* * * FOR ALL
TASK 72-00-24-420-802
1 . General.
A.This procedure gives instructions to install the No. 2 bearing assembly (20-030 , 72-00-02) (SIN 01200). Refer to Figure 401.
B.This procedure starts with the fan hub module, high pressure compressor (HPC) module assembly, and high pressure turbine (HPT) module assembled in the horizontal position and installed on pedestals or installed in the 11C3044   adapter assembly, attached to the customer overhead rail system.
C.The No. 2 ball bearing assembly is in the vertical position on the 2C81801   holding fixture with the 11C4260   lift/turn fixture and optionally with the 11C4881   handling fixture. Refer to Figure 403.
NOTE:
The 11C4669G02   shipping container will facilitate transport of the GEnx No. 2 bearing module over ground, air, or sea.
D.Make sure that personnel read this procedure and know the step-by-step instructions and special tool usage before they install the No. 2 bearing assembly.
E.Make sure that there is no unwanted material in the engine or on the engine parts.
F.Make sure that all parts are serviceable before they are installed.
G.Make sure that the No. 2 bearing assembly, the HPC module assembly, and the HPT module, and assembled engine have the correct support at all times to prevent injury to personnel or damage to engine parts.
H.Be careful with the components of the No. 2 bearing assembly. Refer to TASK 70-14-00-620-003 (HANDLING OF BEARINGS) and TASK 70-60-01-620-002 (PRESERVATION OF ANTIFRICTION BEARINGS) .
CAUTION:
DO NOT TOUCH THE NO. 2 BEARING WITH YOUR BARE HANDS. YOU MUST WEAR LATEX GLOVES TO PREVENT DAMAGE TO THE NO. 2 BEARING.
I.Make sure the No. 2 bearing ball (012A0) components do not come in contact with bare hands. When personnel touch the roller bearing components, latex C10-140  gloves must be worn.
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.
J.Make sure that all mating surfaces are clean before you assemble the parts. If necessary, clean the parts with C04-002  Stoddard solvent, C04-035  isopropyl alcohol, or a 50-50 blend of C04-014  denatured alcohol and C04-035  isopropyl alcohol.
K.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 402.
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
 
2C81801G01
Fixture, Holding - General Purpose (lift/turn fixture)
 
9C1017G01
Fixture, Remove/Install - Variable Center of Gravity (CG) (CG bar)
 
11C3044G01
Adapter Assembly, Overhead Support - Engine Modules (adapter assembly)
 
11C3098G02
Fixture, Guide - Forward Fan Shaft (guide fixture)
 
11C3119G01
Deleted
 
11C4260G02
Fixture, Lift/Turn - Forward Fan Shaft and No. 2 Bearing (lift/turn fixture)
 
11C4669G02
Container, Shipping No. 2 Bearing Assembly (shipping container)
 
11C4881G01
Fixture, Handling - Forward Fan Shaft (handling fixture)
 
9471M24G01
Fixture, Lift/Turn - General Purpose (lift/turn fixture)
 
9429M77G02
Deleted
 
9481M99G01
Stand, Adjustable Roll Over - Sub Assembly (adjustable stand)
(2)Standard Tools and Equipment.
 
Description
Manufacturer
 
Customer Overhead Rail System
Locally Used
 
Heat Gun
Local Purchase
 
Lifting Straps
Local Purchase
 
Shim, 0.001 inch (0.03 mm)
Local Purchase
 
Hydra-Set
Local Purchase
(3)Locally Manufactured Tools. None.
B.Consumable Materials.
 
Code No.
Description
 
C02-019
Oil, Engine Lubricating (engine oil)
 
C02-058
Compound, Thread Lubricating (lubricant)
 
C04-002
Solvent General (Stoddard solvent)
 
C04-014
Solvent General (denatured alcohol)
 
C04-035
Solvent General (isopropyl alcohol)
 
C10-140
Gloves, Film Latex or Nylon/Polyethylene, Disposable (gloves)
 
C10-182
Cloth, Cleaning For Aircraft Structural (wipers)
C.Referenced Procedures.
 
ATA No.
Description
 
70-14-00
Handling of Bearings
 
70-60-01
Preservation of Anti-Friction Bearings
 
72-00-23
Installation 001
 
72-00-24
Inspection 001
D.Expendable Parts.
 
