* * * FOR ALL
TASK 72-00-22-420-801
1 . General.
A.This procedure gives instructions to install the fan booster assembly. Refer to Figure 401.
•
Fan booster assembly (20-010 , 72-00-02) (SIN 80000)
•
Fan booster assembly (20-011 , 72-00-02) (SIN 80000) (SB 72-0156).
B.This procedure starts with the fan hub module installed and the propulsor in a horizontal position and installed in the 11C3044adapter assembly attached to the customer overhead rail system. Do this procedure after the No. 1 bearing assembly is installed on the fan hub module. If necessary, refer to TASK 72-00-23-420-801 (72-00-23, INSTALLATION 001) for No. 1 bearing installation.
C.All clock positions are aft looking forward (ALF), unless specified differently.
D.The fan booster assembly and the 11C4591   booster lift and turn fixture are in the horizontal position with the trunnions (item 4) engaged with the pivot point of the 9446M53   support brackets installed in the 9446M23   universal dolly. Refer to Figure 402.
E.Make sure that personnel read this procedure and know the step-by-step instructions and special tool usage before they install the fan booster assembly.
F.Make sure that there is no foreign material inside the modules or assemblies.
G.Make sure that all parts are serviceable before you install them.
H.Make sure the rest of the assembled engine has the correct support at all times to prevent injury to personnel or damage to engine parts.
I.The torque values given in this procedure are the actual torque to apply to the fastener. If a torque multiplier is used, do the necessary calculations to find the specified torque, the value that appears on the scale or dial of the torque wrench. Refer to TASK 70-51-00-400-004 (TIGHTENING PRACTICES AND TORQUE VALUES) .
J.This assembly contains critical areas of the shaft, that require caution and visual inspection during the assembly process, that are identified throughout this procedure. Refer to Figure 403.
2 . Tools, Equipment, and Materials.
NOTE:
You can use equivalent alternatives for tools, equipment, and consumable materials.
A.Tools and Equipment.
(1)Special Tools.
 
Tool No.
Description
 
11C3044G01
Adapter Assembly, Overhead Support - Engine Modules (engine module adapter assembly)
 
11C3196G01
Pins, Expanding (expanding pins)
 
11C3327G01
Fixture, Guide - LPT Mid Shaft Extension (guide fixture)
 
11C3831G01
Deleted
 
11C4298P01
Booster Nut, Torque System (torque system)
 
11C4303P02
Fixture, Install/Remove - Bolts, Stage 1 Fan Disk Joint (install/remove fixture)
 
11C4591G01
Fixture Lift and Turn - Booster (booster lift and turn fixture)
 
9446M23G02
Dolly, Universal (universal dolly)
 
9446M53G01
Fixture - Support Brackets, LPT Module (support brackets)
(2)Standard Tools and Equipment.
 
Description
Manufacturer
 
Customer Overhead Rail System
Local Purchase
(3)Locally Manufactured Tools. None.
B.Consumable Materials.
 
Code No.
Description
 
C01-122
RTV, Silicone Elastomer (RTV 157)
 
C01-159
Primer, RTV (GE Spec. A15F11A7) (RTV primer)
 
C02-058
Compound, Thread Lubricating (lubricant)
 
C04-002
Solvent, Stoddard (Stoddard solvent)
 
C04-014
Alcohol, Denatured (alcohol)
 
C04-035
Alcohol, Isopropyl (isopropyl alcohol)
 
C10-021
Tape, Plastic (masking tape)
 
C10-182
Cloth, Cleaning for Aircraft Structural (cleaning cloth)
C.Referenced Procedures.
 
ATA No.
Description
 
70-51-00
Tightening Practices and Torque Values
 
72-00-02
Assembly 003
 
72-00-23
Installation 001
 
72-00-24
Inspection 001
 
72-26-00
Assembly 001
D.Expendable Parts.
 
