE REMOVAL/INSTALLATIONINTRODUCTION

The GE90 is designed for high overall system reliabilityand maintainability based on the relevant experience ondifferent successful programs.

Due to its size, the engine is designed around the principleof the fan stator module removal into two parts:

- The fan stator module

- The engine propulsor

This removal increases the engine transportability andreduces the number and the cost of the spare parts byreusing some engine hardware.


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Page 1-11Sep 05B777/GE90-110B, -115B 71-00-05

FAN STATOR MODULE REMOVAL/INSTALLATION EQUIPMENT

9C6030 FAN STATORMODULE TRANSFER

CARRIAGE

9C6025 SHIPPING ANDINSTALLATION STAND

ENGINE PROPULSORFAN STATORMODULE


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Page 1-12Sep 05B777/GE90-110B, -115B 71-00-05


2. Equipment


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Page 2-1Sep 05B777/GE90-110B, -115B 71-00-05

Objectives:

At the completion of this section a student should be able to:

... identify the tooling required for fan stator module removal/installation

FAN STATOR MODULE REMOVAL/INSTALLATION - EQUIPMENT


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Page 2-2Sep 05B777/GE90-110B, -115B 71-00-05

FAN STATOR MODULE REMOVAL/INSTALLATION -EQUIPMENT

The equipment to do the fan stator module removal is asfollows:

- 9C6025 shipping and installation stand- 9C6030 fan stator module transfer system- 9C6014 personnel stand- 9C1202 fan blade spacer removal tool

or 9C3001 fan blade spacer removal tool- 9C6031 component shipping container- 9C6028 fan blade shipping container

The equipment to do the fan stator module installation isas follows:

- 9C6025 shipping and installation stand- 9C6030 fan stator module transfer system- 9C6014 personnel stand- 9C1277 guide pin set- 9C6031 component shipping container- 9C6028 fan blade shipping container


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Page 2-3Sep 05B777/GE90-110B, -115B 71-00-05

FAN STATOR MODULE REMOVAL/INSTALLATION EQUIPMENT

9C6030 FAN STATORMODULE TRANSFER

CARRIAGE

9C6025 SHIPPING ANDINSTALLATION STAND

ENGINE PROPULSORFAN STATORMODULE


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Page 2-4Sep 05B777/GE90-110B, -115B 71-00-05

9C6025 INSTALLATION AND SHIPPING STAND

The 9C6025 stand allows:

- the removal and installation of the engine to theairplane wing.

- the removal and installation of the fan stator casefrom the propulsor.

- the air and ground transportation of the propulsor.

It is made up of two main parts:

- the cradle- the base.

Two aft cradle to engine support adapters and twoforward cradle to engine support adapters allow for thesupport of the propulsor or engine.

There are hydraulic jacks near each wheel of the stand.The hydraulic jacks are controlled from a central hydraulichand pump located on the left side of the stand.

There is a hand operated hyraulic pump attached to thebase for raising and lowering of the cradle on the base.

Forklift tubes are positioned within the base and usablefrom either side of the stand.


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Page 2-5Sep 05B777/GE90-110B, -115B 71-00-05

9C6025 INSTALLATION AND SHIPPING STAND

BASE ASSEMBLY

CRADLE ASSEMBLY

HYDRAULICHAND PUMP

HYDRAULICJACK

(DEPLOYED)

STEERING BAR STOW

TOW BAR STOW

STORAGE BOX

AFT ENGINESUPPORT ADAPTERS

FORWARDENGINE SUPPORT

ADAPTERS

FORKLIFTTUBE


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Page 2-6Sep 05B777/GE90-110B, -115B 71-00-05

9C6030 FAN STATOR MODULE TRANSFER SYSTEM

The 9C6030 fan stator module transfer system supportsthe fan stator module. The 9C6030 transfer system isattached to the GE90 fan stator module and is used toremove or intall the fan stator module onto the propulsor.

To align the fan stator module to the propulsor, alladjustments are made to the fan stator module using the9C6030 fan stator module transfer system.

The 9C6030 has two Aft Adapters, two ForwardAdapters, two 94B Forward Adapter Plates and two SideFrames. All four wheels of the side frames areindividually adjustable up and down.


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Page 2-7Sep 05B777/GE90-110B, -115B 71-00-05

9C6030 FAN STATOR MODULE TRANSFER SYSTEM

SIDE FRAME(RIGHT)

SIDE FRAME(LEFT)

FORWARDADAPTER(RIGHT)

FORWARDADAPTER

(LEFT)

AFT ADAPTER(RIGHT)

AFT ADAPTER(LEFT)


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Page 2-8Sep 05B777/GE90-110B, -115B 71-00-05

9C1202 FAN BLADE SPACER REMOVAL TOOL

The 9C1202 fan blade spacer removal tool is used toremove the fan blade spacer.

Fan Blade Spacer Removal:

- Place the detail pin in the bolt hole of the fan bladespacer.

- move the slide hammer aft and forward to removethe fan blade spacer.


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Page 2-9Sep 05B777/GE90-110B, -115B 71-00-05



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Page 2-10Sep 05B777/GE90-110B, -115B 71-00-05

FAN BLADE SPACER REMOVAL/INSTALLATIONTOOLS

The 9C3001 fan blade spacer removal tool is used toremove the fan blade spacers.


