* * * FOR ALL
TASK 72-00-01-020-801
1 . General.
A.This procedure gives instructions to remove the fan stator module assembly (fan stator module) from the engine. Refer to Figure 301.
•
(30-010 , 72-00-00) (SIN 00103)
•
(30-011 , 72-00-00) (SIN 00103) - SB 72-0156 (Fan Module - PIP 2 Configuration)
•
(30-012 , 72-00-00) (SIN 00103) - SB 79-0018.
B.This procedure starts with the engine in the horizontal position on the 11C3443   shipping stand or 11C3359   shipping stand or 11C4487   shipping stand or 11C4568   shipping stand or 11C4576   shipping stand. As an alternative, you can install the engine in the 11C3281G01   turbine rear frame (TRF) pedestals and 11C3281G02   fan hub frame (FHF) pedestals . Refer to TASK 72-00-00-800-803 (72-00-00, SPECIAL PROCEDURE 003) . As an alternative, the engine can be installed in the 11C3044   adapter assembly, attached to the customer overhead rail system. Refer to Subtask 72-00-01-020-060 (paragraph 3.A.).
C.Make sure that personnel read this procedure and know the step-by-step instruction and special tool usage before they remove the fan stator module.
D.Make sure there is no foreign material in the engine or on engine parts.
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
 
11C3004
Stand, Air Shipping - Fan Module (shipping stand)
 
11C3039G02
Bracket Set, FWD Propulsor, Ground Handling and Shipping (fan hub frame lift brackets)
 
11C3044G01
Adapter Assembly, Overhead Support - Engines Modules (adapter assembly)
 
11C3083G01
Protector - Stage 1 Fan Disk (disk protector)
 
11C3084G01
Protector, Stage 1 Fan Disk Bore (fan disk bore protector)
 
11C3281G01
Bracket Set, Support - Main Engine (TRF pedestals)
 
11C3281G02
Bracket Set, Support - Main Engine (FHF pedestals)
 
11C3311G02
Stand, Personnel - Fan Inlet (personnel) (alternative to 11C4616G04)
 
11C3323G01
Tool, Removal - Stage 1 Fan Blade Spacer (spacer removal tool) (alternative to 11C3398G01)
 
11C3331G02
Protector, Forward Acoustic Liner - Fan Module (acoustic liner protector)
 
11C3359P02
Stand, Full Engine Air Ship (shipping stand)
 
11C3398G01
Tool, Removal - Stage 1 Fan Blade Spacer (slide hammer) (Recommended)
 
11C3443P03
Stand, Shipping (shipping stand) road recommended
 
11C4487P02
Stand, Shipping Engine/Propulsor (shipping stand) ground recommended
 
11C4490P02
Dolly, Separation - Fan Case (fan case separation dolly)
 
11C4514G01
Protector Set, Fan Stator (fan case protective mat)
 
11C4568P01
Stand, Full Engine Air Ship (shipping stand)
 
11C4576P01
Stand, Shipping - Engine/Propulsor (shipping stand)
 
11C4576P02
Stand, Shipping - Engine/Propulsor (shipping stand)
 
11C4576P03
Stand, Shipping - Engine/Propulsor (shipping stand)
 
11C4576P04
Stand, Shipping - Engine/Propulsor (shipping stand)
 
11C4593G02
Cover, Protective - Oil Coolers (surface cooler cover)
 
11C4594G01
Storage Carrousel, Stage 1 Blade (storage carrousel)
 
11C4594G02
Storage Carrousel, Stage 1 Blade (storage carrousel)
 
11C4616G04
Stand, Personnel - Fan Inlet (personnel stand)
 
11C4634G01
Cover, Protector - Booster (protector)
 
11C4645G01
Fixture, Spread - Fan Blade (blade spreading fixture)
 
9429M44G01
Adapter, Overhead Support - Fan Cowling (support adapter)
 
9429M47G01
Adapter, Overhead Support - LPT (support adapter)
 
9482M11G01
Cart, Storage - Fan Blade
(2)Standard Tools and Equipment. None.
(3)Locally Manufactured Tools. None.
B.Consumable Materials.
 
Code No.
Description
 
C05-003
Marking Pen (pen)
 
C10-021
Tape, Plastic (tape)
C.Referenced Procedures.
 
