* * * FOR ALL PIP 2
TASK 72-00-01-420-802
1 . General.
A.This procedure gives instructions to install the fan stator module assembly (fan stator module) to the propulsor module. Refer to Figure 402.
•
Fan stator module (30-011 , 72-00-00) (SIN 00103) - SB 72-0156 (Fan Module - PIP 2 Configuration)
•
Fan stator module (30-012 , 72-00-00) (SIN 00103) - SB 79-0018 (MFOHX with Indicating Capability).
B.This procedure starts with the fan stator module in the 11C4490   fan case separation dolly in the horizontal position and the propulsor module in 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 propulsor module 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. Some steps need to be re-organized in the shop processes.
C.Make sure that the personnel read the procedure and know the step-by-step instructions and special tool usage before they install the fan stator module.
D.Make sure that there is no foreign material in the engine or on the engine parts.
E.Make sure that all parts are serviceable before you install them.
F.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 for 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) .
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 - Engine Modules (adapter assembly)
 
11C3272G01
Deleted
 
11C3281G01
Bracket Set, Support - Main Engine (TRF pedestals)
 
11C3281G02
Bracket Set, Support - Main Engine (FHF pedestals)
 
11C3331G02
Protector, Forward Acoustic Liner - Fan Module (protector)
 
11C3359P02
Stand, Full Engine Air Ship (shipping stand)
 
11C3443P03
Stand, Shipping (shipping stand) road recommended
 
11C4487P02
Stand, Shipping Engine/Propulsor (shipping stand) ground recommended
 
11C4490P02
Dolly, Separation - Fan Case Stand (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
Surface Cooler - Cover (surface cooler cover)
 
11C4645G01
Fixture, Spread - Fan Blade (blade spreading fixture)
 
9429M44G01
Adapter, Overhead Support - Fan Hub Frame (support adapter)
 
9429M47G01
Adapter, Overhead Support - LPT (support adapter)
 
9446M61G05
Program, Balance - Blade Installation/Replacement (mapping program)
(2)Standard Tools and Equipment.
 
Tool No.
Description
 
Block, Dimensional (Jo Block 0.200 inch)
Local Purchase
 
Gloves, Rubber
Local Purchase
 
Mallet, Soft Face
Local Purchase
 
Pliers, Teflon-Jaw
Local Purchase
 
Scale, Digital
Local Purchase
 
Gauge, Clearance (Starret Taper Gauge)
Local Purchase
 
Gauge block/Slip gauge (0.010 inches (0.25 mm))
Local Purchase
 
Gauge block/Slip gauge (0.005 inches (0.127 mm))
Local Purchase
(3)Locally Manufactured Tools. None.
B.Consumable Materials.
 
Code No.
Description
 
C01-007
RTV, Silicone Elastomer (RTV)
 
C02-008
Petroleum Jelly
 
C02-019
Oil, Engine Lubricating (engine oil)
 
C02-023
Oil, Engine Lubricating (engine oil)
 
C02-058
Compound, Thread Lubricating (graphite)
 
C03-079
Primer, Epoxy, (primer)
 
C03-085
Primer, Epoxy, Yellow Zinc Phosphate (primer)
 
C04-035
Solvent, General (isopropyl alcohol)
 
C05-003
Marking Pen (pen)
 
C10-013
Release Agent (compound, release agent)
 
C10-021
Tape, Plastic (tape)
 
C10-140
Gloves, Film Latex or Nylon/Polyethylene Disposable (gloves)
 
C10-215
Release Agent (release agent)
C.Referenced Procedures.
 
ATA No.
Description
 
70-51-00
Tightening Practices and Torque Values
 
72-00-00
Special Procedure 003
 
72-00-01
Assembly 001
 
72-00-03
Installation 001
D.Expendable Parts.
 