CSN
Description
 
30-100 , 72-00-00
Seal
3 . Procedure.
Subtask 72-00-22-210-002
CAUTION:
THIS ASSEMBLY IS A CRITICAL PROCESS. PROPER USE OF PROTECTIVE TOOLING AND POST ASSEMBLY INSPECTION OF FORWARD FAN SHAFT MUST BE COMPLETED PER REQUIREMENTS OF THE ENGINE MANUAL TO MAKE SURE NO DAMAGE HAS BEEN CAUSED BY THE ASSEMBLY PROCESS OR TOOLING.
A.Prepare the fan booster assembly for installation as follows:
(1)Do a visual check of the fan booster assembly and the forward fan shaft (01-170 , 72-24-00) (SIN 81002) or (01-171 , 72-24-00) (SIN 81002) for damages.
(2)Make sure that all rabbet and structural flange mating surfaces have no foreign material, grease, or raised metal. Make sure there is no foreign material in the aft cavity of the fan booster assembly.
WARNING:
STODDARD SOLVENT IS TOXIC. USE PERSONAL PROTECTION EQUIPMENT.
WARNING:
ISOPROPYL ALCOHOL IS TOXIC AND FLAMMABLE. USE PERSONAL PROTECTION EQUIPMENT. USE IN A WELL-VENTILATED AREA.
(3)If necessary, clean the surfaces with C04-002  Stoddard solvent, or C04-035  isopropyl alcohol.
* * * FOR ALL
Figure 401   Fan Booster Installation
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Figure 402   Installation of the Fan Booster Assembly on the Fan Hub Module
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Figure 403   Fan Forward Shaft
Subtask 72-00-22-420-045
B.Install three 11C3196   expanding pins on the inside of the fan rotor disk (01-050 , 72-22-00) (SIN 830A0) or (02-050 , 72-22-00) (SIN 830A0). Refer to Figure 404 and do as follows:
(1)Hold the 11C3196   expanding pin by the handle (item 4).
(2)Insert the guide (item 7) into the bolthole at the match mark notch on the fan rotor disk. Refer to Figure 405.
(3)Turn the knurled knob (item 2) to expand the collet (item 6) until the expanding pin is fully expanded inside the bolthole. Refer to Figure 404.
(4)Install the remaining two 11C3196   expanding pins at equally-spaced locations.
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Figure 404   Installation of the Expanding Guide Pins, 11C3196, Bolts, and Nuts
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Figure 405   (Sheet 1 ) Location of the Match Marked Notches
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Figure 405   (Sheet 2 ) Location of the Match Marked Notches
Subtask 72-00-22-420-046
C.Install the fan booster assembly on the fan hub module. Refer to Figure 402 and do as follows:
(1)Put the fan booster assembly and the 11C4591   booster lift and turn fixture in position in front of the fan hub module.
(2)Adjust the height of the customer overhead rail system to vertically align the fan booster assembly and the forward fan shaft (01-170 , 72-24-00) (SIN 81002) or (01-171 , 72-24-00) (SIN 81002). Refer to Figure 401 and Figure 402.
WARNING:
REFER TO THE PRODUCT LABEL AND THE MANUFACTURER’S (MATERIAL) SAFETY DATA SHEET (SDS) FOR INSTRUCTIONS ON THE HAZARDS, STORAGE, SAFE HANDLING AND PROPER USE OF CONSUMABLE PRODUCTS.
(3)Apply C02-058  lubricant to the threads and friction surfaces of 12 bolts (20-050 , 72-00-02) (SIN 83724).
(4)Install the bolts (20-050 , 72-00-02) (SIN 83724) in the stage 4 flange, bolthead pointing forward, at 12 equally spaced locations. Refer to Figure 406.
(5)Align the hole with the notch on the inner diameter of the fan rotor disk with the hole with the notch on the inner diameter of the forward fan shaft.
(6)Align the top centerline mark on the stage 4 case with the top centerline mark on the stage 5 case.
CAUTION:
USE EXTREME CAUTION WHEN YOU JOIN THESE ASSEMBLIES. DURING THIS PROCEDURE THE FAN STAGE 5 BOOSTER BLADES ARE EXPOSED. ALIGNMENT OF ROTATING AND STATIONARY PARTS IS CRITICAL. OTHERWISE, DAMAGE TO ENGINE PARTS CAN OCCUR.