ATA No.
Description
 
72-00-00
Special Procedure 003
 
72-00-01
Disassembly
 
72-00-03
Removal 001
D.Expendable Parts. None.
3 . Procedure.
Subtask 72-00-01-020-060
A.If customer overhead rail system is used, prepare the engine for installation with 11C3044   adapter assembly, 9429M44   support adapter, and 9429M47   support adapter as follows:
(1)Remove the blank off panels to permit access of 11C3039   fan hub frame lift brackets. Refer to Subtask 72-00-01-020-005 (paragraph 3.G.).
(2)Install the 11C3039   fan hub frame lift brackets. Refer to Subtask 72-00-01-490-002 (paragraph 3.N.).
(3)Install the 9429M44   support adapter to the 11C3039   fan hub frame lift brackets.
(4)Install the 9429M47   support adapter on the low pressure turbine (LPT) module.
(5)Install the engine to the customer furnished overhead rail system with 11C3044   adapter assembly.
Subtask 72-00-01-020-001
B.If not installed, install the 11C3331   acoustic liner protector, on the forward mounting flange of the fan case stator module at the 6:00 o'clock position. Refer to Figure 301.
Subtask 72-00-01-020-044
C.If not installed, install the 11C4593   surface cooler cover. Refer to Figure 302.
* * * FOR ALL
Figure 301   Fan Case Stator Module and the Acoustic Liner Protector, 11C3331
* * * FOR ALL
Figure 302   Installation of the Surface Cooler Cover, 11C4593
Subtask 72-00-01-020-002
D.Remove the fan rotor spinner (83002) and aft support spinner ring (20-100 , 72-00-00) or spinner assembly aft support ring (aft support spinner ring) (20-101 , 72-00-00) as follows. Refer to Figure 303.
CAUTION:
MAKE SURE YOU PUT A PROTECTIVE MAT IN THE INLET COWL. THIS PREVENTS DAMAGE TO THE INLET COWL OR ENGINE IF TOOLS, PARTS, OR UNWANTED MATERIALS FALL ON THE INLET COWL SURFACE.
(1)Put the 11C4514   fan case protective mat in the lower half of the inlet cowl to protect the inlet cowl and engine. Refer to Figure 304.
(2)Remove the fan rotor spinner as follows. Refer to Figure 303.
CAUTION:
DO NOT LOOSEN OR REMOVE THE BALANCE WEIGHT BOLTS, UNLESS YOU REPLACE THE FAN ROTOR SPINNER. AN UNBALANCED CONDITION CAN OCCUR IF THE FAN ROTOR SPINNER IS INSTALLED WITH LOOSE OR REMOVED BALANCE WEIGHT BOLTS.
(a)Remove the 18 bolts (8302C) that attach the fan rotor spinner to the aft spinner ring.
CAUTION:
MAKE SURE THE FAN ROTOR SPINNER DOES NOT FALL WHEN YOU REMOVE IT FROM THE AFT SPINNER RING. DAMAGE TO THE FAN ROTOR SPINNER CAN OCCUR.
(b)Remove the fan rotor spinner.
(c)Put the fan rotor spinner in a protective cover.
(3)Remove the aft support spinner ring as follows:
(a)Remove the 18 bolts (20-110 , 72-00-00) that attach the aft spinner ring to the fan rotor disk.
(b)Put the aft support spinner ring in a protective cover.
* * * FOR ALL
Figure 303   Removal of the Fan Rotor Spinner and Aft Spinner Ring
* * * FOR ALL
Figure 304   Installation of the Fan Case Protective Mat, 11C4514
Subtask 72-00-01-020-003
E.Remove each of the stage 1 fan blades (fan blades) (20-200 , 72-00-00) (SIN 83004) or (20-201 , 72-00-00) (SIN 83004). Refer to Figure 306 and do as Follows:
(1)Number the fan blades from No. 1 thru No. 18 as follows:
(a)Find the No. 1 fan blade.
(b)Use a C05-003  pen and mark No. 1 on the fan blade dovetail.
(c)Continue to number the blades from No. 2 thru No. 18 in a counterclockwise (CCW) direction.
CAUTION:
DO NOT USE THE LPT BLADES TO TURN N1 ROTOR. THE BLADES ARE BRITTLE AT ROOM TEMPERATURE AND CAN EASILY BREAK. DAMAGE TO THE ENGINE CAN OCCUR.
CAUTION:
DO NOT TURN THE FAN DISK BY PUSHING ON THE TIPS OF THE BLADES. SLOWLY TURN THE FAN DISK AT THE ROOT WITH YOUR HAND.
(2)Turn the fan disk so that No. 1 blade is at the 6:00 o'clock position.
Subtask 72-00-01-020-057
(3)Alternative Procedure Available. Remove the fan platforms (20-120 , 72-00-00) (SIN 83005) or (20-121 , 72-00-00) (SIN 83005) as follows:
(a)Prepare the 11C4645   blade spreading fixture for use. Refer to Figure 305 and do as follows:
1Align the left foot (item 4) hole with the left support (item 13) hole that has the GENX-1B mark.
2Put the ball lock pin (item 15) through the two holes.
CAUTION:
MAKE SURE TO USE C10-021  TAPE TO HOLD THE FAN PLATFORMS IN POSITION, OR THE FAN PLATFORMS CAN FALL AND CAUSE DAMAGE TO THE FAN CASE OR FAN PLATFORM.
(b)Apply C10-021  tape from the fan blade side to the top of each fan platform (20-120 , 72-00-00) (SIN 83005) or (20-121 , 72-00-00) (SIN 83005) to make sure that the platform does not fall.
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.