CSN
Description
 
01-130 , 79-22-30
Flange Seal Gasket (Gasket)
3 . Procedure.
Subtask 72-00-01-420-077
A.Prepare the fan stator module. Refer to Figure 403 and do as follows:
(1)If the fan stator module is installed on the 11C3004   shipping stand, transfer it to the 11C4490   fan case separation dolly as follows:
(a)Before the fan stator module removal, make sure that the 11C3004   shipping stand is in the pallet vertical (engine horizontal) orientation.
(b)If necessary, remove the safety pins for the shipping braces to be removed from the center support and main base. Return the shipping braces to their storage location on the 11C3004   shipping stand.
(c)If installed, remove the fan stator module cover.
(d)Shift the “C” valve handle to the “UP” position to fully raise the center support. Once the center support is fully raised, shift the “C” valve to the “OFF” position.
(e)Remove the safety pins to disconnect the four turnbuckle braces between the OGV support ring and the center support.
(f)Remove the locking pin from the fan mounting plate and rotate the fan stator module to the designated “LOAD” position. Install the locking pin again.
(g)Identify the two cut-outs in the fan mounting ring a the 3:00 o'clock and 9 o'clock positions. The 11C4490   fan case separation dolly will be installed at these locations. Remove any fasteners between the fan case and the fan mounting ring with the span of these cut-outs only.
(h)Slide the 11C4490   fan case separation dolly up to the fan case so that their brackets with holes are on the AFT side of the fan case flange.
(i)Adjust the jacklegs on the 11C4490   fan case separation dolly as necessary to achieve hole alignment.
(j)Attach the 11C4490   fan case separation dolly to the fan stator module. Refer to Figure 401 and as follows:
1Use the jacking caster legs on the 11C4490   fan case separation dolly to align the support bracket of the 11C4490   fan case separation dolly with the fan stator case flanges.
2Attach the left and right support brackets on the forward and aft flanges on the fan stator module.
(k)Make sure that the 11C4490   fan case separation dolly supports the weight of the fan stator module.
(l)Remove the fasteners that hold the fan stator module to the fan mounting ring.
(m)Pull the fan stator module forward or push the 11C3004   shipping stand aft to slowly separate the fan stator module from the 11C3004   shipping stand.
(2)Put an 11C4514   fan case protective mat in the lower fan case area at the 6:00 o'clock location to prevent damage to the inside surfaces of the fan stator module. Refer to Figure 404.
CAUTION:
DO NOT SCRATCH THE ACOUSTIC PANELS OR THE FAN CASE ABRADABLE SURFACE. DAMAGE TO THE PARTS CAN OCCUR.
(3)Install the 11C3331   protectors if they are not installed. This will protect the forward edge of the acoustic panels. Refer to Figure 403.
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.
(4)Clean the forward and aft flanges of the fan hub module and the fan stator module with C04-035  isopropyl alcohol. Refer to Figure 405.
(5)Remove the tape around the fan hub module.
(6)Make sure that all nut plates are installed on the fan hub module.
(7)If not installed, install the 11C4593   surface cooler cover.
* * * FOR ALL PIP 2
Figure 401   Installation of the 11C4490, Fan Case Separation Dolly
* * * FOR ALL PIP 2
Figure 402   Installation of the Fan Stator Module to the Engine Propulsor
* * * FOR ALL PIP 2
Figure 403   Fan Stator Module
* * * FOR ALL PIP 2
Figure 404   Installation of the Fan Case Protective Mat, 11C4514
* * * FOR ALL PIP 2
Figure 405   (Sheet 1 ) Fan Stator Module Attaching to the Fan Hub Module
* * * FOR ALL PIP 2
Figure 405   (Sheet 2 ) Fan Stator Module Attaching to the Fan Hub Module
* * * FOR ALL PIP 2
Figure 405   (Sheet 3 ) Fan Stator Module Attaching to the Fan Hub Module
Subtask 72-00-01-420-078
B.Install the fan stator module to the propulsor as follows:
(1)Make sure that the fan stator module and the propulsor are level. Lower the workstation and/or adjust the fan case dolly to align the fan stator module with the propulsor.
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)Apply C03-079  primer or C03-085  primer to the forward side only of two fan hub module flange grooves in areas AA and AB around the circumference of the fan hub module. Refer to Figure 405.
(3)Deleted.
(4)Slowly push the propulsor into the fan stator module as follows:
(a)Use visual indicators to make sure that the propulsor and fan stator module are in close alignment. Make adjustments as necessary to attach the two modules correctly.
(b)Make sure that the OGV boltholes are aligned with the boltholes in the aft flange of the fan hub frame.
(c)Make sure that all tools or foreign objects are removed from inside the fan case. Make sure that the drain lines at the 12:00 o'clock position are clear of the mating flanges.
(d)Push the modules together until the bolts (30-070 , 72-00-00) (SIN 84021) can be started into the fan hub frame flanges by hand a minimum of 0.25 inch (6.4 mm) before wrenches are used.
(e)Temporarily install several bolts (30-070 , 72-00-00) (SIN 84021) to hold the flanges together. They will be removed and install again in a later step.
Subtask 72-00-01-420-079
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.
(5)Lubricate the threads of 192 machine bolts (30-060 , 72-00-00) (SIN 84022) and (30-070 , 72-00-00) (SIN 84021) with C02-058  graphite .
NOTE:
Bolts (30-070 , 72-00-00) (SIN 84021) must be installed wet. If the bolts become dry, they must be coated again before the installation. Bolts (30-060 , 72-00-00) (SIN 84022) and (30-070 , 72-00-00) (SIN 84021) must be installed within two hours of the lubricant application.
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.
(6)Apply C03-079  primer or C03-085  primer to all surfaces of the bolt assemblies (30-060 , 72-00-00) (SIN 84022), (30-070 , 72-00-00) (SIN 84021), but not to the threads or wrenching surfaces.
(7)Install 184 bolts (30-070 , 72-00-00) (SIN 84021) into the forward and aft flanges. Refer to Figure 405 for the bolt pattern.
NOTE:
The boltheads point forward on the forward flange. The boltheads point aft on the aft flange.
(8)Install eight bolts (30-060 , 72-00-00) (SIN 84022) at the 12:00 and 6:00 o'clock positions on the aft flange into the titanium OGVs.
(9)If necessary, remove, lubricate, and re-install the temporary bolts (30-070 , 72-00-00) (SIN 84021) that were installed before.
(10)Tighten all the bolts (30-060 , 72-00-00) (SIN 84022) and (30-070 , 72-00-00) (SIN 84021) in a criss-cross pattern to seat the flanges together. Do not torque the bolts at this time.
Subtask 72-00-01-420-080
C.Torque the bolts on the forward and aft fan hub frame flanges as follows:
(1)Apply an initial torque to the forward flange bolts (30-070 , 72-00-00) (SIN 84021) to 300 lb in. (33.9 Nm) in a criss-cross pattern.
(2)Apply an initial torque to the aft flange bolts (30-070 , 72-00-00) (SIN 84021) to 300 lb in. (33.9 N.m) and to the bolts (30-060 , 72-00-00) (SIN 84022) to 450 lb in. (45.2 N.m) in a criss-cross pattern.
(3)Apply a final torque to the forward flange bolts (30-070 , 72-00-00) (SIN 84021) to 368 to 432 lb in. (41.6 to 48.8 Nm) in a sequential pattern.
(4)Do a 360 degrees torque check of the forward flange bolts (30-070 , 72-00-00) (SIN 84021) to 368 to 432 lb in. (41.6 to 48.8 Nm).
(5)Apply a final torque to the aft flange bolts (30-070 , 72-00-00) (SIN 84021) to 368-432 lb in. (41.6-48.8 N.m), and to the bolts (30-060 , 72-00-00) (SIN 84022) to 552-648 lb in. (62.4-73.2 N.m) in a sequential pattern.
(6)Do a 360-degree torque check of the aft flange bolts. Torque the bolts (30-070 , 72-00-00) (SIN 84021) to 368-432 lb in. (41.6-48.8 N.m) and the bolts (30-060 , 72-00-00) (SIN 84022) to 552-648 lb in. (62.4-73-2 N.m).
Subtask 72-00-01-220-030
(7)Do a visual inspection of the forward flange and make sure that all fasteners are installed and torqued.