- Place the fan blade spacer removal tool detail pininto the fan blade spacer bolt hole and usehydraulic pressure to remove the fan blade spacer.


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Page 2-11Sep 05B777/GE90-110B, -115B 71-00-05

9C3001FAN BLADE SPACER REMOVAL TOOL


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Page 2-12Sep 05B777/GE90-110B, -115B 71-00-05

9C6014 PERSONNEL STAND

The 9C6014 personnel stand allows for access to the fanstator module forward flange bolts.

The stand is made up of three parts and is placed into thefan stator module after the fan blades have beenremoved. When assembled, the 9C6014 personnel standprovide steps for the mechanic to reach the upper bolts ofthe fan stator module forward bolt flange.

Forklift tubes are positioned within the stand and usablefrom the front side of the stand.


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Page 2-13Sep 05B777/GE90-110B, -115B 71-00-05


9C6014STAND

B

A

B


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Page 2-14Sep 05B777/GE90-110B, -115B 71-00-05

9C1277 GUIDE PIN SET

The 9C1277 guide pin set is used align the fan statormodule bolt flanges onto the propulsor bolt flanges.

The guide pin set contains eight guides pins. The guidepins are installed by hand into the fan stator module aftbolt flange.

- Install the guides pins at equal distances around theaft fan stator module bolt flange.


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Page 2-15Sep 05B777/GE90-110B, -115B 71-00-05


FAN STATOR MODULEOUTLET GUIDE VANES

FAN HUB FRAME

AFT FAN STATORMODULE FLANGE

FORWARD FAN STATORMODULE FLANGE

9C1277 GUIDE PIN(8 LOCATIONS)

GUIDE PIN


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Page 2-16Sep 05B777/GE90-110B, -115B 71-00-05

9C6031 SPINNER AND COMPONENTS SHIPPINGCONTAINER & 9C6028 FAN BLADES SHIPPINGCONTAINER

The purpose of these containers is to ensure thetransportation and the storage of the fan case modulereusable hardware, in a safe and secure manner.

Each is made up of two main parts:

- the fiberglass cover- the metal base assembly.

A document storage receptacle and a view port areprovided.

Hoist rings are built into the cover for removaland installation of the cover. Forklift tubes are positionedwithin the base and usable from either side of the unit.

The interior is divided in several areas to ensure propersupport of items during all container motions. Thecontainer has been designed to ship the followingitems:

9C6031 Components Shipping Container holds:

- fan blade platforms- fan blade spacers- dovetail key

- fan blade retainers- spinner- support ring- acoustic panels- air bleed deflector panels- blankoff panels- lower bifurcation module- drain module- center vent tube extension- starter air duct- booster anti-ice tubes- booster splitter fairing.

9C6028 Fan Blade Shipping Container holds:

- fan blades


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Page 2-17Sep 05B777/GE90-110B, -115B 71-00-05

9C6031 FAN BLADES, SPINNER ANDCOMPONENTS SHIPPING CONTAINER

9C6031CONTAINER

FIBERGLASSCOVER

BASE

BASE

9C6028 FAN BLADE SHIPPING CONTAINER

BASE

FIBERGLASSCOVER

9C6028CONTAINER

FANBLADES


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Page 2-18Sep 05B777/GE90-110B, -115B 71-00-05


3. Engine Preparation


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B777/GE90-110B, -115BPage 3-1

Sep 0571-00-05

Objectives:


... identify the engine items removed for fan stator module removal/installation

FAN STATOR MODULE REMOVAL/INSTALLATION - ENGINE PREPARATION


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Page 3-2Sep 05B777/GE90-110B, -115B 71-00-05

ENGINE PREPARATION FOR FAN STATOR MODULEREMOVAL/INSTALLATION

Prepare the engine for removal of the fan stator modulefrom the engine propulsor.

Note: The steps of engine preparation can be done withthe engine on wing or in the installation/shipping stand.

Following are the main steps of engine preparation for theengine fan stator removal:

- drain the oil from the engine, IDG and BackupGenerator

- remove the drain and service module assembly- disconnect the electrical harnesses from the fan stator

assembly- remove the lower hydraulic bifurcation assembly- remove the blank off panels- remove the upper and lower fillet fairings- remove the air bleed defector panels- remove the upper and lower bifurcation bridges- disconnect the seal pressurization and oil tank vent

tube- disconnect the EAI duct- remove the spinner and support ring- remove the fan blade platforms- remove the fan blades and mounting hardware- remove the acoustic panels- remove the booster anti-ice tubes and splitter fairing

Complete the engine preparation after the fan statormodule as been installed on the engine propulsor.

Note: The steps of engine preparation can be done withthe engine in the installation/shipping stand or on wing.

Following are the main steps of engine preparation afterthe engine fan stator module installation:

- install the splitter fairing and booster anti-ice tubes- install the acoustic panels- install the fan blades and mounting hardware- install the fan blade platforms- install the support ring and spinner- connect the EAI duct- connect the seal pressurization and oil tank vent tube- install the upper and lower bifurcation bridges- install the bleed air deflector panels- install the upper and lower fillet fairings- install the blank off panels- install the lower hydraulic bifurcation assembly- connect the electrical harnesses to the fan stator

module assembly- install the drain and service module assembly- fill the oil of the engine, IDG and Backup Generator.