(c)Carefully lift the 11C4645   blade spreading fixture with the handle (item 14) and put it between the fan blades with the base (item 10) on the inside surface of the fan case.
(d)Use the left hand to pull the arm (item 8) down with the lever arm (item 20) while putting the right hand on the base (item 10) to balance the 11C4645   blade spreading fixture.
NOTE:
This will cause the left foot (item 4) and right foot (item 5) to spread which, in turn, will push the fan blades apart.
(e)Pull the arm (item 8) until the mark OPEN in the wedge (item 7) can be seen.
(f)Carefully pull the fan platform straight down. Make sure not to scratch the adjacent fan blades.
(g)Pull the arm (item 8) up with the lever arm (item 20) until the left foot (item 4) and right foot (item 5) are fully contracted in order to put the fan blades back into the initial position.
(h)Use the handle (item 14) to lift and remove the 11C4645   blade spreading fixture.
(i)Manually turn the fan rotor disk and continue to remove the fan platforms from the 6:00 o'clock position.
(j)Keep each fan platform together with the machine bolt (bolt) (20-150 , 72-00-00) (SIN 8302A), stage 1 fan blade spacer (spacer) (20-170 , 72-00-00) (SIN 83008), dovetail key (20-180 , 72-00-00) (SIN 8300B), and stage 1 retainer (retainer) (20-190 , 72-00-00) (SIN 83007) that were removed from each blade. Refer to Figure 306.
* * * FOR ALL
Figure 305   (Sheet 1 ) Installation of the Blade Spreading Fixture, 11C4645
* * * FOR ALL
Figure 305   (Sheet 2 ) Installation of the Blade Spreading Fixture, 11C4645
* * * FOR ALL
Figure 305   (Sheet 3 ) Installation of the Blade Spreading Fixture, 11C4645
Subtask 72-00-01-020-058
(3).A.Alternative Procedure. Remove the fan platforms (20-120 , 72-00-00) (SIN 83005) or (20-121 , 72-00-00) (SIN 83005) as follows:
NOTE:
Have two people remove the fan platforms.
CAUTION:
MAKE SURE TO USE C10-021  TAPE TO HOLD THE FAN PLATFORMS IN POSITION, OR THE FAN PLATFORMS CAN FALL AND CAUSE DAMAGE TO THE FAN CASE OR FAN PLATFORM.
(a)Apply C10-021  tape from the fan blade side to the top of each fan platform (20-120 , 72-00-00) (SIN 83005) or (20-121 , 72-00-00) (SIN 83005) to make sure that the platform does not fall.
(b)Apply as much side force as possible to two fan blades at the 6:00 o'clock position without causing damage to them.
(c)Have a second person move the fan platform back and forth and pull it down to remove it from between the fan blades.
(d)Carefully pull the fan platform straight down. Make sure that you do not scratch the adjoining fan blades.
(e)Manually turn the fan rotor disk and continue to remove the fan platforms from the 6:00 o'clock position.
(f)Keep each fan platform together with the bolt (20-150 , 72-00-00) (SIN 8302A), spacer (20-170 , 72-00-00) (SIN 83008), dovetail key (20-180 , 72-00-00) (SIN 8300B), and retainer (20-190 , 72-00-00) (SIN 83007) that were removed from each blade. Refer to Figure 306.
Subtask 72-00-01-020-059
(4)Make sure that the No. 1 fan blade is at the 6:00 o'clock position.
* * * FOR ALL
Figure 306   Removal of the Fan Blades Components
Subtask 72-00-01-020-004
(5)Remove the fan blades (20-200 , 72-00-00) (SIN 83004) or (20-201 , 72-00-00) (SIN 83004) from the fan rotor disk (01-050 , 72-22-00) (SIN 830A0). Refer to Figure 306 and do as follows:
(a)Start at the 6:00 o'clock position and remove the bolt (8302A) that attaches the spacer (83008) to the fan blade retainer (83007).
(b)Remove the spacer, retainer, and dovetail key as follows. Refer to Figure 307.
1Alternative Procedure Available. Remove the spacer with the 11C3398 slide hammer tool as follows:
NOTE:
The 11C3398 slide hammer is the primary fan blade spacer removal tool.
aPut the pin (item 4) in the spacer bolt hole.
bMove the slide hammer (item 2) forward and aft to remove the spacer from the fan disk blade slot.
cRemove the spacer from the slide hammer removal tool.
Subtask 72-00-01-020-042
1.A.Alternative Procedure. Remove the spacer with the 11C3323   spacer removal tool, as follows:
aInstall the 11C3323   spacer removal tool as follows. Refer to Figure 307A.
bMake sure that the hydraulic cylinder (item 7) is completely retracted.
cAlign the hydraulic cylinder (item 7) with the fan blade spacer and the fan disk.
dRemove the dust cap (item 9) and connect a hydraulic hand pump to the female coupler (item 8).
eInstall the pin (item 5) in the hole of the fan blade spacer.
WARNING:
BE CAREFUL WHEN YOU USE THE PUSHER/PULLER TO APPLY PRESSURE. MAKE SURE YOU DO NOT USE MORE THAN THE MAXIMUM HYDRAULIC PRESSURE. STAY AWAY FROM THE AREA BEHIND OR IN FRONT OF THE PUSHER/PULLER. A MALFUNCTION CAN CAUSE INJURY OR CAN KILL YOU.