CSN
Description
 
20-350 , 72-00-02
Push-on Nut
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Figure 401   Installation of the No. 2 Bearing Assembly into the Fan Hub Module
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Figure 402   Fan Forward Shaft
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Figure 403   Installation of the No. 2 Bearing Assembly on the Holding Fixture, 2C81801
3 . Procedure.
Subtask 72-00-24-420-010
A.Prepare the fan hub module to receive the No. 2 bearing assembly (20-030 , 72-00-02) (SIN 01200). Refer to Figure 401 and do as follows:
(1)Install the shear bolts (20-450 , 72-00-02) (SIN 01220) at 64 locations from the aft side of the fan hub frame (FHF) inner flange. The boltheads point aft and the flat side of the shear bolts points outboard. Refer to Figure 404.
(2)Install the push-on nuts (20-350 , 72-00-02) (SIN 01282) at 64 locations from the forward side of the FHF inner flange. Make sure that the push-on nuts are past the shear bolts threads and give sufficient locking to the shear bolts.
* * * FOR ALL
Figure 404   Installation of the Shear Bolts on the Fan Hub Module
Subtask 72-00-24-420-011
B.Install the 11C3098   guide fixture in the forward shaft (01-780 , 72-31-00) (SIN 050B5) or (02-780 , 72-31-00) (SIN 050B5). Refer to Figure 405 and do as follows:
(1)Turn the knob (item 11) and make sure that the arms guide (2, 3, 4) are fully retracted.
(2)Use your hands to install the 11C3098   guide fixture smoothly on the engine centerline in the FHF and in the forward shaft.
(3)Hold the threaded pusher (item 10) and turn the knob (item 11) counterclockwise (forward looking aft) until the pads of the arms guide extend and compress firmly against the inside diameter of the forward shaft.
* * * FOR ALL
Figure 405   Installation of the Guide Fixture, 11C3098, to the Forward Shaft
Subtask 72-00-24-420-012
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.
C.Attach the 9471M24   lift/turn fixture to the 11C4260   lift/turn fixture. Refer to Figure 406 and do as follows:
WARNING:
ALWAYS USE APPROVED EQUIPMENT AND PROCEDURES TO LIFT PARTS. STAY OUT FROM BELOW LOADS. IF THE PARTS ACCIDENTALLY MOVE OR FALL, THEY CAN CAUSE AN INJURY OR KILL YOU.
(1)Attach the load scale to the overhead hoist.
(2)Attach the lift plate (item 3) of the 9471M24   lift/turn fixture to the load scale.
(3)Put the shackle (item 12) on the cable assembly (item 9) in the same numbered hole in the lift plate (item 3). Make sure that the cable assembly is straight up from the 11C4260 lift/turn fixture.
(4)Pull on the release pin (item 10) of the 9471M24   lift/turn fixture to permit the lock plate adapter (item 4) to be installed on the trunnion of the 11C4260 lift/turn fixture.
(5)Install the release pin (item 10) of the 9471M24   lift/turn fixture in the lock plate adapter (item 4).
* * * FOR ALL
Figure 406   Installation of the Lift/Turn Fixture, 9471M24, to the Lift/Turn Fixture, 11C4260
Subtask 72-00-24-420-013
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.Lift the No. 2 bearing assembly (20-030 , 72-00-02) (SIN 01200) with the 9471M24   lift/turn fixture. Refer to Figure 407 and do as follows:
WARNING:
ALWAYS USE APPROVED EQUIPMENT AND PROCEDURES TO LIFT PARTS. STAY OUT FROM BELOW LOADS. IF THE PARTS ACCIDENTALLY MOVE OR FALL, THEY CAN CAUSE AN INJURY OR KILL YOU.
CAUTION:
DO NOT USE THE “DOWN” HANDLE ON THE HYDRA-SET. USE THE HOIST TO MOVE THE NO. 2 BEARING ASSEMBLY DOWN.
(1)Use the hoist to slowly move the No. 2 bearing assembly near the FHF as follows:
(a)Make sure that the centerline of the No. 2 bearing assembly is aligned with the centerline of the FHF. Use visual indicators to make sure that the modules are aligned.
1Use the 11C3098   guide fixture installed in the forward shaft (01-780 , 72-31-00) (SIN 050B5) or (02-780 , 72-31-00) (SIN 050B5) as a visual indicator to align the No. 2 bearing assembly with the FHF.
2Use the alignment of the boltholes on the perimeter of the No. 2 bearing support housing and the shear bolts in the FHF as a visual indicator.