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B777/GE90-110B, -115BPage 3-3

Sep 0571-00-05 ENGINE PREPARATION FOR FAN STATOR MODULE REMOVAL/INSTALLATION

BLEED AIRDEFLECTOR

PANELSENGINE

PROPULSOR

BOOSTERSPLITTERFAIRING


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Page 3-4Sep 05B777/GE90-110B, -115B 71-00-05

ENGINE OIL (CHANGE) SERVICING

WARNING: DO NOT LET HOT OIL GET ON YOU. HOTOIL CAN BURN YOU.

The oil tank is drained by using the two quick disconnectports in the oil supply and scavenge return lines and abucket.

The drain ports are located in the oil supply and scavengereturns lines at the 6:00 position off the fan case.

Oil Tank Draining:

- connect locally manufactured drain tube to the drainports and catch the oil (11 gallons or 42 liters) in acontainer.

Oil Tank Servicing:

The oil tank is manually filled by hand pouring quart cans ofoil into the oil tank at the manual fill port.

The manual fill port cap has a dipstick attached to it. Thisdipstick indicated the amount of oil that needs to be addedto bring the oil level to full.

The oil tank dipstick reads in gallons:

- the 1/2 mark means that 1/2 gallon (2 quarts) needs tobe added.

- the 3/4 mark means that 3/4 gallon (3 quarts) needs tobe added

- the 4/4 mark means that 1 gallon (4 quarts) needs tobe added

- the 5/4 mark means that 1.25 gallon (5 quarts) needsto be added.

Note: There is no need to service the oil tank unless it is at or below the 4/4 mark - 1 gallon or 4 quarts low.

12-22-01


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B777/GE90-110B, -115BPage 3-5

Sep 0571-00-05ENGINE OIL (CHANGE) SERVICING

12-22-01


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Page 3-6Sep 05B777/GE90-110B, -115B 71-00-05

INTEGRATED DRIVE GENERATOR - SERVICING (OILCHANGE)


The Integrated Drive Generator is located on the left, aftface of the accessory gearbox.

IDG Oil Servicing:

- attaching a hose to the overfill remote service line torelieve any pressure in the system.

- removing the IDG case drain plug and catching the oil(1.5 gallons or 6 liters) in a container.

The generator remote oil service lines are attached to theaft side of the engine drain lines.

The IDG oil is serviced by:

- installing the IDG case drain plug

- pressure servicing the IDG through the remote servicelines.

12-22-07


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B777/GE90-110B, -115BPage 3-7

Sep 0571-00-05INTEGRATED DRIVE GENERATOR - SERVICING (OIL CHANGE)

12-22-07


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Page 3-8Sep 05B777/GE90-110B, -115B 71-00-05

BACKUP GENERATOR - SERVICING (OIL CHANGE)


The Backup Generator is located on the left, forward faceof the accessory gearbox.

Backup Generator Oil Draining:

- attach a hose to the overfill remote service line torelieve any pressure in the system.

- remove the Backup Generator case drain plug andcatching the oil (1 gallon or 3.7 liters) in a container.

The generator remote oil service lines are attached to theaft side of the engine drain lines.

The Backup Generator oil is serviced by:

- installing the Backup Generator case drain plug

- pressure servicing the Backup Generator through theremote service lines.

12-22-09


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B777/GE90-110B, -115BPage 3-9

Sep 0571-00-05BACKUP GENERATOR - SERVICING (OIL CHANGE)

12-22-09


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Page 3-10Sep 05B777/GE90-110B, -115B 71-00-05

DRAIN AND SERVICE MODULE ASSEMBLYREMOVAL/INSTALLATION

The drain and service module assembly is located on theaft side of the fan stator module at the 6:00 position.

The drain module takes engine accessory gearbox drivepad, fuel driven actuator and fuel driven valve internalleakage overboard.

The service module contains the engine oil lines, air linesand electrical harnesses that run between the fan stator andpropulsor.

Drain Module Removal:

- disconnect the forward lower fire detector- disconnect the manual override flexible cable from the

starter- disconnect the IDG and Backup Generator remote

service lines- disconnect the eight drain tubes- remove the drain assembly.

Drain Module Installation:

- install the drain assembly- connect the eight drain tubes- connect the IDG and Backup Generator remote

service lines- connect the manual override flexible cable from the

starter- connect the forward lower fire detector.


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B777/GE90-110B, -115BPage 3-11

Sep 0571-00-05

IDG FILLTUBE

IDGOVERFLOW

TUBE

BACKUPGENERATOR

FILL TUBE

BACKUPGENERATOROVERFLOW

TUBE

DRAIN AND SERVICE MODULE ASSEMBLY REMOVAL/INSTALLATION (SHEET 1)

FORWARD LOWERFIRE DETECTOR(NOT SHOWN)

SERVICEMODULE

71-00-05Page 3-11

Jan 03

B


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Page 3-12Sep 05B777/GE90-110B, -115B 71-00-05



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B777/GE90-110B, -115BPage 3-13

Sep 0571-00-05DRAIN AND SERVICE MODULE ASSEMBLY REMOVAL/INSTALLATION (SHEET 2)

MANUAL OVERRIDEFLEXIBLE CABLE

B


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Page 3-14Sep 05B777/GE90-110B, -115B 71-00-05

ELECTRICAL HARNESS REMOVAL/INSTALLATION

Electrical Harness Removal:

- disconnect the electrical harness connectors at thebottom of the fan case

- remove the heatshield blanket- remove the bottom of the fire seal- remove the electrical connectors from the springs clips

and quarter turn clamps. Tie the electricalharnesses out of the way on the propulsor.