(8)Do a visual inspection of the aft flange and make sure that all fasteners are installed and torqued.
Subtask 72-00-01-420-081
D.Change the engine mounting arrangements as follows:
NOTE:
If customer shop overhead rail system and 11C3044   adapter assembly are used, skip Subtask 72-00-01-420-081 (paragraph 3.D.) and Subtask 72-00-01-420-084 (paragraph 3.E.) until the steps from assembly are complete.
(1)Alternative Procedure Available. Remove the four large nuts that attach the forward fan ring brackets to the fan case dolly to remove the fan case from the fan dolly. Remove the clamps at the 1:00 and 11:00 o'clock positions.
Subtask 72-00-01-420-082
(1).A.Alternative Procedure. If the fan case was installed with spreader bars, disconnect all hanging hardware from the fan case.
Subtask 72-00-01-420-083
(2)Put the engine in the dolly as follows:
NOTE:
This step is not applicable if the fan case was installed with spreader bars.
(a)Install LPT trunnions if they are not installed to the LPT.
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.
(b)Lower the engine into the dolly and make sure that the LPT trunnions do not bind.
(c)Attach the fan case to the dolly at the fan case ground handling mounts.
(d)Disconnect all hanging hardware from the engine at the LPT lift brackets and 11C3039 fan hub frame lift brackets.
(3)Hang the engine from the aft fan case and LPT brackets as follows:
NOTE:
This step is not applicable if the engine will be installed into the beam at this time.
(a)Attach the hanging hardware to the aft fan case and at the LPT lift bracket.
(b)Remove the locking hardware from the LPT trunnions and from the lower fan case ground handling mounts.
(c)Slowly raise the engine from the dolly.
Subtask 72-00-01-420-084
E.Remove the fan hub frame lift brackets and install remaining hardware. Refer to Figure 406 and do as follows:
CAUTION:
TWO PERSONS MUST REMOVE 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)Carefully remove the 11C3039   fan hub frame lift brackets from the left and right sides of the engine as follows:
(a)Remove the bolts that attach the brackets to the fan hub frame.
(b)Make sure not to damage the engine when the brackets are removed.
(2)Install the remaining machine bolts (bolts) (30-675 , 72-00-02) (SIN 9502A) in the fan hub frame.
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.
(3)Lubricate the threads and mating surfaces of the bolts with C02-058  graphite.
(4)Install the bolts and sleeve spacers (spacers) (30-061 , 72-00-02) (SIN 95070) into the fan hub module, except at one location on the right side and left side of the engine at VSV door cover plate (blankoff panels) (30-140 , 72-00-02) (SIN 9500K). At these two locations, install one bolt with one flat washer (30-685 , 72-00-02) (SIN 95037).
(5)Torque the bolts (30-675 , 72-00-02) (SIN 9502A) to 368-432 lb in. (41.6-48.8 N.m).
(6)If any machine bolts (bolts) (30-130 , 72-00-02) (SIN 95022) that attach the blankoff panels (30-140 , 72-00-02) (SIN 9500K) were removed, then install those bolts again. Torque the bolts (30-130 , 72-00-02) (SIN 95022) to 106-124 lb in. (12.0-14.0 N.m).
* * * FOR ALL PIP 2
Figure 406   Removal of the Fan Hub Frame Lift Brackets
Subtask 72-00-01-420-085
F.Install the tubes and fairings behind the outlet guide vanes as follows:
(1)Install the oil vent hose tube (vent tube) (01-091 , 79-22-30) (SIN 46004) at the 12:00 o'clock position above the fan hub frame. Refer to Figure 407 and do 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)Lubricate two gaskets (01-130 , 79-22-30) (SIN 46052) with C02-019  engine oil or C02-023  engine oil.
(b)Attach the vent tube (01-091 , 79-22-30) (SIN 46004) through the upper bifurcation strut to the top of the cowl support (30-021 , 72-00-02) (SIN 95008) or (30-022 , 72-00-02) (SIN 95008) with one gasket and four machine bolts (bolts) (01-120 , 79-22-30) (SIN 46028).
Subtask 72-00-01-420-086
(c)Attach the vent tube (01-091 , 79-22-30) (SIN 46004) and oil vent hose tube (vent hose) (01-151 , 79-22-30) (SIN 46005) below the cowl support with one gasket and two brackets (01-145 , 79-22-30) (SIN 46014).
Subtask 72-00-01-420-087
(d)Torque the bolts (01-120 , 79-22-30) (SIN 46028) to 106-124 lb in. (12.0-14.0 N.m).
Subtask 72-00-01-420-088
(2)Install the upper bifurcation bridge (upper bridge) (25-171 , 72-00-00) (SIN 95002). Refer to Figure 408 and do 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)Lubricate the seven studs on the cowl support, four bolts (25-151 , 72-00-00) (SIN 84429), and seven nuts (25-180 , 72-00-00) (SIN 95040) with C02-058  graphite.
(b)Install the upper bridge (25-171 , 72-00-00) (SIN 95002) to the aft side of the fan hub frame and over the cowl supports (30-011 , 72-00-02) (SIN 95001) or (30-012 , 72-00-02) (SIN 95001) and (30-021 , 72-00-02) (SIN 95008) or (30-022 , 72-00-02) (SIN 95008) at the 12:00 o'clock position.
(c)Attach the upper bridge (25-171 , 72-00-00) (SIN 95002) with three flat washers (washers) (25-190 , 72-00-00) (SIN 95030) and three nuts (25-180 , 72-00-00) (SIN 95040).
(d)Attach the upper bridge (25-171 , 72-00-00) (SIN 95002) to the upper firewall (01-152 , 72-21-00) (SIN 84401) with four bolts (25-151 , 72-00-00) (SIN 84429) and four flat washers (washers) (25-160 , 72-00-00) (SIN 84434).
(e)Torque the bolts (25-151 , 72-00-00) (SIN 84429) to 106-124 lb in. (12.0-14.0 N.m).
NOTE:
Upper bridge must contact upper bifurcation firewall before torquing nuts (25-180 , 72-00-00) (SIN 95040).
(f)Deleted.
(3)Install the bracket (25-210 , 72-00-00) (SIN 68812) and do as follows:
(a)Install the bracket (25-210 , 72-00-00) (SIN 68812) on the upper bifurcation bridge (25-171 , 72-00-00) (SIN 95002) with two nuts (25-180 , 72-00-00) (SIN 95040).
(4)Install the bracket (25-200 , 72-00-00) (SIN 9931A) and do as follows:
(a)Install the bracket (25-200 , 72-00-00) (SIN 9931A) with two nuts (25-180 , 72-00-00) (SIN 95040).
(5)Torque the seven nuts to 69 to 81 lb in. (7.7 to 9.1 Nm).
(6)Install the upper fillet fairings 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)Lubricate the threads and mating surfaces of ten torx bolts (bolts) (25-130 , 72-00-00) (SIN 84427), four machine screws (screws) (25-120 , 72-00-00) (SIN 84428), and four torx bolts (bolts) (25-140 , 72-00-00) (SIN 8442H) with C02-058   graphite.
(b)Install the upper left fillet fairing (fillet fairing) (25-100 , 72-00-00) (SIN 84407) to the left side of the upper bifurcation with five bolts (25-130 , 72-00-00) (SIN 84427), two screws (25-120 , 72-00-00) (SIN 84428), and two bolts (25-140 , 72-00-00) (SIN 8442H).
(c)Install upper right fillet fairing (fillet fairing) (25-110 , 72-00-00) (SIN 8440A) to the right side of the upper bifurcation with five bolts (25-130 , 72-00-00) (SIN 84427), two screws (25-120 , 72-00-00) (SIN 84428), and two bolts (25-140 , 72-00-00) (SIN 8442H).
(d)Deleted.
(7)Apply C01-007  RTV to the upper bridge 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)Clean the upper bridge and the adjacent surfaces with C04-035  isopropyl alcohol.
(b)Apply C01-007  RTV to the transition areas where the upper bridge touches other surfaces. Make sure that there is a smooth transition of the sealant between mating components.
(c)Apply RTV sealant within 2.00 inches (50.8 mm) maximum of either side of the mating surfaces and within 2.00 inches (50.8 mm) maximum from the aft edge of seal.
(d)Let the C01-007  RTV cure for 12 hours.
* * * FOR ALL PIP 2
Figure 407   Installation of the Oil Tank Vent Tube and Hose
* * * FOR ALL PIP 2
Figure 408   (Sheet 1 ) Installation of the Upper Bridge, Brackets, and Fillet Fairings
* * * FOR ALL PIP 2
* * * PRE SB   73-0060( Old Design for W30 and W31 Harnesses )
Figure 408   (Sheet 2 ) Installation of the Upper Bridge, Brackets, and Fillet Fairings
* * * FOR ALL PIP 2
* * * SB   73-0060( W30 and W31 Redesigned Harnesses )