(7)Move the fan booster assembly aft. Make sure the 11C3196   expanding pins are aligned with the holes in the forward fan shaft. Make sure the bolts in the stage 4 mating flange are aligned with the boltholes of the stage 5 flange. Move the fan booster assembly aft until it is fully seated against the forward fan shaft.
(8)Install self-locking nuts (nuts) (20-040 , 72-00-02) (SIN 83744) on the bolts (20-050 , 72-00-02) (SIN 83724). Torque the self-locking nuts in a criss-cross pattern to 235-275 lb in. (26.6-31.1 N.m).
* * * FOR ALL
Figure 406   Installation of the Fan Booster Assembly Stage 4-5 Mating Flange
Subtask 72-00-22-420-047
CAUTION:
THIS ASSEMBLY IS A CRITICAL PROCESS. PROPER USE OF PROTECTIVE TOOLING AND POST ASSEMBLY INSPECTION OF FORWARD FAN SHAFT MUST BE COMPLETED PER REQUIREMENTS OF THE ENGINE MANUAL TO MAKE SURE NO DAMAGE HAS BEEN CAUSED BY THE ASSEMBLY PROCESS OR TOOLING.
D.Attach the fan booster assembly to the forward fan shaft (01-170 , 72-24-00) (SIN 81002) or (01-171 , 72-24-00) (SIN 81002) as follows:
WARNING:
REFER TO THE PRODUCT LABEL AND THE MANUFACTURER’S (MATERIAL) SAFETY DATA SHEET (SDS) FOR INSTRUCTIONS ON THE HAZARDS, STORAGE, SAFE HANDLING AND PROPER USE OF THIS PRODUCT.
(1)Clean the threads of bolts (20-090 , 72-00-02) (SIN 83020) and the fan rotor disk boltholes with a 50-50 blend of C04-014  denatured alcohol and C04-035  isopropyl alcohol.
WARNING:
REFER TO THE PRODUCT LABEL AND THE MANUFACTURER’S (MATERIAL) SAFETY DATA SHEET (SDS) FOR INSTRUCTIONS ON THE HAZARDS, STORAGE, SAFE HANDLING AND PROPER USE OF CONSUMABLE PRODUCTS.
(2)Apply C02-058  lubricant to the threads and washer faces of the self-locking nuts (20-070 , 72-00-02) (SIN 83040), bolts (20-090 , 72-00-02) (SIN 83020), and the bolt area that makes contact with the fan rotor disk. Refer to Figure 404.
(3)Attach the fan rotor disk to the forward fan shaft with 23 bolts (20-090 , 72-00-02) (SIN 83020) and self-locking nuts (20-070 , 72-00-02) (SIN 83040), boltheads pointing aft. Tighten the self-locking nuts in a criss-cross pattern, but do not torque them at this time.
(4)Remove the three 11C3196   expanding pins from the fan rotor disk as follows:
(a)Hold the 11C3196   expanding pins by the handle (item 4) and loosen the knurled knob (item 2).
(b)Pull the pin forward and out of the fan rotor disk. If necessary, use a soft mallet to remove the pins.
(5)Install the remaining bolts (20-090 , 72-00-02) (SIN 83020) and self-locking nuts (20-070 , 72-00-02) (SIN 83040).
(6)Install the 11C4303   install/remove fixture or 11C4298   torque system on the fan rotor disk as follows:
NOTE:
The 11C4298 torque system is alternative to the 11C4303 install/remove fixture. This procedure uses tool 11C4303 install/remove fixture, however, either can be used.
(a)Put the match mark notch of the fan rotor disk at the 12:00 o'clock position.
(b)Install the protective cover of the 11C4303   install/remove fixture in the bore of the fan rotor disk.
(c)Assemble the 11C4303   install/remove fixture with the applicable gear box. Refer to the 11C4303   install/remove fixture instructions.
(d)Install nine dovetail inserts (item 3) of the 11C3327   guide fixture at equally spaced locations on the fan rotor disk. Do not put an insert at the 12:00 o'clock position. Refer to Figure 407.
(e)Install the 11C4303   install/remove fixture on to the fan rotor disk. Refer to the 11C4303   install/remove fixture instructions.
(f)Put the 11C4303   install/remove fixture in the dovetail inserts (item 3). Tighten the flange nuts (item 13) of the dovetail inserts (item 3).
(7)Torque the 26 self-locking nuts (20-070 , 72-00-02) (SIN 83040) to 120 lb ft. (162.7 N.m) in a criss-cross pattern.
NOTE:
Make sure that the bolts (20-090 , 72-00-02) (SIN 83020) do not rotate while applying torque to the bolts.