fApply hydraulic pressure to the hydraulic cylinder (item 7) to remove the fan blade spacer from the fan disk.
gRemove the pin (item 5) from the spacer and remove the hydraulic cylinder. This tool will be used again to remove the remaining fan blade spacers (83007).
Subtask 72-00-01-020-043
(c)Remove the dovetail key (8300B). Refer to Figure 306.
(d)Remove the fan blade retainer.
(e)Remove the fan blade. Manually move the fan blade directly forward out of the dovetail slot.
(f)Store the fan blades, spacers, dovetail keys, retainers, and bolts in the 11C4594 storage carrousel. Refer to Figure 308.
Subtask 72-00-01-020-038
CAUTION:
AS YOU REMOVE FAN BLADES, THE UNBALANCED MASS OF THE REMAINING FAN ROTOR DISK TURNS TO THE BOTTOM OF THE FAN STATOR CASE. BE CAREFUL WHEN REMOVING FAN BLADES. MAKE ANOTHER PERSON SUPPORT THE MASS OF THE FAN ROTOR DISK. OTHERWISE, DAMAGE TO PARTS OR AN INJURY CAN OCCUR.
(g)Do Subtask 72-00-01-020-004 (paragraph 3.C.(5)(a)) thru Subtask 72-00-01-020-043 (paragraph 3.C.(5)(e)) to remove the remaining 17 fan blades (20-200 , 72-00-00) (SIN 83004) or (20-201 , 72-00-00) (SIN 83004).
Subtask 72-00-01-020-039
(h)After all 18 fan blades (20-200 , 72-00-00) (SIN 83004) or (20-201 , 72-00-00) (SIN 83004) are removed, remove the 18 shims (20-210 , 72-00-00) (SIN 83071) from the fan rotor disk posts.
* * * FOR ALL
Figure 307   Installation of the Slide Hammer, 11C3398
* * * FOR ALL
Figure 307A   Installation of the Spacer Removal Tool, 11C3323
* * * FOR ALL
Figure 308   Stage 1 Blade Storage Carrousel, 11C4594
Subtask 72-00-01-020-005
F.Remove the variable bypass valve (VBV) panels as follows. Refer to Figure 309.
(1)Locate the ACC inlet flow shield at the 9:30 o'clock position (aft looking forward). Loosen the four screws and remove the ACC inlet flow shield.
(2)Remove the remaining blankoff panels (25-520 , 72-00-00) (SIN 9500D) and (25-540 , 72-00-00) (SIN 9500B) or (25-541 , 72-00-00) (SIN 9500B), (25-515 , 72-00-00) (SIN 9500C), (25-521 , 72-00-00) (SIN 9500D), (25-525 , 72-00-00) (SIN 9500E), (25-535 , 72-00-00) (SIN 9500F), (25-545 , 72-00-00) (SIN 9500G), and (25-555 , 72-00-00) (SIN 9500H) (four on the right side, three on the left side) as follows:
(a)Loosen the four machine screws (screws) (25-510 , 72-00-00) (SIN 95025) that attach each blankoff panel to the bleed air deflector panels (25-550 , 72-00-00) (SIN 9500A).
(b)Slowly pull the blankoff panel aft out of the groove under the trailing edge of the outlet guide vanes.
(3)Remove the ten bleed air deflector panels as follows:
(a)Loosen the two screws (95025) in the center of the aft side of each bleed air deflector panel that attaches it to the deflector panel support segments.
(b)At the 12:00 o'clock and 6:00 o'clock positions, bleed air deflector panels are installed underneath fillet fairings. Loosen the eight fairing screws that attach the four fillet fairings to the four bleed air deflector panels.
(c)Slowly pull the bleed air deflector panel aft out of the groove under the trailing edge of the outlet guide vanes.
* * * FOR ALL
Figure 309   (Sheet 1 ) Removal of the VBV panels
* * * FOR ALL
Figure 309   (Sheet 2 ) Removal of the VBV panels
* * * FOR ALL
Figure 309   (Sheet 3 ) Removal of the VBV panels
Subtask 72-00-01-020-006
G.Remove the lower bifurcation assembly. Refer to TASK 72-00-03-020-802 (72-00-03, REMOVAL 001).
Subtask 72-00-01-020-007
H.Remove the upper fillet fairings and upper bifurcation bridge (upper bridge) (25-170 , 72-00-00 or 25-171 , 72-00-00) as follows. Refer to Figure 310.
(1)Remove the five bolts and the two bolts that attach the upper left fillet fairing to the left side of the upper firewall assembly.
(2)Remove the upper left fillet fairing.
(3)Remove the five bolts and the two bolts that attach the upper right fillet fairing to the right side of the upper firewall assembly.
(4)Remove the upper right fillet fairing.
(5)Remove the four bolts (25-150 , 72-00-00 or 25-151 , 72-00-00) and four washers that attach the upper bridge to the upper firewall assembly.
(6)Remove the seven nuts and three washers that attach the upper bridge to the cowl supports (30-010 , 72-00-02) (SIN 95001) or (30-011 , 72-00-02) (SIN 95001) or (30-012 , 72-00-02) (SIN 95001) and (30-020 , 72-00-02) (SIN 95008) or (30-021 , 72-00-02) (SIN 95008) or 30-022 , 72-00-02) (SIN 95008) and control cables bridge bracket (bracket) (25-210 , 72-00-00) (SIN 68812) and fire suppression support bracket (bracket) (25-200 , 72-00-00) (SIN 9931A).