Figure 408   (Sheet 3 ) Installation of the Upper Bridge, Brackets, and Fillet Fairings
Subtask 72-00-01-440-001
* * * PRE SB   75-0013( Booster Anti-Ice without Improvement )
G.Install the leading edge splitter (booster splitter) (30-051 , 72-00-00) (SIN 84202). Refer to Figure 409 and do as follows:
(1)Install the insulation blankets to the manifold (01-010 , 75-11-40) (SIN 63705) as follows:
(a)Install two insulation blankets (01-160 , 75-11-40) (SIN 63790) on the forward side of the manifold.
(b)Install two insulation blankets (01-170 , 75-11-40) (SIN 63791) on the aft side of the manifold.
(c)Attach firmly each insulation blanket pair with five tiedown straps (01-280 , 75-11-40) (SIN 6379H). Make sure that the tail clip of the tiedown strap is outboard, if not, it will rub the booster case.
(d)Install two insulation blankets (01-240 , 75-11-40) (SIN 6379D) on the inboard side of the manifold.
(e)Install two insulation blankets (01-250 , 75-11-40) (SIN 6379E) on the outboard side of the manifold.
(f)Attach firmly each insulation blanket pair with six tiedown straps (01-280 , 75-11-40) (SIN 6379H). Make sure that the tail clip of the tiedown strap is outboard, if not, it will rub the booster case.
(2)Install the insulation blankets to the manifold (01-030 , 75-11-40) (SIN 63707) as follows:
(a)Install two insulation blankets (01-180 , 75-11-40) (SIN 63792) on the forward and aft sides of the manifold.
(b)Install two insulation blankets (01-190 , 75-11-40) (SIN 63793) on the aft and forward sides of the manifold.
(c)Attach firmly each insulation blanket pair with five tiedown straps (01-280 , 75-11-40) (SIN 6379H). Make sure that the tail clip of the tiedown strap is outboard, if not, it will rub the booster case.
(d)Install two insulation blankets (01-260 , 75-11-40) (SIN 6379F) on the inboard side of the manifold.
(e)Install two insulation blankets (01-270 , 75-11-40) (SIN 6379G) on the outboard side of the manifold.
(f)Attach firmly each insulation blanket pair with six tiedown straps (01-280 , 75-11-40) (SIN 6379H). Make sure that the tail clip of the tiedown strap is outboard, if not, it will rub the booster case.
(3)Install the insulation blankets to the manifold (01-020 , 75-11-40) (SIN 63706) as follows:
(a)Install two insulation blankets (01-160 , 75-11-40) (SIN 63790) on the forward side of the left side of the manifold.
(b)Install two insulation blankets (01-170 , 75-11-40) (SIN 63791) on the aft side of the left side of the manifold.
(c)Attach firmly each insulation blanket pair with five tiedown straps (01-280 , 75-11-40) (SIN 6379H). Make sure that the tail clip of the tiedown strap is outboard, if not, it will rub the booster case.
(d)Install one insulation blanket (01-240 , 75-11-40) (SIN 6379D) on the inboard side of the left side of the manifold.
(e)Install one insulation blanket (01-250 , 75-11-40) (SIN 6379E) on the outboard side of the left side of the manifold.
(f)Attach firmly each insulation blanket pair with six tiedown straps (01-280 , 75-11-40) (SIN 6379H). Make sure that the tail clip of the tiedown strap is outboard, if not, it will rub the booster case.
(g)Install one insulation blanket (01-200 , 75-11-40) (SIN 63794) on the inboard side of the left side of the manifold.
(h)Install one insulation blanket (01-210 , 75-11-40) (SIN 63795) on the outboard side of the left side of the manifold.
(i)Attach firmly the insulation blanket pair with one tiedown strap (01-280 , 75-11-40) (SIN 6379H). Make sure that the tail clip of the tiedown strap is outboard, if not, it will rub the booster case.
(j)Install three insulation blankets (01-160 , 75-11-40) (SIN 63790) on the forward side of the right side of the manifold.
(k)Install three insulation blankets (01-170 , 75-11-40) (SIN 63791) on the aft side of the right side of the manifold.
(l)Attach firmly each insulation blanket pair with five tiedown straps (01-280 , 75-11-40) (SIN 6379H). Make sure that the tail clip of the tiedown strap is outboard, if not, it will rub the booster case.
(m)Install one insulation blanket (01-260 , 75-11-40) (SIN 6379F) on the inboard side of the right side of the manifold.
(n)Install one insulation blanket (01-270 , 75-11-40) (SIN 6379G) on the outboard side of the right side of the manifold.
(o)Attach firmly each insulation blanket pair with six tiedown straps (01-280 , 75-11-40) (SIN 6379H). Make sure that the tail clip of the tiedown strap is outboard, if not, it will rub the booster case.
(p)Install one insulation blanket (01-220 , 75-11-40) (SIN 63796) on the inboard side of the right side of the manifold.
(q)Install one insulation blanket (01-230 , 75-11-40) (SIN 63797) on the outboard side of the right side of the manifold.
(r)Attach firmly the insulation blanket pair with two tiedown straps (01-280 , 75-11-40) (SIN 6379H). Make sure that the tail clip of the tiedown strap is outboard, if not, it will rub the booster case.
(4)Install the manifold (01-020 , 75-11-40) (SIN 63706) on the fan booster assembly as follows:
(a)Install the manifold to the BAI air tube (01-180 , 75-11-30) (SIN 63704) with a ring seal (01-080 , 75-11-40) (SIN 63752).
(b)Attach the manifold and the BAI air tube with a coupling clamp (01-120 , 75-11-40) (SIN 63783).
(c)Torque the coupling clamp (01-120 , 75-11-40) (SIN 63783) to 60-70 lb in. (6.8-7.9 N.m).
(5)Install the manifold (01-010 , 75-11-40) (SIN 63705) on the fan booster assembly as follows:
(a)Install the manifold (01-010 , 75-11-40) (SIN 63705) to the manifold (01-020 , 75-11-40) (SIN 63706) with a ring seal (01-140 , 75-11-40) (SIN 63751).
(b)Attach the two manifolds with a coupling clamp (01-090 , 75-11-40) (SIN 63781).
(c)Torque the coupling clamp (01-090 , 75-11-40) (SIN 63781) to 51-59 lb in. (5.8-6.7 N.m).
(6)Install the manifold (01-030 , 75-11-40) (SIN 63707) on the fan booster assembly as follows:
(a)Install the manifold (01-030 , 75-11-40) (SIN 63705) to the manifold (01-020 , 75-11-40) (SIN 63706) with a ring seal (01-140 , 75-11-40) (SIN 63751).
(b)Attach the two manifolds with a coupling clamp (01-090 , 75-11-40) (SIN 63781).
(c)Torque the coupling clamp (01-090 , 75-11-40) (SIN 63781) to 51-59 lb in. (5.8-6.7 N.m).
(7)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 support brackets (01-040 , 75-11-40) (SIN 63713) and (01-060 , 75-11-40) (SIN 63714) on the fan booster assembly with 11 loop clamps (01-100 , 75-11-40) (SIN 63782) and machine bolts (bolts) (01-130 , 75-11-40) (SIN 63720). Do not torque the bolts at this time.
Subtask 72-00-01-210-002
(8)Make sure that the seal (30-100 , 72-00-00) (SIN 63759) is installed. If it is not, install the seal. Refer to TASK 72-00-22-420-801 (72-00-22, INSTALLATION 001).
Subtask 72-00-01-420-112
(9)Attach 24 brackets (30-110 , 72-00-00) (SIN 83710) to the booster splitter with machine bolts (30-131 , 72-00-00) (SIN 83721), flat washers (30-140 , 72-00-00) (SIN 83731), and self-locking nuts (nuts) (30-150 , 72-00-00) (SIN 83741). Boltheads aft and washers under the bolt head.
(10)Torque the machine bolts (30-131 , 72-00-00) (SIN 83721) to 60-70 lb in. (6.8-7.9 N.m).
(11)Install the booster splitter (30-051 , 72-00-00) (SIN 84202) 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  graphite to the threads of 12 machine bolts (bolts) (01-110 , 75-11-40) (SIN 63721).
(b)Put the booster splitter against the aft flange of the IGV assembly (02-100 , 72-22-00) (SIN 837A0).
(c)Align the part number of the booster splitter with the notch in the flange of the fan booster assembly at the 12:00 o'clock position, top vertical centerline and align the openings in the aft face of the booster splitter with the tubes (30-090 , 72-00-00) (SIN 6370B), seals (01-150 , 75-11-40) (SIN 63755), and manifolds (01-010 , 75-11-40) (SIN 63705), (01-020 , 75-11-40) (SIN 63706), and (01-030 , 75-11-40) (SIN 63707).
(d)Install the 12 bolts (01-110 , 75-11-40) (SIN 63721) to attach the manifolds to the booster splitter. Do not torque the bolts at this time.