(8)Loosen the self-locking nut (20-070 , 72-00-02) (SIN 83040) in a circular pattern, a minimum of one full turn, and torque the self-locking nut to 70 lb ft. (95 N.m).
(9)Do a final torque to the self-locking nut (20-070 , 72-00-02) (SIN 83040) to 150.0-250.0 lb ft. (203.4-339.0 N.m) as follows:
(a)Set the torque wrench to read zero degrees.
(b)Turn the self-locking nut 43-47 degrees in a CW direction to tighten.
(c)If the torque is out of limits, remove the self-locking nut and lubricate again. Repeat the self-locking nut torque sequence.
(d)If after two attempts the torque is not in limits, remove and discard the self-locking nut. Repeat the self-locking nut tightening sequence with new self-locking nut.
(10)Remove the 11C4303   install/remove fixture from the fan rotor disk. Refer to the 11C4303   install/remove fixture instructions.
(11)Remove the nine dovetail inserts (item 3) of the 11C3327   guide fixture.
(12)Use a C10-182  cleaning cloth and wipe off all unwanted C02-058  lubricant.
(13)Do a general visual inspection of the exposed surfaces of the forward fan shaft for nicks, dents, and scratches after the removal of tooling. Refer to TASK 72-00-24-200-801 (72-00-24, INSPECTION 001).
* * * FOR ALL
Figure 407   Installation of the Guide Fixture, 11C3327
Subtask 72-00-22-420-048
E.Attach the fan booster assembly to the stage 5 booster case. Refer to Figure 406 and do as follows:
NOTE:
The stage 5 booster case was previously installed on the fan hub module. Refer to TASK 72-26-00-440-802 (72-26-00, ASSEMBLY 001).
WARNING:
REFER TO THE PRODUCT LABEL AND THE MANUFACTURER’S (MATERIAL) SAFETY DATA SHEET (SDS) FOR INSTRUCTIONS ON THE HAZARDS, STORAGE, SAFE HANDLING AND PROPER USE OF CONSUMABLE PRODUCTS.
(1)Apply C02-058  lubricant to 22 bolts (20-060 , 72-00-02) (SIN 83725).
(2)Install the support bracket (01-060 , 75-11-40) (SIN 63714) on the forward side of the flange with two bolts (20-060 , 72-00-02) (SIN 83725), boltheads forward, and two nuts (20-040 , 72-00-02) (SIN 83744) in boltholes 1 and 96 at the 12 o'clock position in a clockwise (CW) direction.
(3)Install 10 support brackets (01-040 , 75-11-40) (SIN 63713) on the forward side of the flange with 20 bolts (20-060 , 72-00-02) (SIN 83725), boltheads forward, and 20 nuts (20-040 , 72-00-02) (SIN 83744) in boltholes 8-9, 13-14, 21-22, 29-30, 37-38, 45-46, 53-54, 72-73, 80-81, and 88-89 in a clockwise (CW) direction.
(4)Apply C02-058  lubricant to the threads and friction surfaces of the remaining bolts (20-050 , 72-00-02) (SIN 83724).
(5)Install the remaining bolts (20-050 , 72-00-02) (SIN 83724) and nuts (20-040 , 72-00-02) (SIN 83744) at the stage 4-5 mating flange.
(6)Torque all the nuts (20-040 , 72-00-02) (SIN 83744) to 235-275 lb in. (26.6-31.1 N.m) in a criss-cross pattern.
(7)Torque again all the nuts (20-040 , 72-00-02) (SIN 83744) to 235-275 lb in. (26.6-31.1 N.m) in a circular pattern.
Subtask 72-00-22-420-049
F.Remove the 11C4591   booster lift and turn fixture from the fan booster assembly. Refer to Figure 408 and do as follows:
(1)Loosen the hand knob assemblies (item 9) and move the clamp body (item 14) radially out to disengage the fan booster assembly from the 11C4591   booster lift and turn fixture.
(2)Loosen the hand knob assemblies (item 10) and move the clamp base (item 8) radially out to disengage the fan booster assembly from the 11C4591   booster lift and turn fixture.
(3)Carefully move the 11C4591   booster lift and turn fixture away from the fan booster assembly.
* * * FOR ALL
Figure 408   (Sheet 1 ) Removal of the Booster Lift and Turn Fixture, 11C4591
* * * FOR ALL
Figure 408   (Sheet 2 ) Removal of the Booster Lift and Turn Fixture, 11C4591
Subtask 72-00-22-420-050
G.Install the barrel nuts (20-130 , 72-00-00) (SIN 83042) on the fan rotor disk (01-050 , 72-22-00) (SIN 830A0) or (02-050 , 72-22-00) (SIN 830A0) as follows:
(1)Install the barrel nuts in the retainers (20-140 , 72-00-00) (SIN 83093).
(2)Install the barrel nuts and retainers, with the barrel nut forward, in the holes in the outer diameter of the fan rotor disk dovetails.
Subtask 72-00-22-420-052
H.Install the seal (30-100 , 72-00-00) (SIN 63759) as follows:
NOTE:
The seal is received as a single piece molded component. The seal can be divided into two segments to make the installation easier.
(1)If the seal is divided into two segments, do as follows:
(a)Make sure that the cuts are perpendicular to the leading edge of the seal.
(b)Make sure that the spaces between the segments are not more than 0.020 inch (0.51 mm) in length.
(c)Do a dry fit of the seal after cleaning the inlet guide vane (IGV) assembly (01-100 , 72-22-00) (SIN 837A0) or (02-100 , 72-22-00) (SIN 837A0).
WARNING:
REFER TO THE PRODUCT LABEL AND THE MANUFACTURER’S (MATERIAL) SAFETY DATA SHEET (SDS) FOR INSTRUCTIONS ON THE HAZARDS, STORAGE, SAFE HANDLING AND PROPER USE OF THIS PRODUCT.
(2)Clean the outer band surface of the IGV assembly (01-100 , 72-22-00) (SIN 837A0) or (02-100 , 72-22-00) (SIN 837A0) that will contact the seal with C04-035  isopropyl alcohol and a C10-182   cleaning cloth or equivalent and let the surface dry.
(3)Make sure that the bonding surface is clean, dry, and completely free of any contamination.
(4)Define the area for RTV and seal application with C10-021  masking tape. Refer to Figure 409.
(5)Apply C01-159  RTV primer to the masked area.
(6)Let C01-159  RTV primer to dry as indicated in the manufacturer's instructions.
WARNING:
ISOPROPYL ALCOHOL IS TOXIC AND FLAMMABLE. USE PERSONAL PROTECTION EQUIPMENT. USE IN A WELL-VENTILATED AREA.
(7)Clean the bonding surface of the seal with C04-035  isopropyl alcohol.
(8)Apply C01-122  RTV 157 to the masked area.
(a)The thickness of the adhesive must be limited to the amount needed to fill any surface discontinuities and to get a coating of approximately 0.125 inch (3.18 mm) in depth.
NOTE:
This thickness will allow the adhesive to fill in spaces/voids on the surface of the IGV assembly.
(9)Install the seal (30-100 , 72-00-00) (SIN 63759) with the vent holes facing forward. Refer to Figure 410.
(10)Make sure that the vent holes are facing forward.
(11)Make sure that the forward edge of the seal is installed with a distance between 0.030-0.130 inch (0.76-3.30 mm), from the inside edge of the IGV assembly (01-100 , 72-22-00) (SIN 837A0) or (02-100 , 72-22-00) (SIN 837A0) edge.
(12)Push the seal against the IGV assembly (01-100 , 72-22-00) surface to release any entrapped air.
(13)Before the adhesive gets a SET state, smooth the joint where the seal edge and the IGV assembly (01-100 , 72-22-00) (SIN 837A0) or (02-100 , 72-22-00) (SIN 837A0) touch to improve sealing qualities.
(14)Clean excess of adhesive per manufacturer's instructions.
Subtask 72-00-22-420-053
(15)If the seal was segmented to seal the spaces between the segments, do Subtask 72-00-22-420-052 (paragraph 3.H.(5)) thru (paragraph 3.H.(14)) again.
Subtask 72-00-22-420-054
(16)Trim excess seal material and apply C01-122   RTV 157 to bond the space.
(17)Make sure that the spaces between the seal are no more than 0.020 inch (0.51 mm) in length.
(18)Let the adhesive cure for eight hours.
(19)Remove all C10-021  masking tape.
* * * FOR ALL
Figure 409   Primer and RTV Application Area
* * * FOR ALL
Figure 410   (Sheet 1 ) Seal Installation
* * * FOR ALL
Figure 410   (Sheet 2 ) Seal Installation
* * * FOR ALL
Figure 410   (Sheet 3 ) Seal Installation
Subtask 72-00-22-420-051
I.Continue to assemble the propulsor. Refer to TASK 72-00-02-430-814 (72-00-02, ASSEMBLY 003).
* * * FOR ALL
Figure 411   Installation of the Barrel Nuts