Electrical Harness Installation:

- install the electrical harnesses into the springs clipsand quarter turn clamps

- connect the electrical harness connectors at thebottom of the fan case

- install the bottom of the fire seal- install the heatshield blanket.


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B777/GE90-110B, -115BPage 3-15

Sep 0571-00-05ELECTRICAL HARNESSES REMOVAL/INSTALLATION (SHEET 1)


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Page 3-16Sep 05B777/GE90-110B, -115B 71-00-05



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B777/GE90-110B, -115BPage 3-17



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Page 3-18Sep 05B777/GE90-110B, -115B 71-00-05

HEATSHIELDBLANKET W722

W724

W728

W738

W729

FWD

SAFETY CLIPS(3 LOCATIONS)

BOLTS(2 LOCATIONS)

ELECTRICAL HARNESSES REMOVAL/INSTALLATION (SHEET 3)

D

FIRE SEAL

SEE E


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B777/GE90-110B, -115BPage 3-19


E

1134065-05-A


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Page 3-20Sep 05B777/GE90-110B, -115B 71-00-05

LOWER HYDRAULIC BIFURCATION ASSEMBLYREMOVAL/INSTALLATION

Lower Hydraulic Bifurcation Assembly Removal:

- disconnect the eight pressure air tubes in front of thelower bifurcation fire seal and at 12:00 position atthe upper end of the service module

- disconnect the oil tank and oil return tubes in front ofthe lower bifurcation fire seal and at 12:00 positionat the upper end of the service module

- remove the lower hydraulic bifurcation assembly.

Lower Hydraulic Bifurcation Assembly Installation:

- install the lower hydraulic bifurcation assembly- connect the oil tank and oil return tubes in front of the

lower bifurcation fire seal and at 12:00 position atthe upper end of the service module

- connect the eight pressure air tubes in front of thelower bifurcation fire seal and at 12:00 position atthe upper end of the service module.


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B777/GE90-110B, -115BPage 3-21

Sep 0571-00-05LOWER HYDRAULIC BIFURCATION ASSEMBLY REMOVAL/INSTALLATION (SHEET 1)


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Page 3-22Sep 05B777/GE90-110B, -115B 71-00-05



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B777/GE90-110B, -115BPage 3-23


C


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Page 3-24Sep 05B777/GE90-110B, -115B 71-00-05

LOWER HYDRAULIC BIFURCATION ASSEMBLY REMOVAL/INSTALLATION (SHEET 3)


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B777/GE90-110B, -115BPage 3-25



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Page 3-26Sep 05B777/GE90-110B, -115B 71-00-05

BLANK OFF PANELS REMOVAL/INSTALLATION

The eight Blank Off Panels are located between the bleedair deflector panels on the inner cowl support.

The blank off panels are removed to get access to the fanstator module aft mount bolts.

To help during installation, the blank off panel installationpositions are etched into the panels (Example - POS 1&5).The panels are numbered from aft looking forward startingat 12:00 o'clock of the engine.

Blank Off Panel Removal:

- remove the screws from the blank off panels andremove the panels

Blank Off Panel Installation:

- install the blank off panels by position number andinstall the screws.


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B777/GE90-110B, -115BPage 3-27

Sep 0571-00-05BLANK OFF PANELS REMOVAL/INSTALLATION


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Page 3-28Sep 05B777/GE90-110B, -115B 71-00-05

FILLET FAIRINGS REMOVAL/INSTALLATION

The four Fillet Fairings are located on the bleed airdeflector panels and upper (12:00 o'clock) and lower (6:00o'clock) bifurcation firewalls.

The fillet fairings are removed to get access to the fanstator module aft mount bolts.

Fillet Fairing Removal:

- remove the two different length screws of the filletfairings and remove the fairings

Fillet Fairings Installation:

- install the fillet fairings and the two different lengthscrews.


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B777/GE90-110B, -115BPage 3-29

Sep 0571-00-05FILLET FAIRINGS REMOVAL/INSTALLATION


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Page 3-30Sep 05B777/GE90-110B, -115B 71-00-05

BLEED AIR DEFLECTOR PANELS REMOVAL/INSTALLATION

The ten Bleed Air Deflector Panels are located around theinner cowl support.

The Bleed Air Deflector Panels are removed to get accessto the fan stator module aft mount bolts.

To help during installation, the bleed air deflector panelinstallation positions are etched into the panels (Example -POS 5&10). The panels are numbered from aft lookingforward starting at 12:00 o'clock of the engine.

Bleed Air Deflector Panel Removal:

- remove the screws from the bleed air deflector panelsand remove the panels.

Bleed Air Deflector Panel Installation:

- install the bleed air deflector panels and install thescrews.


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B777/GE90-110B, -115BPage 3-31

Sep 0571-00-05BLEED AIR DEFLECTOR PANELS REMOVAL/INSTALLATION

BLEED AIRDEFLECTOR

PANEL

BLEED AIRDEFLECTOR

PANEL

BLEED AIRDEFLECTOR

PANEL

BLEED AIRDEFLECTOR

PANEL

BLEED AIRDEFLECTOR

PANEL

SCREW(29 LOCATIONS)

FWD

NOTE: LEFT SIDE IS SHOWN,RIGHT SIDE IS OPPOSITE

INSTALLATIONPOSITIONLOCATION

(EACH PANEL)


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Page 3-32Sep 05B777/GE90-110B, -115B 71-00-05

LOWER BIFURCATION BRIDGE

The Lower Bifurcation Bridge is located at the top of thelower bifurcation firewall.