(12)Torque the bolts (01-130 , 75-11-40) (SIN 63720) to 60-70 lb in. (6.8-7.9 N.m).
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.
(13)Lubricate the threads and mating surfaces of 48 bolts (30-080 , 72-00-00) (SIN 837F0) with C02-058  graphite.
(14)Attach the booster splitter to the flange of the IGV assembly with 48 bolts (30-080 , 72-00-00) (SIN 837F0).
(15)Torque the bolts (30-080 , 72-00-00) (SIN 837F0) to 85 lb in. (9.6 N.m) in a criss-cross pattern.
(16)Torque the bolts (30-080 , 72-00-00) (SIN 837F0) to 106-124 lb in. (12.0-14.0 N.m) again in a criss-cross pattern.
(17)Do a 360-degree torque check of the bolts to 106-124 lb in. (12.0-14.0 N.m).
(18)Torque the bolts (01-110 , 75-11-40) (SIN 63721) to 51-59 lb in. (5.8-6.7 N.m).
Subtask 72-00-01-220-034
(19)Do a visual inspection of the fan booster area. Make sure that there is no damage and the area is clear of tools and unwanted material.
* * * END PRE SB   75-0013
Subtask 72-00-01-420-089
* * * SB   75-0013( Booster Anti-Ice Manifold Improvement )
G.A.Install the leading edge splitter (booster splitter) (30-051 , 72-00-00) (SIN 84202). Refer to Figure 409 and do as follows:
(1)Install the insulation blankets to the manifold (01-011 , 75-11-40) (SIN 63705) as follows:
(a)Install two insulation blankets (01-161 , 75-11-40) (SIN 63790) on the forward side of the manifold.
(b)Install two insulation blankets (01-171 , 75-11-40) (SIN 63791) on the aft side of the manifold.
(c)Attach firmly each insulation blanket pair with four tiedown straps (01-281 , 75-11-40) (SIN 6379H). Make sure that the tail clip of the tiedown strap is outboard, otherwise it will rub the booster case.
(d)Install two insulation blankets (01-241 , 75-11-40) (SIN 6379D) on the inboard side of the manifold.
(e)Install two insulation blankets (01-251 , 75-11-40) (SIN 6379E) on the outboard side of the manifold.
(f)Attach firmly each insulation blanket pair with six tiedown straps (01-281 , 75-11-40) (SIN 6379H). Make sure that the tail clip of the tiedown strap is outboard, otherwise it will rub the booster case.
(2)Install the insulation blankets to the manifold (01-031 , 75-11-40) (SIN 63707) as follows:
(a)Install two insulation blankets (01-181 , 75-11-40) (SIN 63792) on the forward and aft sides of the manifold.
(b)Install two insulation blankets (01-191 , 75-11-40) (SIN 63793) on the aft and forward sides of the manifold.
(c)Attach firmly each insulation blanket pair with four tiedown straps (01-281 , 75-11-40) (SIN 6379H). Make sure that the tail clip of the tiedown strap is outboard, otherwise it will rub the booster case.
(d)Install two insulation blankets (01-261 , 75-11-40) (SIN 6379F) on the inboard side of the manifold.
(e)Install two insulation blankets (01-271 , 75-11-40) (SIN 6379G) on the outboard side of the manifold.
(f)Attach firmly each insulation blanket pair with six tiedown straps (01-281 , 75-11-40) (SIN 6379H). Make sure that the tail clip of the tiedown strap is outboard, otherwise it will rub the booster case.
(3)Install the insulation blankets to the manifold (01-021 , 75-11-40) (SIN 63706) as follows:
(a)Install two insulation blankets (01-161 , 75-11-40) (SIN 63790) on the forward and aft sides of the left side of the manifold.
(b)Install two insulation blankets (01-171 , 75-11-40) (SIN 63791) on the aft and forward sides of the left side of the manifold.
(c)Attach firmly each insulation blanket pair with four tiedown straps (01-281 , 75-11-40) (SIN 6379H). Make sure that the tail clip of the tiedown strap is outboard, otherwise it will rub the booster case.
(d)Install one insulation blanket (01-241 , 75-11-40) (SIN 6379D) on the inboard side of the left side of the manifold.
(e)Install one insulation blanket (01-251 , 75-11-40) (SIN 6379E) on the outboard side of the left side of the manifold.
(f)Attach firmly each insulation blanket pair with six tiedown straps (01-281 , 75-11-40) (SIN 6379H). Make sure that the tail clip of the tiedown strap is outboard, otherwise it will rub the booster case.
(g)Install one insulation blanket (01-201 , 75-11-40) (SIN 63794) on the inboard side of the left side of the manifold.
(h)Install one insulation blanket (01-211 , 75-11-40) (SIN 63795) on the outboard side of the left side of the manifold.
(i)Attach firmly the insulation blanket pair with one tiedown strap (01-281 , 75-11-40) (SIN 6379H). Make sure that the tail clip of the tiedown strap is outboard, otherwise it will rub the booster case.
(j)Install two insulation blankets (01-161 , 75-11-40) (SIN 63790) on the forward side of the right side of the manifold.
(k)Install two insulation blanket (01-171 , 75-11-40) (SIN 63791) on the aft side of the right side of the manifold.
(l)Attach firmly each insulation blankets pair with four tiedown straps (01-281 , 75-11-40) (SIN 6379H). Make sure that the tail clip of the tiedown strap is outboard, otherwise it will rub the booster case.
(m)Install one insulation blanket (01-300 , 75-11-40) (SIN 6379M) on the forward side of the right side of the manifold.
(n)Install one insulation blanket (01-290 , 75-11-40) (SIN 6379L) on the aft side of the right side of the manifold.
(o)Attach firmly each insulation blanket pair with four tiedown straps (01-281 , 75-11-40) (SIN 6379H). Make sure that the tail clip of the tiedown strap is outboard, otherwise it will rub the booster case.
(p)Install one insulation blanket (01-261 , 75-11-40) (SIN 6379F) on the inboard side of the right side of the manifold.
(q)Install one insulation blanket (01-271 , 75-11-40) (SIN 6379G) on the outboard side of the right side of the manifold.
(r)Attach firmly each insulation blanket pair with six tiedown straps (01-281 , 75-11-40) (SIN 6379H). Make sure that the tail clip of the tiedown strap is outboard, otherwise it will rub the booster case.
(s)Install one insulation blanket (01-221 , 75-11-40) (SIN 63796) on the inboard side of the right side of the manifold.
(t)Install one insulation blanket (01-231 , 75-11-40) (SIN 63797) on the outboard side of the right side of the manifold.
(u)Attach firmly the insulation blanket pair with two tiedown straps (01-281 , 75-11-40) (SIN 6379H). Make sure that the tail clip of the tiedown strap is outboard, otherwise it will rub the booster case.
(4)Install the manifold (01-021 , 75-11-40) (SIN 63706) on the fan booster assembly as follows:
(a)Install the manifold to the BAI air tube (01-180 , 75-11-30) (SIN 63704) with a ring seal (01-080 , 75-11-40) (SIN 63752).
(b)Attach the manifold and the BAI air tube with a coupling clamp (01-120 , 75-11-40) (SIN 63783).
(c)Torque the coupling clamp (01-120 , 75-11-40) (SIN 63783) to 60-70 lb in. (6.8-7.9 N.m).
(5)Install the manifold (01-011 , 75-11-40) (SIN 63705) on the fan booster assembly as follows:
(a)Install the manifold (01-011 , 75-11-40) (SIN 63705) to the manifold (01-021 , 75-11-40) (SIN 63706) with a ring seal (01-140 , 75-11-40) (SIN 63751).
(b)Attach the two manifolds with a coupling clamp (01-090 , 75-11-40) (SIN 63781).
(c)Torque the coupling clamp (01-090 , 75-11-40) (SIN 63781) to 51-59 lb in. (5.8-6.7 N.m).
(6)Install the manifold (01-031 , 75-11-40) (SIN 63707) on the fan booster assembly as follows:
(a)Install the manifold (01-031 , 75-11-40) (SIN 63707) to the manifold (01-021 , 75-11-40) (SIN 63706) with a ring seal (01-140 , 75-11-40) (SIN 63751).
(b)Attach the two manifolds with a coupling clamp (01-090 , 75-11-40) (SIN 63781).
(c)Torque the coupling clamp (01-090 , 75-11-40) (SIN 63781) to 51-59 lb in. (5.8-6.7 N.m).
(7)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 support brackets (01-040 , 75-11-40) (SIN 63713) and (01-060 , 75-11-40) (SIN 63714) on the fan booster assembly with 11 loop clamps (01-100 , 75-11-40) (SIN 63782) and machine bolts (bolts) (01-130 , 75-11-40) (SIN 63720). Do not torque the bolts at this time.