(7)Remove the bracket (25-210 , 72-00-00) (SIN 68812) and bracket (25-200 , 72-00-00) (SIN 9931A).
(8)Remove the upper bridge.
Subtask 72-00-01-020-008
I.Remove the lower fillet fairings and lower bifurcation bridge (lower bridge) (25-480 , 72-00-00 or 25-481 , 72-00-00) as follows. Refer to Figure 311.
(1)Remove the five bolts and the two bolts that attach the lower left fillet fairing to the left side of the lower firewall assembly.
(2)Remove the lower left fillet fairing.
(3)Remove the five bolts and the two bolts that attach the lower right fillet fairing to the right side of the lower firewall assembly.
(4)Remove the lower right fillet fairing.
(5)Remove the four bolts (25-490 , 72-00-00 or 25-491 , 72-00-00) and four washers that attach the lower bridge to the upper firewall assembly.
(6)Remove the four nuts and four washers that attach the lower bridge to the cowl supports (30-010 , 72-00-02) (SIN 95001) or (30-011 , 72-00-02) (SIN 95001) or (30-012 , 72-00-02) (SIN 95001) and (30-020 , 72-00-02) (SIN 95008) or (30-021 , 72-00-02) (SIN 95008) or (30-022 , 72-00-02) (SIN 95008).
(7)Remove the lower bridge.
* * * FOR ALL
* * * PRE SB   72-0050
Figure 310   (Sheet 1 ) Removal of the Upper Fillet Fairings, Brackets, and Upper Bifurcation Bridge
* * * FOR ALL
* * * PRE SB   73-0060( Old Design for W30 and W31 Harnesses )
* * * PRE SB   72-0050
Figure 310   (Sheet 2 ) Removal of the Upper Fillet Fairings, Brackets, and Upper Bifurcation Bridge
* * * FOR ALL
* * * SB   72-0050
Figure 310   (Sheet 3 ) Removal of the Upper Fillet Fairings, Brackets, and Upper Bifurcation Bridge
* * * FOR ALL
* * * SB   73-0060( W30 and W31 Redesigned Harnesses )
* * * SB   72-0050
Figure 310   (Sheet 4 ) Removal of the Upper Fillet Fairings, Brackets, and Upper Bifurcation Bridge
* * * FOR ALL
* * * PRE SB   72-0050
Figure 311   (Sheet 1 ) Removal of the Lower Fillet Fairings and Lower Bifurcation Bridge
* * * FOR ALL
* * * SB   72-0050
Figure 311   (Sheet 2 ) Removal of the Lower Fillet Fairings and Lower Bifurcation Bridge
Subtask 72-00-01-490-001
J.Install the 11C4616   personnel stand in the fan stator module. Refer to Figure 312 and do as follows:
(1)Install the support base (item 22) 4.0 inches (102 mm) from the forward flange of fan stator module to engage the support base (item 22) in the bottom side of the fan stator module.
WARNING:
STAND RIGHT BASE AND STAND LEFT BASE MUST BE ON LATERAL SIDES OF THE SUPPORT BASE. DO NOT OPERATE THE TOOL FROM THE LATERAL SUPPORTS TO AVOID HAND CRUSH WHEN TOOL IS BEING ASSEMBLED.
(2)Install the stand right base (item 23) by inserting three alignment pins from the block in the three holes located at the right side plates of the base support (item 22).
(3)When the stand right base (item 23) is installed on the base support (item 22) and plates, lock the axial movement.
(4)Install the stand left base (item 24) by inserting three alignment pins from the block in the three holes located at the left side plates of the base support (item 22).
(5)When the stand left base (item 24) is installed on the base support (item 22) and plates, lock the axial movement.
(6)To increase the height on the right side of the tool to an additional 12.0 inches (305 mm), install the right step (item 20) on the stand right base (item 23) by inserting two alignment pins into the corresponding holes on the stand right base (item 23).
(7)Install the ball lock pin (item 7) between the right step (item 20) and stand right base (item 23) to attach both parts.
(8)To increase the height on the left side of the tool to an additional 12.0 inches (305 mm), do Subtask 72-00-01-490-001 (paragraph 3.J.(6)) and Subtask 72-00-01-490-001 (paragraph 3.J.(7)) with the left step (item 21) on the stand left base (item 24).
(9)Attach the two parts with the ball lock pin (item 7).
* * * FOR ALL
Figure 312   Installation of the Personnel Stand, 11C4616
Subtask 72-00-01-020-009
K.Remove the acoustic linners (30-030 , 72-00-00) (SIN 84200) or (30-031 , 72-00-00) (SIN 84200) and the leading edge splitter (booster splitter) (30-050 , 72-00-00) (SIN 84202) or (30-051 , 72-00-00) (SIN 84202). Refer to Figure 313 and do as follows:
(1)Begin with the acoustic liner that spans across the 12:00 o'clock position.
(2)Remove the four screws (30-040 , 72-00-00) (SIN 84220) that attach the acoustic liner to the brackets (30-110 , 72-00-00) (SIN 83710).
(3)Use your hand and carefully remove the acoustic liner.
(4)Do Subtask 72-00-01-020-009 paragraphs 3.K.(1) thru 3.K.(3) for the five remaining acoustic liners.