The lower bifurcation bridge must be removed to allow forfan stator module removal.

Lower Bifurcation Bridge Removal:

- remove sealant between the contact surfaces- remove the nuts and bolts that attach the lower

bifurcation bridge to the fan stator- remove the lower bifurcation bridge.

Lower Bifurcation Bridge Installation:

Note: Clean the lower bifurcation bridge using the AircraftMaintenance Manual procedures before installation.

- install the lower bifurcation bridge.- install the nuts and bolts that attach the lower

bifurcation bridge to the fan stator- apply sealant between the contact surfaces.


EFFECTIVITY


B777/GE90-110B, -115BPage 3-33

Sep 0571-00-05LOWER AND UPPER BIFURCATION BRIDGES REMOVAL/INSTALLATION (SHEET 1)

WASHER(5 LOCATIONS)

NUT(5 LOCATIONS)

BOLT(4 LOCATIONS)

LOWERBIFURCATION

BRIDGE

WASHER(4 LOCATIONS)

LOWERBIFURCATION

FIREWALL


EFFECTIVITY


Page 3-34Sep 05B777/GE90-110B, -115B 71-00-05

UPPER BIFURCATION BRIDGE

The Upper Bifurcation Bridge is located at the bottom ofthe upper bifurcation firewall.

The upper bifurcation bridge must be removed to allow forfan stator module removal.

Upper Bifurcation Bridge Removal:

- remove sealant between the contact surfaces- remove the nuts and bolts that attach the upper

bifurcation bridge to the fan stator- remove upper bifurcation bridge.

Upper Bifurcation Bridge Installation:

Note: Clean the upper bifurcation bridge using the AircraftMaintenance Manual procedures before installation.

- install the upper bifurcation bridge.- install the nuts and bolts that attach the upper

bifurcation bridge to the fan stator- apply sealant between the contact surfaces.


EFFECTIVITY


B777/GE90-110B, -115BPage 3-35

Sep 0571-00-05LOWER AND UPPER BIFURCATION BRIDGES REMOVAL/INSTALLATION (SHEET 2)


EFFECTIVITY


Page 3-36Sep 05B777/GE90-110B, -115B 71-00-05

SEAL PRESSURIZATION AND OIL TANKVENTILATION TUBES REMOVAL/INSTALLATION

The seal pressurization and oil tank ventilation tubes arelocated at the 12:00 position in the upper bifurcation firewall.

These tubes must be disconnected to allow for fan statormodule separation.

Seal Pressurization and Oil Tank Ventilation TubeRemoval:

- disconnect the seal pressurization and oil tankventilation tubes.

Seal Pressurization and Oil Tank Ventilation TubeInstallation:

- connect the seal pressurization and oil tank ventilationtubes.


EFFECTIVITY


B777/GE90-110B, -115BPage 3-37

Sep 0571-00-05SEAL PRESSURIZATION AND OIL TANK VENTILATION TUBES REMOVAL/INSTALLATION


EFFECTIVITY


Page 3-38Sep 05B777/GE90-110B, -115B 71-00-05

ENGINE ANTI-ICE DUCT REMOVAL/INSTALLATION

The Engine Anti-Ice Duct is located at the 12:00 position inthe upper bifurcation fire wall.

The engine anti-ice duct must be disconnected to allow forfan stator module separation.

Engine Anti-Ice Duct Removal:

- disconnect the engine anti-ice duct.

Engine Anti-Ice Duct Installation:

- connect the engine anti-ice duct.


EFFECTIVITY


B777/GE90-110B, -115BPage 3-39

Sep 0571-00-05ENGINE ANTI-ICE DUCT REMOVAL/INSTALLATION


EFFECTIVITY


Page 3-40Sep 05B777/GE90-110B, -115B 71-00-05

FAN BLADE REMOVAL / INSTALLATION

The spinner is attached to the front of the fan disk.

To remove the spinner do the following:

- Remove the 22 axial mount bolts on the spinner andremove the spinner.

NOTE: The 44 radial screws on the outer diameter ofthe spinner - and on either side of each axial mount bolt -are fan assembly balance screws.

- Remove the 22 bolts and the support ring.

To install the spinners do the following:

- Align the support ring number "1"s with the number"1"s on the fan disk. Install the 22 bolts.

Note: The number "1" is marked on the backside and frontside of two bolt flanges of the support ring. These number"1"s are aligned with the number "1"s marked on eitherside of the fan disk number 1 blade slot. The offset bolthole is marked with an "O". Alignment of the number "1"swill align the offset bolt holes of the support ring and fandisk.

- Align the "1" of the spinner with number "1" on thesupport ring to align the offset bolt holes.

NOTE: The number "1" is marked on the front of thesupport ring and on the spinner.