(8)Attach 24 brackets (30-110 , 72-00-00) (SIN 83710) to the booster splitter with machine bolts (30-131 , 72-00-00) (SIN 83721), flat washers (30-140 , 72-00-00) (SIN 83731), and self-locking nuts (nuts) (30-150 , 72-00-00) (SIN 83741). Boltheads aft and washers under the bolt head.
(9)Torque the machine bolts (30-131 , 72-00-00) (SIN 83721) to 60-70 lb in. (6.8-7.9 N.m).
Subtask 72-00-01-220-031
(10)Make sure that the seal (30-100 , 72-00-00) (SIN 63759) is installed. If it is not, install the seal. Refer to TASK 72-00-22-420-801 (72-00-22, INSTALLATION 001).
Subtask 72-00-01-420-090
(11)Install the booster splitter on the fan booster assembly. Align the part number of the booster splitter with the notch in the flange of the fan booster assembly at the 12:00 o'clock position, top vertical centerline and align the openings in the aft face of the booster splitter with the manifolds (01-011 , 75-11-40) (SIN 63705), (01-021 , 75-11-40) (SIN 63706), and (01-031 , 75-11-40) (SIN 63707).
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.
(12)Apply C02-058  graphite to the threads of the 12 machine bolts (bolts) (01-111 , 75-11-40) (SIN 63721).
(13)Install the 12 bolts (01-111 , 75-11-40) (SIN 63721) to 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. Do not torque the bolts at this time.
(14)Torque the bolts (01-130 , 75-11-40) (SIN 63720) to 60-70 lb in. (6.8-7.9 N.m).
(15)Make sure that the seal (30-100 , 72-00-00) (SIN 63759) is installed. If it is not, install the seal. Refer to TASK 72-00-22-420-801 (72-00-22, INSTALLATION 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.
(16)Lubricate the threads and mating surfaces of 48 bolts (30-080 , 72-00-00) (SIN 837F0) with C02-058  graphite.
(17)Attach the booster splitter to the flange of the fan booster assembly with 48 bolts (30-080 , 72-00-00) (SIN 837F0).
(18)Torque bolts (30-080 , 72-00-00) (SIN 837F0) to 85 lb in. (9.6 N.m) in a criss-cross pattern.
(19)Torque the bolts (30-080 , 72-00-00) (SIN 837F0) to 106-124 lb in. (12.0-14.0 N.m) again in a criss-cross pattern.
(20)Do a 360-degree torque check of the bolts to 106-124 lb in. (12.0-14.0 N.m).
(21)Torque the bolts (01-111 , 75-11-40) (SIN 63721) to 51-59 lb in. (5.8-6.7 N.m).
Subtask 72-00-01-220-032
(22)Do a visual inspection of the fan booster area. Make sure that there is no damage and the area is clear of tools and unwanted material.
* * * END SB   75-0013
Subtask 72-00-01-420-091
H.Install the fan duct inner acoustic liners (acoustic liner) (30-031 , 72-00-00) (SIN 84200) (acoustic liners). Refer to Figure 409 and do 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)Apply C02-058  graphite to the threads of 24 screws (30-040 , 72-00-00) (SIN 84220).
(2)Apply C02-008  petroleum jelly to the aft end of the acoustic liners to ease installation and prevent the rubber from tearing.
CAUTION:
THE SCREWS (30-040 , 72-00-00) (SIN 84220) IN THE ACOUSTIC LINERS MUST BE ALIGNED AND STARTED BY HAND. OTHERWISE, DAMAGE TO THE NUT PLATE EMBOSSED IN THE FAN BOOSTER WILL OCCUR.
CAUTION:
MAKE SURE THAT THERE IS NO FOREIGN OBJECT DAMAGE (FOD) IN THE FAN BOOSTER CASE CAVITIES BEFORE THE ACOUSTIC LINERS ARE INSTALLED.
(3)Install the first acoustic liner to the bracket (30-110 , 72-00-00) (SIN 83710) from the 11:00 o'clock position to the 1:00 o'clock position on the aft side of the booster splitter fairing with four screws (30-040 , 72-00-00) (SIN 84220). The acoustic liners must span across (not split at) the 12:00 o'clock and 6:00 o'clock position centerlines.
(4)Install the remaining five liners to the outer diameter of the fan booster assembly between the booster splitter flange and the fan case outlet guide vanes with 20 screws (30-040 , 72-00-00) (SIN 84220).
CAUTION:
MAKE SURE THAT THE BOOSTER ACOUSTIC PANEL BUSHINGS TOUCH THE T-BRACKETS BEFORE YOU START TO TIGHTEN THE SCREWS.
CAUTION:
THE SCREWS (30-040, 72-00-00) (SIN 84220) IN THE ACOUSTIC LINERS MUST BE ALIGNED AND STARTED BY HAND. OTHERWISE, DAMAGE TO THE NUT PLATE EMBOSSED IN THE FAN BOOSTER WILL OCCUR.
(5)Torque all the screws (30-040 , 72-00-00) (SIN 84220) to 60-70 lb in. (6.8-7.9 N.m).
(6)Wait 15 minutes, then torque the screws (30-040 , 72-00-00) (SIN 84220) again to 60-70 lb in. (6.8-7.9 N.m).
Subtask 72-00-01-220-033
(7)Do a visual inspection of the acoustic liners (30-031 , 72-00-00) (SIN 84200). Make sure that there is no damage and that the area is clear of tools and unwanted material.
(8)Make sure that the booster acoustic panel leading edge has a step of not more than 0.005 inches (0.127 mm) above the splitter. Refer to Figure 409 (sheet 13 through sheet 17) and do as follows:
(a)Arrange a gauge block/slip gauge that is 0.005 inches (0.127 mm) on the surface of the booster splitter upstream of the leading edge of the inner acoustic liner. Slide another gauge block/slip gauge of 0.01 inches (0.25 mm) in thickness or more above the 0.005 inches (0.127 mm) gauge block/slip gauge towards the inner acoustic liner. If the gauge block/slip gauge of 0.01 inches (0.25 mm) faces resistance at the leading edge of the acoustic liner, then the step is more than 0.005 inches (0.127 mm). If the gauge block/slip gauge of 0.01 inches (0.25 mm) crosses the leading edge of the acoustic liner, then the step is equal or less than 0.005 inches (0.127 mm). Refer to Figure 409 (sheet 15).
(b)If the step is more than 0.005 inches (0.127 mm), do the steps to remove and install the booster inner acoustic liners again.
(c)Do this step measurement at least at three locations between the bolts and at all 4 bolt locations for each inner acoustic liner (Refer to Figure 409 (sheet 16 and sheet 17).
NOTE:
Step measurement is not required if the inner acoustic liner leading edge is seated below the booster splitter. This condition is acceptable.
* * * FOR ALL PIP 2
Figure 409   (Sheet 1 ) Installation of the Booster Splitter and Acoustic Liners
* * * FOR ALL PIP 2
Figure 409   (Sheet 2 ) Installation of the Booster Splitter and Acoustic Liners
* * * FOR ALL PIP 2
* * * PRE SB   75-0013( Booster Anti-Ice Manifold without Improvement )
Figure 409   (Sheet 3 ) Installation of the Booster Splitter and Acoustic Liners
* * * FOR ALL PIP 2
* * * SB   75-0013( Booster Anti-Ice Manifold Improvement )
Figure 409   (Sheet 4 ) Installation of the Booster Splitter and Acoustic Liners
* * * FOR ALL PIP 2
* * * PRE SB   75-0013( Booster Anti-Ice Manifold without Improvement )
Figure 409   (Sheet 5 ) Installation of the Booster Splitter and Acoustic Liners
* * * FOR ALL PIP 2
* * * SB   75-0013( Booster Anti-Ice Manifold Improvement )
Figure 409   (Sheet 6 ) Installation of the Booster Splitter and Acoustic Liners
* * * FOR ALL PIP 2
* * * PRE SB   75-0013( Booster Anti-Ice Manifold without Improvement )
Figure 409   (Sheet 7 ) Installation of the Booster Splitter and Acoustic Liners
* * * FOR ALL PIP 2
* * * SB   75-0013( Booster Anti-Ice Manifold Improvement )
Figure 409   (Sheet 8 ) Installation of the Booster Splitter and Acoustic Liners
* * * FOR ALL PIP 2
* * * PRE SB   75-0013( Booster Anti-Ice Manifold without Improvement )
Figure 409   (Sheet 9 ) Installation of the Booster Splitter and Acoustic Liners
* * * FOR ALL PIP 2
* * * SB   75-0013( Booster Anti-Ice Manifold Improvement )
Figure 409   (Sheet 10 ) Installation of the Booster Splitter and Acoustic Liners
* * * FOR ALL PIP 2
* * * PRE SB   75-0013( Booster Anti-Ice Manifold without Improvement )
Figure 409   (Sheet 11 ) Installation of the Booster Splitter and Acoustic Liners
* * * FOR ALL PIP 2
* * * SB   75-0013( Booster Anti-Ice Manifold Improvement )
Figure 409   (Sheet 12 ) Installation of the Booster Splitter and Acoustic Liners
* * * FOR ALL PIP 2
Figure 409   (Sheet 13 ) Installation of the Booster Splitter and Acoustic Liners
* * * FOR ALL PIP 2
Figure 409   (Sheet 14 ) Installation of the Booster Splitter and Acoustic Liners
* * * FOR ALL PIP 2
Figure 409   (Sheet 15 ) Installation of the Booster Splitter and Acoustic Liners