(5)Remove the 48 bolts (30-080 , 72-00-00) (SIN 837F0) that attach the booster splitter to the forward flange of the fan booster assembly.
Subtask 72-00-01-020-054
* * * PRE SB   75-0013( Booster Anti-Ice Manifold without Improvement )
(6)Remove the 12 machine bolts (bolts) (01-110 , 75-11-40) (SIN 63721) that attach the manifolds (01-010 , 75-11-40) (SIN 63705), (01-020 , 75-11-40) (SIN 63706), and (01-030 , 75-11-40) (SIN 63707) to the tubes (30-090 , 72-00-00) (SIN 6370B) and fan booster splitter (30-050 , 72-00-00) (SIN 84202). Remove the tubes and seals (01-150 , 75-11-40) (SIN 63755).
* * * END PRE SB   75-0013
Subtask 72-00-01-020-055
* * * SB   75-0013( Booster Anti-Ice Manifold Improvement )
(6).A.Remove the 12 machine bolts (bolts) (01-111 , 75-11-40) (SIN 63721) that attach the manifolds (01-011 , 75-11-40) (SIN 63705), (01-021 , 75-11-40) (SIN 63706), and (01-031 , 75-11-40) (SIN 63707) to the booster splitter (30-051 , 72-00-00) (SIN 84202).
* * * END SB   75-0013
Subtask 72-00-01-020-056
(7)Remove the booster splitter directly forward.
(8)Remove the bolts (30-130 , 72-00-00) (SIN 83721) and washers (30-140 , 72-00-00) (SIN 83731) that attach the brackets (30-110 , 72-00-00) (SIN 83710) to the booster splitter (30-050 , 72-00-00) (SIN 84202) or (30-051 , 72-00-00) (SIN 84202). Remove the brackets.
(9)Remove the 11 machine bolts (bolts) (01-130 , 75-11-40) (SIN 63720) that attach the manifolds to the support brackets (01-040 , 75-11-40) (SIN 63713) and (01-060 , 75-11-40) (SIN 63714) on the fan booster assembly (20-010 , 72-00-02) (SIN 80000) or (20-011 , 72-00-02) (SIN 80000).
(10)Remove the coupling clamp (01-090 , 75-11-40) (SIN 63781) that attaches the manifold (01-010 , 75-11-40) (SIN 63705) or (01-011 , 75-11-40) (SIN 63705) to the manifold (01-020 , 75-11-40) (SIN 63706) or (01-021 , 75-11-40) (SIN 63706).
(11)Remove the coupling clamp (01-090 , 75-11-40) (SIN 63781) that attaches the manifold (01-020 , 75-11-40) (SIN 63706) or (01-021 , 75-11-40) (SIN 63706) to the manifold (01-030 , 75-11-40) (SIN 63707) or (01-031 , 75-11-40) (SIN 63707).
(12)Remove the manifolds from the fan booster assembly.
(13)Remove the tiedown straps and the insulation blankets from the manifolds.
Subtask 72-00-01-020-010
L.Disconnect the oil vent tube (vent hose) (01-090 , 79-22-30 or 01-091 , 79-22-30) and hose (vent hose) (01-150 , 79-22-30 or 01-150 , 79-22-30) as follows. Refer to Figure 314.
(1)Locate the vent hose at the 12:00 o'clock position on the cowl support.
Subtask 72-00-01-020-045
* * * PRE SB   79-0009( Oil Vent Hose Tube Attached with Nuts )
(2)Loosen the four nuts (01-140 , 79-22-30) (SIN 46041) and remove the four bolts (01-120 , 79-22-30) (SIN 46028) that attach the two ends of the vent hose together through the cowl support.
* * * END PRE SB   79-0009
Subtask 72-00-01-020-046
* * * SB   79-0009( Oil Vent Hose Tube Attached with Brackets )
(2).A.Loosen the four bolts (01-120 , 79-22-30) (SIN 46028) and remove the two brackets (01-145 , 79-22-30) (SIN 46014) that attach the two ends of the vent hose together through the cowl support.
* * * END SB   79-0009
Subtask 72-00-01-020-047
(3)Move the two ends of the vent hose away from the cowl support (30-020 , 72-00-02) (SIN 95008) or (30-021 , 72-00-02) (SIN 95008) or (30-022 , 72-00-02) (SIN 95008).
(4)Remove and discard the two gaskets (01-130 , 79-22-30) (SIN 46052).
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Figure 313   (Sheet 1 ) Removal of the Acoustic Liners and Booster Splitter
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Figure 313   (Sheet 2 ) Removal of the Acoustic Liners and Booster Splitter
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Figure 313   (Sheet 3 ) Removal of the Acoustic Liners and Booster Splitter
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Figure 313   (Sheet 4 ) Removal of the Acoustic Liners and Booster Splitter
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Figure 313   (Sheet 5 ) Removal of the Acoustic Liners and Booster Splitter
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Figure 313   (Sheet 6 ) Removal of the Acoustic Liners and Booster Splitter
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* * * PRE SB   79-0009( Oil Vent Hose Tube Attached with Nuts )
Figure 314   (Sheet 1 ) Disconnect the Oil Vent Tube and Hose
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* * * SB   79-0009( Oil Vent Hose Tube Attached with Brackets )