72-21-01


EFFECTIVITY


B777/GE90-110B, -115BPage 3-41

Sep 0571-00-05SPINNER CONE (ONE PIECE) REMOVAL / INSTALLATION

B

SPINNEROFFSET

BOLTHOLE

SUPPORTRING OFFSETBOLT HOLE

FORWARDLOOKING AFT

72-21-01

SEE B


EFFECTIVITY


Page 3-42Sep 05B777/GE90-110B, -115B 71-00-05

FAN BLADE REMOVAL

The twenty-two fan blades are located in the forward end ofthe engine.

The fan blades must be removed to allow for fan statormodule separation.

NOTE: The blades are numbered counter clockwise whenyou are facing them. The number "1" is engraved on theforward face of the fan disk, on either side of the numberone blade slot.

Note: The fan blade platforms and fan blades are balancecritical. Before removal use a felt tip pen and tape to markthe location of the fan blade platforms, fan blades and otherhardware.

- Number the blades and platforms before removal.

- Turn the fan assembly counterclockwise to put the firstfan blade to be removed at the 6 o'clock position.

- Remove the blade platform on either side of theblade to be removed. Record their original position,to be sure to install them at the same location.

NOTE: A rubber seal around the platform creates a tight fitbetween the blades holding the platform in place during theassembly process. The platforms are secured in place bythe spinner.

- Remove the bolt securing the spacer and theretainer together.


- Remove the spacer using the fan blade spacerremoval tool (9C1202) or hydraulic removal tool(9C3001)

- Place the detail pin in the bolt hole of the fan bladespacer

- move the slide hammer aft and forward to remove thefan blade spacer.

- Remove the dovetail key from the fan disk slot.

- Remove the retainer from the fan disk slot.

- Remove the fan blade from the fan disk slot.

Note: Do not remove the fan disk shims.

72-21-02


EFFECTIVITY


B777/GE90-110B, -115BPage 3-43

Sep 0571-00-05FAN BLADE REMOVAL

72-21-02


EFFECTIVITY


Page 3-44Sep 05B777/GE90-110B, -115B 71-00-05


The 9C1202 fan blade spacer removal tool is used toremove the fan blade spacer.


- Place the detail pin in the bolt hole of the fan bladespacer

- move the slide hammer aft and forward to remove thefan blade spacer.

Fan Blade Installation:

- install the fan blade into the fan blade dovetail slot- use a soft mallet to drive the fan blade spacer into

position.

72-21-02


EFFECTIVITY


B777/GE90-110B, -115BPage 3-45

Sep 0571-00-05FAN BLADE SPACER REMOVAL TOOL

72-21-02


EFFECTIVITY


Page 3-46Sep 05B777/GE90-110B, -115B 71-00-05

FAN BLADE SPACER REMOVAL/INSTALLATIONTOOLS

The 9C3001 fan blade spacer removal tool is used toremove the fan blade spacers.


- Place the fan blade spacer removal tool detail pin intothe fan blade spacer bolt hole and use hydraulicpressure to remove the fan blade spacer.


EFFECTIVITY


B777/GE90-110B, -115BPage 3-47

Sep 0571-00-05FAN BLADE SPACER REMOVAL TOOL (9C3001)


EFFECTIVITY


Page 3-48Sep 05B777/GE90-110B, -115B 71-00-05

FAN BLADE INSTALLATION

Install the fan blades and fan blade platforms at theiroriginal locations (for balancing purposes).

- Turn the fan assembly counterclockwise to put thefan blade slot for the fan blade to be installed at the6 o'clock position.

Note: Be sure to clean and lubricate the fan blades and fandisk before installation.

- Install the fan blade into the fan disk blade slot.

- Install the blade retainer into the fan disk retainerslot.

- Install the dovetail key into the fan disk blade slot.

- Insert the fan blade spacer between the fan bladeand the dovetail key.

- Hit the spacer with a plastic mallet until fullyinstalled or use the hydraulic installation tool(9C3001).

- Install the bolt that holds the retainer and the spacertogether.

- Install the blade platforms on either side of the fanblade. Insert the rear of the platform under thebooster flange, then push the forward part of theplatform toward the fan disk.

NOTE: A rubber seal around the platform creates a tight fitbetween the blades holding the platform in place during theassembly process. The platforms are secured in place bythe spinner.

72-21-02


EFFECTIVITY


B777/GE90-110B, -115BPage 3-49

Sep 0571-00-0572-21-02FAN BLADE INSTALLATION


EFFECTIVITY


Page 3-50Sep 05B777/GE90-110B, -115B 71-00-05

ACOUSTIC PANEL REMOVAL/INSTALLATION

The Acoustic Panels are located around the fan booster.

The acoustic panels are removed to get access to the fanstator module forward mount bolts.

There are six acoustic panels.

Acoustic Panel Removal:

- Remove the screws that attach the acoustic panels tothe fan booster

- remove the acoustic panels.

Acoustic Panel Installation:

- install the acoustic panels.- Install the screws that attach the acoustic panels to the

fan booster.


EFFECTIVITY


B777/GE90-110B, -115BPage 3-51

Sep 0571-00-05ACOUSTIC PANEL REMOVAL/INSTALLATION

FAN STATORMODULE (OGVS)


EFFECTIVITY


Page 3-52Sep 05B777/GE90-110B, -115B 71-00-05

BOOSTER SPLITTER FAIRING

The Booster Splitter Fairing is attached to the leading edgeof the low pressure compressor case.

The Booster Splitter Fairing is removed to provideclearance between the pressure compressor case and fanstator while removing and installing the fan stator.