* * * FOR ALL PIP 2
Figure 409   (Sheet 16 ) Installation of the Booster Splitter and Acoustic Liners
* * * FOR ALL PIP 2
Figure 409   (Sheet 17 ) Installation of the Booster Splitter and Acoustic Liners
Subtask 72-00-01-420-092
I.Install the lower bifurcation bridge (lower bridge) (25-481 , 72-00-00) (SIN 95003) and lower fillet fairings (25-430 , 72-00-00) (SIN 84506) and (25-440 , 72-00-00) (SIN 84507). Refer to Figure 410 and do 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)Lubricate the threads of four bolts (25-491 , 72-00-00) (SIN 84526), four studs on the cowl supports (30-011 , 72-00-02) (SIN 95001) or (30-012 , 72-00-02) (SIN 95001), (30-021 , 72-00-02) (SIN 95008) or (30-022 , 72-00-02) (SIN 95008), and four nuts (25-180 , 72-00-00) (SIN 95040) with C02-058   graphite.
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 lower bridge (25-481 , 72-00-00) (SIN 95003) with C04-035  isopropyl alcohol.
(3)Install the lower bridge to the aft side of the fan hub frame at the 6:00 o'clock position with four nuts (25-180 , 72-00-00) (SIN 95040) and four washers (25-190 , 72-00-00) (SIN 95030). Do not torque the nuts.
(4)Attach the lower bridge to the lower firewall (01-372 , 72-21-00) (SIN 84501) with four bolts (25-491 , 72-00-00) (SIN 84526) and four washers (25-500 , 72-00-00) (SIN 84531).
NOTE:
The lower bridge must contact the lower bifurcation firewall before the nuts (25-180 , 72-00-00) (SIN 95040) are torqued.
(5)Torque the bolts (25-491 , 72-00-00) (SIN 84526) to 106-124 lb in. (12.0-14.0 N.m).
(6)Torque the nuts (25-180 , 72-00-00) (SIN 95040) to 69-81 lb in. (7.8-9.2 N.m).
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.
(7)Lubricate the threads of ten bolts (25-470 , 72-00-00) (SIN 84524), four screws (25-450 , 72-00-00) (SIN 84525), and four bolts (25-460 , 72-00-00) (SIN 8442G) with C02-058  graphite.
(8)Install the fillet fairing (25-440 , 72-00-00) (SIN 84507) to the left side of the lower bridge with five bolts (25-470 , 72-00-00) (SIN 84524), two screws (25-450 , 72-00-00) (SIN 84525) and two bolts (25-460 , 72-00-00) (SIN 8442G).
(9)Install the fillet fairing (25-430 , 72-00-00) (SIN 84506) to the right side of the lower bridge with five bolts (25-470 , 72-00-00) (SIN 84524), two screws (25-450 , 72-00-00) (SIN 84525) and two bolts (25-460 , 72-00-00) (SIN 8442G).
(10)Deleted.
Subtask 72-00-01-420-093
(11)Install the lower bifurcation assembly. Refer to TASK 72-00-03-420-802 (72-00-03, INSTALLATION 001).
* * * FOR ALL PIP 2
Figure 410   Installation of the Lower Bridge and Fillet Fairings
Subtask 72-00-01-420-094
(12)Apply C01-007  RTV to the lower bridge. Refer to Figure 410 and do 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)Clean the lower bridge and the adjacent surfaces with C04-035  isopropyl alcohol.
(b)Apply C01-007  RTV to the transition areas where the lower bridge touches other surfaces. Make sure that there is a smooth transition of the sealant between mating components.
NOTE:
The C01-007  RTV must be applied within 2.00 inches (50.8 mm) maximum of either side of mating surfaces and within 2.00 inches (50.8 mm) maximum from aft edge of seal.
(c)Apply C01-007  RTV to the space located above the cable bulkhead on the lower bifurcation module assembly on the right and left sides.
(d)Let the C01-007  RTV cure for 12 hours.
Subtask 72-00-01-420-095
J.Install the VBV panels. Refer to Figure 411 and do as follows:
NOTE:
If customer furnished overhead system and 11C3044   adapter assembly are used, some panels can not be assembled until the engine is transferred to a shipping dolly because of the installation of the 11C3039   fan hub frame lift brackets. For the installation or storage of these panels, follow instructions for the shipping dolly.
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)Lubricate the threads of 52 machine screws (screws) (25-510 , 72-00-00) (SIN 95025) and the four fairing screws (screws) (25-120 , 72-00-00) (SIN 84428), and four fairing screws (screws) (25-450 , 72-00-00) (SIN 84525) with C02-058   graphite.
(2)Install the bleed air deflector panels (deflector panels) (25-550 , 72-00-00) (SIN 9500A) as follows:
NOTE:
Before installing the deflector panel, make sure that the rubber bumpers and its seating groove are clean. Insert the rubber bumper squarely into the groove to prevent damage or disbond.
CAUTION:
BE CAREFUL WHEN THE DEFLECTOR PANELS ARE INSTALLED NEAR 12:00 O'CLOCK AND 6:00 O'CLOCK POSITIONS BECAUSE THE FILLET FAIRINGS ARE ALREADY INSTALLED.
(a)Loosely install one deflector panel (25-550 , 72-00-00) (SIN 9500A) at the 1:00 o'clock, 5:00 o'clock, 7:00 o'clock, and 11:00 o'clock positions aft looking forward (ALF). Refer to Figure 411 for the installation pattern.
NOTE:
One side of each deflector panel must slide underneath a fillet fairing which has already been installed.
(b)Insert the forward edge of the deflector panel into the groove below the trailing edge of the outlet guide vanes. Two holes in the center of the aft side of the deflector panel will be aligned with the nut plate holes in the deflector panel support segments (30-071 , 72-00-02) (SIN 95010), (30-081 , 72-00-02) (SIN 95011), (30-091 , 72-00-02) (SIN 95012), and (30-101 , 72-00-02) (SIN 95013).
(c)Insert two screws (25-510 , 72-00-00) (SIN 95025) through the holes in the center of the aft side of the deflector panel and into the deflector panel support segment.
(d)Install four screws (25-120 , 72-00-00) (SIN 84428) near the 12:00 o'clock position where the fillet fairings (25-100 , 72-00-00) (SIN 84407) and (25-110 , 72-00-00) (SIN 8440A) overlap the deflector panels.
(e)Install four screws (25-450 , 72-00-00) (SIN 84525) near the 6:00 o'clock position where the fillet fairings (25-430 , 72-00-00) (SIN 84506) and (25-440 , 72-00-00) (SIN 84507) overlap the deflector panels.
(f)Loosely install one deflector panel at the 2:00 o'clock, 3:00 o'clock, 4:00 o'clock, 8:00 o'clock, 9:00 o'clock, and 10:00 o'clock positions.
(g)Insert the forward edge of the deflector panel into the groove below the trailing edge of the outlet guide vanes. Two holes in the center of the aft side of the deflector panel will be aligned with the nut plate holes in the deflector panel support segments (30-071 , 72-00-02) (SIN 95010), (30-081 , 72-00-02) (SIN 95011), (30-091 , 72-00-02) (SIN 95012), and (30-101 , 72-00-02) (SIN 95013).
(h)Install two screws (25-510 , 72-00-00) (SIN 95025) in the holes in the center of the aft edge of each deflector panel.
(3)Install the blankoff panels as follows:
(a)Align the blankoff panels ALF until they overlap with two deflector panels as follows:
1Blankoff panel (25-521 , 72-00-00) (SIN 9500D) at the 1:30 o'clock position.
2Blankoff panel (25-541 , 72-00-00) (SIN 9500B) at the 2:30 o'clock position.
3Blankoff panel (25-515 , 72-00-00) (SIN 9500C) at the 3:30 o'clock position.
4Blankoff panel (25-535 , 72-00-00) (SIN 9500F) at the 4:30 o'clock position.
5Blankoff panel (25-545 , 72-00-00) (SIN 9500G) at the 7:30 o'clock position.
6Blankoff panel (25-525 , 72-00-00) (SIN 9500E) at the 8:30 o'clock position.
7Blankoff panel (25-555 , 72-00-00) (SIN 9500H) at the 10:30 o'clock position.
(b)Insert the leading edge of each blankoff panel into the groove below the trailing edge of the outlet guide vanes.
(c)Make sure that the holes of the blankoff panels are aligned with the holes in the deflector panels.
(d)Attach each blankoff panel to the deflector panels with four screws (25-510 , 72-00-00) (SIN 95025).
(4)Install the ACC inlet flow shield (flow shield) (25-530 , 72-00-00) (SIN 9500L) as follows:
NOTE:
The flow shield has the same shape as the other blankoff panels but has a different appearance. Do not confuse the flow shield with one of the other blankoff panels.
NOTE:
After installing the flow shield, check that the seal is not pinched between the panel and the duct during installation. Refer to Figure 412, if the seal is found pinched between the panel and the duct then remove and install the panel again correctly.