(b)Stop the No. 2 bearing support housing when 3-4 feet (0.9-1.2 m) of space remains between the two modules.
NOTE:
You must keep this space for access to the front of the FHF.
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Figure 407   Positioning of the No. 2 Bearing Assembly to the Fan Hub Module
Subtask 72-00-24-420-014
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.
E.Install the No. 2 Bearing Assembly (20-030 , 72-00-02) (SIN 01200) on the FHF. Refer to Figure 408 and do as follows:
Subtask 72-00-24-160-001
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 THIS PRODUCT.
(1)Before the installation of the No. 2 bearing assembly on the fan hub frame, do a last chance wipe of the aft side of the fan extension shaft, where the oil supply comes from, using new C10-182  wipers with clean C02-019  engine oil.
Subtask 72-00-24-420-025
(2)Prepare the self-locking nuts (20-340 , 72-00-02) (SIN 01240) to attach the No. 2 bearing assembly to the FHF 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.
(a)Apply C02-058  lubricant to the threads and seating surfaces of the 64 self-locking nuts (20-340 , 72-00-02) (SIN 01240).
WARNING:
USE THERMAL GLOVES WHEN YOU MOVE OR TOUCH HOT OR COLD PARTS. HOT OR COLD PARTS CAN CAUSE INJURY.
(3)If necessary, use a heat gun to increase the temperature of the mating surface of the forward flange of the FHF to 220ºF (104ºC).
(4)Use a temperature probe and make sure that the temperature of the flange is at 250ºF (121ºC).
WARNING:
ALWAYS USE APPROVED EQUIPMENT AND PROCEDURES TO LIFT PARTS. STAY OUT FROM BELOW LOADS. IF THE PARTS ACCIDENTALLY MOVE OR FALL, THEY CAN CAUSE AN INJURY OR KILL YOU.
(5)Use the hoist and hydra-set and slowly move the No. 2 bearing assembly into contact with the FHF. Make sure that the No. 2 bearing support housing engages with the shear bolts (20-450 , 72-00-02) (SIN 01220) and the 11C3098   guide fixture.
(6)Attach the No. 2 bearing housing to the FHF as follows:
(a)Install the self-locking nuts (20-340 , 72-00-02) (SIN 01240) in groups of three at eight equally spaced locations on the FHF flange.
(b)Torque the self locking nuts to 300-320 lb in. (33.9-36.1 N.m). This will seat the No. 2 bearing support housing on the FHF rabbet.
(7)Let the FHF forward flange return to room temperature. Use a temperature probe and make sure that the flange is between 60-80ºF (16 to 26ºC).
(8)Install the remaining 40 self-locking nuts (20-340 , 72-00-02) (SIN 01240).
(9)Torque all 64 self locking nuts (20-340 , 72-00-02) (SIN 01240) to 851-999 lb in. (96.2-112.9 N.m) in a criss-cross pattern.
(10)Circle torque the nuts again to 851-999 lb in. (96.2-112.9 N.m).
* * * FOR ALL
Figure 408   Installation of the No. 2 Bearing Housing with Nuts and Shim Check
Subtask 72-00-24-220-004
(11)Use a 0.001 inch (0.025 mm) shim and do a clearance check of the seating of the No. 2 bearing support housing aft flange to the FHF forward flange. Do the clearance check at the scalloped-shaped edges of the No. 2 bearing support housing. Refer to Figure 408.
Subtask 72-00-24-420-015
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.
F.Remove the 9471M24   lift/turn fixture to the 11C4260   lift/turn fixture from the No. 2 bearing support housing. These tools will be used again to install the No. 1 bearing housing in a later step.
Subtask 72-00-24-420-024
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.
G.Remove the 11C3098   guide fixture as follows. Refer to Figure 405.
(1)Use your hands and reach inside the No. 2 bearing support housing to reach the 11C3098   guide fixture.
(2)Hold the threaded pusher (item 10) to turn the knob (item 11) of the 11C3098   guide fixture clockwise (forward looking aft) to retract the arm guides (items 2) thru (item 4) and slowly slide the tool forward and out of the forward shaft and then out of the forward shaft. Put the 11C3098   guide fixture tool back into storage.
Subtask 72-00-24-220-006
(3)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) and Figure 402.
Subtask 72-00-24-420-016
H.Continue to assemble the engine. To install the No. 1 bearing assembly, refer to TASK 72-00-23-420-801 (72-00-23, Installation).