Booster Splitter Fairing Removal:

- Remove the bolts that attach the booster splittlerfairing to the low pressure compressor leadingedge.

- remove the booster splitter fairing.

Booster Splitter Faiting Installation:

- Install the booster splitter fairing.- install the bolts that attach the booster splittler fairing to

the low pressure compressor leading edge.


EFFECTIVITY


B777/GE90-110B, -115BPage 3-53

Sep 0571-00-05

LPC ANTI-ICE TUBE ATTACHMENTPOINTS WILL NOT EXIST ON NON

ANTI-ICED BOOSTER SPLITTERFAIRING

* SEE C

* *

* *

FAN STATORMODULE (OGVS)

A


SCREW(50 LOCATIONS)


BOOSTER SPLITTER FAIRINGA-A

SEE B

FANBOOSTER


EFFECTIVITY


Page 3-54Sep 05B777/GE90-110B, -115B 71-00-05

LOW PRESSURE COMPRESSOR (LPCAI) ANTI-ICETUBES

GE SB 75-003 deleted the Low pressure compressor anti-ice system and was introduced in production on engines900-129 and up.

Reason for service bulletin introduction:Engine tests indicate that the LPC Anti-Ice system is notrequired.

For those engines that still have the LPC Anti-Ice Tubesthey are located at four locations around the boostermodule. The acoustic panels much be removed to getaccess to them.

The LPC Anti-Ice Tubes delivers seventh stage HPC air tothe booster splitter fairing. The tubes must be removed toallow for fan stator removal.

LPC Anti-IceTube Removal:

- disconnect the two bolts that attach the tube to thebooster splitter fairing at the forward end, the nut atthe aft end and the clamp.

LPC Anti-IceTube Installation:

- connect the two bolts that attach the tube to thebooster splitter fairing at the forward end, the nut atthe aft end and the clamp.


EFFECTIVITY


B777/GE90-110B, -115BPage 3-55

Sep 0571-00-05LOW PRESSURE COMPRESSOR ANTI-ICE TUBES

* LPC ANTI-ICE TUBES DELETED BY SB 75-003

*


EFFECTIVITY


Page 3-56Sep 05B777/GE90-110B, -115B 71-00-05


4. 9C6030 System


EFFECTIVITY


B777/GE90-110B, -115B 71-00-05Page 4-1

Sep 05

FAN STATOR REMOVAL & INSTALLATION - 9C6030 TRANSFER SYSTEM

Objectives:


... identify the tooling required for fan stator module removal/installation


EFFECTIVITY


Page 4-2Sep 05B777/GE90-110B, -115B 71-00-05

FAN STATOR MODULE REMOVAL/INSTALLATION -9C6030 TRANSFER SYSTEM

The Fan Stator Module is located on the front of theengine.

The fan stator module must be removed to perform anormal engine change. The fan stator module can beremoved and installed with or without the inlet cowlinstalled.

The fan stator module removal/installation, using the9C6030 Transfer System, can be done with the engine inthe 9C6000 or 9C6025 Installation and Shipping Stands.

Note: If using9C6000 Installation and Shipping Standmake sure that the fan hub frame mount support adaptersare installed first.

Fan Stator Module Removal:

- attach the left and right 9C6030P01 ForwardAdapters to the fan case flange.

- attach the left and right 9C6030 Aft Adapters to theaft fan case ground handling mounts

- attach the left 9C6030 Side Frame to the leftForward Adapter and Aft Adapter.

- attach the right 9C6030 Side Frame to the rightForward Adapter and Aft Adapter.

Fan Stator Module Installation:

- install the 9C1277 guide pin set into the fan statormodule aft flange


EFFECTIVITY


B777/GE90-110B, -115B 71-00-05Page 4-3

Sep 05

FAN STATOR MODULE REMOVAL/INSTALLATION - 9C6030 TRANSFER SYSTEM

SIDE FRAME (RIGHT SIDE SHOWN, LEFT SIDE OPPOSITE)

FORWARDADAPTER MOUNT

AFT ADAPTERMOUNT

FRAME HEIGHTADJUSTING

HANDLE


HANDLE


EFFECTIVITY


Page 4-4Sep 05B777/GE90-110B, -115B 71-00-05

SIDE FRAME

FORWARDADAPTER

SIDE FRAME

FORWARDADAPTER


HANDLE

SIDE BEAM AND FORWARD ADAPTERS (LEFT SIDE SHOWN, RIGHT SIDE OPPOSITE)

FAN STATOR(AFT LOOKING

FORWARD)



EFFECTIVITY


B777/GE90-110B, -115B 71-00-05Page 4-5

Sep 05

SIDE FRAME

AFT ADAPTER

FAN STATOR(AFT LOOKING

FORWARD)


HANDLE

SIDE FRAMEAFT

ADAPTER

SIDE FRAME AND AFT ADAPTER (RIGHT SIDE SHOWN, LEFT SIDE OPPOSITE)


AFT ADAPTER

PAD

AFT ADAPTER

PAD

FAN STATORAFT MOUNT


EFFECTIVITY


Page 4-6Sep 05B777/GE90-110B, -115B 71-00-05



EFFECTIVITY


B777/GE90-110B, -115B 71-00-05Page 4-7

Sep 05



HANDLE(4 LOCATIONS)


EFFECTIVITY


Page 4-8Sep 05B777/GE90-110B, -115B 71-00-05

FAN STATOR MODULE REMOVAL/INSTALLATION -9C6030 TRANSFER SYSTEM (CONT.)