Figure 314   (Sheet 2 ) Disconnect the Oil Vent Tube and Hose
Subtask 72-00-01-490-002
M.If necessary, install the 11C3039   fan hub frame lift bracketsas follows. Refer to Figure 315.
CAUTION:
HAVE TWO PERSONS INSTALL THE 11C3039 FAN HUB FRAME LIFT BRACKETS. THE LIFT BRACKETS ARE APPROXIMATELY 40 LBS (18 KG) EACH. DAMAGE TO ENGINE PARTS OR AN INJURY CAN OCCUR.
(1)Locate the left lift bracket (item 3) and right lift bracket (item 2) and the 14 cap bolts (item 4) that attach the brackets to the aft side of the fan hub frame.
NOTE:
Seven bolts and seven spacers must be removed from each side of the engine where the cowl support attaches to the fan hub frame before the lift brackets can be installed. Make sure you identify which bolts and spacers must be removed.
(2)Use two people and align the brackets against the aft side of the fan hub frame.
(3)Remove the seven bolts and seven spacers from each side of the fan hub frame. Put the bolts and spacers in a clear plastic bag and attach the bag to the fan hub frame for later use.
(4)It may be necessary to remove a bolt from a blankoff panel, in order to remove the bolts and spacers. If this is required, temporarily remove the bolt from the blankoff plate. Install the bolt again as soon as possible after the lifting brackets are installed.
(5)Use two people and attach a lift bracket to each side of the fan hub frame with seven cap bolts (item 4).
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Figure 315   Installation of the 11C3039, Fan Hub Frame Lift Brackets
Subtask 72-00-01-020-011
N.Prepare to separate the fan stator module from the propulsor 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)Remove the 11C4616   personnel stand from the fan stator module as follows.
(2)Remove the three bolts that attach the 11C3331   acoustic liner protector to the forward flange of the fan stator module. Remove the 11C3331   acoustic liner protector and return it to storage. Refer to Figure 301.
(3)Attach the 11C4490   fan case separation dolly to the fan stator case as follows. Refer to Figure 316.
(a)Use the jacking caster legs of the 11C4490   fan case separation dolly to align the support bracket of the dolly with the fan stator case flanges.
(b)Attach the left and right support brackets to the forward and aft flanges of the fan stator module.
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Figure 316   Installation of the 11C4490, Fan Case Separation Dolly
Subtask 72-00-01-020-012
O.Remove the fan stator module from the propulsor as follows.
(1)Adjust the 11C4490   fan case separation dolly to make sure that the engine does not move or cause injury or damage during removal. Refer to Figure 316.
(a)Turn the jacking caster leg of the side frame forward wheels until the wheels do not touch the ground.
(b)Turn the jacking caster leg of the side frame aft wheels until there is a gap between the aft adapter pads and the fan stator module.
(c)Turn the jacking caster leg of the forward wheels until the wheels touch the ground and the aft adapter pads touch the fan stator module.
(d)Adjust the jacking caster leg of the forward wheels one full turn to tighten the aft adapter pads.
(e)Put the jacking caster legs into the locked position.
(2)Remove the 192 bolts from the forward and aft flanges of the fan hub frame that attach it to the fan stator case. Refer to Figure 317.
(3)Unlock the jacking caster legs of the 11C4490   fan case separation dolly.
CAUTION:
MAKE SURE THERE ARE NO OTHER FASTENERS OR HOSES OR HARNESSES THAT CONNECT THE FAN STATOR CASE TO THE PROPULSOR. OTHERWISE, DAMAGE TO THE ENGINE CAN OCCUR.
(4)Slowly separate the fan stator module from the propulsor by pulling the fan stator module forward, or by pushing the propulsor aft. Refer to Figure 318.
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Figure 317   (Sheet 1 ) Separation of the Fan Hub Frame and Fan Stator Case
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Figure 317   (Sheet 2 ) Separation of the Fan Hub Frame and Fan Stator Case
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Figure 318   Separation of the Fan Stator from the Propulsor Module
Subtask 72-00-01-020-037
P.Install the 11C3084   fan disk bore protector, 11C4634   protector, and 11C3083   disk protector in the stage 1 fan disk. Refer to Figure 319 and do as follows:
(1)Fold the 11C4634   protector and install it in the bore behind the last web of the stage 1 fan disk. Unfold the 11C4634   protector.
(2)Fold the 11C3084   fan disk bore protector and install it in the bore of the stage 1 fan disk. Unfold the 11C3083   disk protector.