Fan Stator Module Removal:

Maintenance tip:To prevent the engine from shifting and causing damageor injury during fan stator removal do the following:

- adjust the left 9C6030 side frame forward wheelhandle "down" until the wheel is off the ground.

- adjust the left 9C6030 side beam aft wheel handle"down" until there is a gap between the Aft AdapterPad and the fan stator.

- adjust the 9C6030 Side Frame wheel handles "up"until the forward wheel make contact with theground and the Aft Adapter pad makes contactwith the fan stator

- adjust the 9C6030 Side Frame "up" one full turn ofthe handle.

Fan Stator Bolt Removal:- remove the bolts from the forward flange of the fan

stator module at the fan hub frame. Use the9C6014 personnel stand as necessary.

- remove the bolts from the aft flange of the fan statormodule at the fan hub frame.

- move the 9C6030 and fan stator, by hand, awayfrom the propulsor.

Fan Stator Module Installation:

Note: Clean, lubricate and torque fan stator moduleflanges and bolts as stated in the Aircraft MaintenanceManual.

- apply lubricant to the threads of the bolts.- apply either zinc chromate primer or epoxy primer to

the fan hub frame flanges, the shank of the boltsand to the bearing surface of the integral washerson the bolts.

Note: Use the 9C6030 Side Frame wheels to adjust theheight of the fan module and move the 9C6030 side toside, by hand, to adjust side clearance during installation.

- move the 9C6030 and fan stator, by hand, towardthe propulsor.

- install the bolts to the forward flange of the fan statormodule at the fan hub frame. Use the 9C6014personnel stand as necessary.

- install the bolts to the aft flange of the fan statormodule at the fan hub frame.


EFFECTIVITY


B777/GE90-110B, -115B 71-00-05Page 4-9

Sep 05

A

B B

A



EFFECTIVITY


Page 4-10Sep 05B777/GE90-110B, -115B 71-00-05


The 9C6014 personnel stand allows for access to the fanstator module forward flange bolts and acoustical panels.

The stand is made up of three parts and is placed into thefan stator module after the fan blades have beenremoved.

When assembled, the 9C6014 personnel stand providesteps for the mechanic to reach the acoustic panels andupper bolts of the fan stator module forward bolt flange.

Forklift tubes are positioned within the stand and usablefrom front side of the stand.


EFFECTIVITY


B777/GE90-110B, -115B 71-00-05Page 4-11

Sep 05


9C6014STAND

A

B

B


EFFECTIVITY


Page 4-12Sep 05B777/GE90-110B, -115B 71-00-05


The 9C1277 guide pin set is used align the fan statormodule bolt flanges onto the propulsor bolt flanges.

The guide pin set contains eight guides pins. The guidepins are installed by hand into the fan stator module aftbolt flange. Install the guides pins at equal distancesaround the aft fan stator module bolt flange.

When the fan stator and fan hub frame flanges aretogether, remove the guide pins as the bolts are installed.


EFFECTIVITY


B777/GE90-110B, -115B 71-00-05Page 4-13

Sep 05


FAN STATOR MODULEOUTLET GUIDE VANES

FAN HUB FRAME

AFT FAN STATORMODULE FLANGE

FORWARD FAN STATORMODULE FLANGE

9C1277 GUIDE PIN(8 LOCATIONS)

GUIDE PIN


EFFECTIVITY


Page 4-14Sep 05B777/GE90-110B, -115B 71-00-05


5. Engine Replacement Test


EFFECTIVITY


Page 5-1Sep 05B777/GE90-110B, -115B 71-00-05

REPLACEMENT ENGINE TEST

Objectives:


... identify the tests required for fan stator module removal/installation


EFFECTIVITY


Page 5-2Sep 05B777/GE90-110B, -115B 71-00-0571-00-00


The engine replacement test is located in the Power Plant -Adjustment/Test section of the Aircraft Maintenance Manualchapter 71-00-00.

The replacement engine test is done to make sure that theengine will operate normally after an engine change.

Replacement Engine (Pretested Engine) Test:

- if engine is preserved, do an engine depreservation- do Test No. 16 - EEC (FADEC) Test

(MAT Initiated Test)- do the Engine Fire Detection Operational Test- do Test No. 1 - Pneumatic Leak Test- do Test No. 2 - Dry Motor Leak Test- do Test No. 3 - Standard Wet Motor if not done during

depreservation- do Test No. 14 - Engine Fuel Driven Actuator Test

(MAT Initiated Test)- do Test No. 5 - Idle Leak Test- do Test No. 15 - Engine Air Driven Actuator Test

(MAT Initiated Test)- do Test No. 10 - Low Pressure System (Fan/LPT)

Vibration Survey- do the Engine Air Supply Operational Test- do a check of the engine maintenance status

messages on the EICAS.


EFFECTIVITY


Page 5-3Sep 05B777/GE90-110B, -115B 71-00-05


71-00-00


EFFECTIVITY


Page 5-4Sep 05B777/GE90-110B, -115B 71-00-05


COVERINTRODUCTIONTABLE OF CONTENTS

EQUIPMENTENGINE PREPARATION9C6030 SYSTEMENGINE REPLACEMENT TEST

Documents

Fan Removal