(3)Push the cover (item 2) of the 11C3083   disk protector on the stage 1 fan disk and attach it with the bolts (item 5).
Subtask 72-00-01-040-072
Q.Remove the cross-tie brackets (25-010 , 71-00-02) (SIN 25015) and (25-020 , 71-00-02) (SIN 25016), turbine rear frame (TRF) lower bumper brackets (25-030 , 71-00-02) (SIN 25010) and (25-070 , 71-00-02) (SIN 25019), deflection limiter brackets (25-040 , 71-00-02) (SIN 25011) and (25-050 , 71-00-02) (SIN 25012), and lower bumper bracket (25-060 , 71-00-02) (SIN 25014) from the aft flange of the TRF (01-010 , 72-57-00) (SIN 940A0) or (01-011 , 72-57-00) (SIN 940A0) and put them in a large and clear plastic bag.
NOTE:
All the brackets are removed from the engine during removal of the primary nozzle.
Subtask 72-00-01-040-042
R.To continue to disassemble the fan stator module. Refer to TASK 72-00-01-040-805 (72-00-01, DISASSEMBLY 001).
Subtask 72-00-01-020-040
S.If you do not continue to disassemble, then storage the fan stator module.
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Figure 319   Installation of the Disk Protector, 11C3083, Fan Disk Bore Protector, 11C3084, and Protector, 11C4634
Subtask 72-00-01-420-116
* * * FOR ALL.ALL
T.If the fan stator module will be shipped separately, then install the fan stator module into the 11C3004   shipping stand as follows:
(1)Before installing the fan stator module, the 11C3004   shipping stand must be in the configuration as follows:
(a)Stand in the pallet vertical position with the pallet base in the B747 position.
(b)The center support in the raised position.
(c)The mounting plate rotated to the 12 o'clock position and secured by the rotation lock pin. Refer to Figure 320.
(2)Make sure that the center support frame is in the maximum raised position and the holding valve is closed.
(3)Rotate the fan mounting plate to the “LOAD” position and engage the locking pin.
(4)Remove the mounting hardware from the storage container located on the center support frame.
(5)Remove the OGV support ring from the storage location on the center support frame and set aside.
(6)Bring the fan stator module to the 11C3004   shipping stand with the forward flange facing the stand 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.
(a)If the fan stator module is supported by an overhead hoist, pull the rotation lock pin out of the mounting plate lock plate to let rotation of the plate to align the mounting holes to the fan stator module.
(b)If the fan stator module is supported by a fan transfer dolly, use the dolly's jacking legs to align the fan stator module to the mounting plate holes.
NOTE:
The 11C4490   fan case separation dolly must align with the two large cut-outs in the fan mounting plate. This will provide access to later remove the bolts retaining the 11C4490   fan case separation dolly to the fan case.
(7)Install all the mounting hardware. Insert the bolts from the mounting plate side. Attach firmly the bolts in place with a flat washer, lock washer and nut. Tighten the nuts to 400 lb in (45.1 Nm).
CAUTION:
THE MOUNTING BOLTS MUST BE INSTALLED FROM THE MOUNTING SIDE PLATE. DAMAGE TO THE FAN STATOR MODULE CAN OCCUR.
(8)Install the OGV support ring. Align the top C/L mark at the 12 o'clock position. There are two hole patterns on the ring mounting surface. Each hole is marked either “1B” or “2B”. Only one bolt is necessary for each OGV support ring.
(9)Remove the fan stator module support. Pull the rotation lock pin clear of the mounting plate and rotate the plate to the designated “SHIP” position. Install all the remaining hardware.
(10)If necessary, install the cover.
(11)Install four turnbuckle shipping braces between the OGV support ring and the center support frame. Tighten the turnbuckle shipping braces to push out against the OGV support ring. Refer to Figure 321 and Figure 322.
(12)Lower the center support frame until upper ends of the shipping braces can be pinned. Shift the “C” valve to the “OFF” position to stop the center support frame descent.
(13)Close the holding valve and shift the “C” valve to the “OFF” position.
(14)The stand is now ready to be moved to a truck or rotated to the pallet horizontal position.
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* * * FOR ALL.ALL
Figure 320   Shipping Stand in Fan Module Installation Position
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Figure 321   Mounting Hardware
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Figure 322   Shipping Configuration