(a)Align the flow shield (25-530 , 72-00-00) (SIN 9500L) at the 9:30 o'clock position ALF until it overlaps with two deflector panels.
(b)Insert the leading edge of the flow shield into the groove below the trailing edge of the outlet guide vanes.
(c)Make sure that the holes of the flow shield are aligned with the holes in the deflector panels.
(d)Attach the flow shield to the deflector panels with four screws (25-510 , 72-00-00) (SIN 95025).
(5)Torque the 10 bolts (25-470 , 72-00-00) (SIN 84524), four bolts (25-460 , 72-00-00) (SIN 8442G), 10 bolts (25-130 , 72-00-00) (SIN 84427), four bolts (25-140 , 72-00-00) (SIN 8442H), four screws (25-120 , 72-00-00) (SIN 84428), four screws (25-450 , 72-00-00) (SIN 84525), and the 52 screws (25-510 , 72-00-00) (SIN 95025) to 60 to 70 lb in. (6.8 to 7.9 Nm), in an alternating pattern. Refer to Figure 413 and as follows:
NOTE:
Bolts/screws heads can sit proud even after torque. Do not over torque.
(a)Torque in an identified sequence.
(b)Torque the left and right/upper and lower fillet fairing panels in the same sequence.
(6)Do a 360-degree torque inspection of the 10 bolts (25-470 , 72-00-00) (SIN 84524), four bolts (25-460 , 72-00-00) (SIN 8442G), 10 bolts (25-130 , 72-00-00) (SIN 84427), four bolts (25-140 , 72-00-00) (SIN 8442H), four screws (25-120 , 72-00-00) (SIN 84428), four screws (25-450 , 72-00-00) (SIN 84525), and 52 screws (25-510 , 72-00-00) (SIN 95025) to 60 to 70 lb in. (6.8 to 7.9 Nm).
* * * FOR ALL PIP 2
Figure 411   (Sheet 1 ) Installation of the Bleed Air Deflector Panels and Blankoff Panels
* * * FOR ALL PIP 2
Figure 411   (Sheet 2 ) Installation of the Bleed Air Deflector Panels and Blankoff Panels
* * * FOR ALL PIP 2
Figure 411   (Sheet 3 ) Installation of the Bleed Air Deflector Panels and Blankoff Panels
* * * FOR ALL PIP 2
Figure 412   Installation of the Flow Shield and Seal
* * * FOR ALL PIP 2
Figure 413   Fillet Fairing Panel Installation Torque Sequence
Subtask 72-00-01-420-096
K.Install the air duct (01-030 , 75-11-20) (SIN 61004) on the core forward EAI insulated air duct (01-020 , 75-11-20) (SIN 61002). Refer to Figure 414 and do as follows:
(1)Install the retainer V coupling (retainer) (01-190 , 75-11-20) (SIN 61081) on the lower side of the air duct. Do not tighten the retainer bolt at this time.
(2)Install one ring seal (01-200 , 75-11-20) (SIN 61051) on the core forward EAI insulated air duct.
(3)Align the air duct with the ring seal and core forward EAI insulated air duct.
(4)Adjust the retainer to connect the lower side of the air duct on the core forward EAI insulated air duct.
(5)Torque the retainer bolt to 106-124 lb in. (12.0-14.0 N.m).
* * * FOR ALL PIP 2
Figure 414   Installation of the Air Duct on the Core Forward EAI Insulated Air Duct
Subtask 72-00-01-420-097
L.Install the stage 1 blade shims (shims) (20-210 , 72-00-00) (SIN 83071) to the fan rotor disk (02-050 , 72-22-00) (SIN 830A0). Refer to Figure 415 and do 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.
CAUTION:
WEAR RUBBER GLOVES AT ALL TIMES WHILE HANDLING SHIMS.
(1)Use C04-035  isopropyl alcohol to clean the disk slots and posts of the stage 1 disk, and the forward end of the booster drum.
(2)Find the 18 shims. Do a visual inspection of each shim for bends or wrinkles.
CAUTION:
MAKE SURE THAT EACH SHIM IS PUSHED FULLY AFT ON THE FAN ROTOR DISK POSTS TO PREVENT DAMAGE DURING RETAINER INSTALLATION.
(3)Wear C10-140  gloves and install each shim over each disk post with the forward mark facing forward.
NOTE:
The color of the shims and the disk posts are similar. Make sure all 18 shims were installed.
(4)Make sure that all barrel nuts are installed at this time.
* * * FOR ALL PIP 2
Figure 415   Installation of Fan Blade Components
Subtask 72-00-01-420-098
M.Prepare the Stage 1 Blades (fan blades) (20-201 , 72-00-00) (SIN 83004) for installation 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)Use C04-035  isopropyl alcohol to clean the two sides of each of the 18 shims (20-210 , 72-00-00) (SIN 83071) previously installed, 18 stage 1 fan blade spacers (spacers) (20-170 , 72-00-00) (SIN 83008), and the two sides of the fabric coating on the root of the fan blade dovetails.
(2)Let the fan blade roots dry, then apply C10-013   compound, release agent or C10-215  release agent (10 percent PTFE paint on dry film lubricant) to all the fabric coating dovetail surface areas. Stir the solution as it is applied to make sure that the lubricant is thoroughly mixed.
(3)Apply a total of four coats of dry film lubricant to the fan blade root fabric.
NOTE:
The lubricant must not be left to dry between each application. Each application must be made immediately after the previous one.
(4)Let the lubricant dry for approximately 20 minutes.
(5)Make sure that the fan blade root areas are completely covered with lubricant.
NOTE:
The coated surfaces must not be touched during the assembly procedure.
Subtask 72-00-01-420-099
N.Apply dry film lubricant to the large, flat surfaces of the fan blade spacer 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)Apply C10-013  compound, release agent or C10-215  release agent to the entire spacer except for the end block. Stir the solution as it is applied to make sure the lubricant is thoroughly mixed.
(2)Do not apply the lubricant to the end block (the location of the threaded bushing).
(3)Apply a total of four coats of dry film lubricant to the spacer. Do not let it dry between applications.
(4)Let the lubricant dry for approximately 20 minutes and make sure the spacer is completely covered by doing a visual inspection for remaining white powder.
Subtask 72-00-01-420-100
O.Install the 18 fan blades (20-201 , 72-00-00) (SIN 83004). Refer to Figure 415 and do as follows:
(1)Put the 18 fan blades in sequence, by their individual radial moment-weight, from the heaviest to the lightest blade.
NOTE:
The radial moment-weight of the blade is identified as RAD M/W on a label attached to the shank, close to the bottom of the blade.
Subtask 72-00-01-430-599
(2)Alternative Procedure Available. Number the fan blades (20-201 , 72-00-00) (SIN 83004) in ascending sequence (1 to 18) from the heaviest to the lightest as follows:
(a)Put a piece of C10-021  tape (yellow tape recommended) on each fan blade.
(b)Put a mark with a C05-003  pen on the tape that was put on the fan blades.
(c)Put a number 1 on the heaviest fan blade and continue the number sequence until the lightest blade is identified with a number 18.
Subtask 72-00-01-420-101
(2).A.Alternative Procedure. Identify the fan blade sequence by plotting fan blades (20-201 , 72-00-00) (SIN 83004) with the software as follows:
(a)Put a piece of C10-021  tape (yellow tape recommended) on each fan blade.
(b)Put a mark with a C05-003  pen on the tape that was put on the fan blades 1 through 18 to identify the current blade sequence.
(c)Enter all fan blade radial moment weights in order, from 1 through 18, into the 9446M61   mapping program.
(d)With the 9446M61   mapping program results, strike the current number and number the fan blades again with a C05-003  pen, 1 through 18, on the tape that was put on the fan blades.
NOTE:
The results from the 9446M61   mapping program can be printed and kept for quality records and easy numbering of the fan blades.
(3)Put the fan blades in their correct location on the fan disk as follows:
(a)The fan disk slot locations for the fan blades are given in a counterclockwise (CCW) direction, forward looking aft (FLA).
(b)A number 1 is stamped on each side of the number 1 fan disk slot on the forward face of the fan disk.
1This is to identify the position for the installation of the fan blade number 1.
(c)A number 5 is stamped on the forward face of the fan disk at the number 5 fan disk slot location.
1This gives the CCW reference direction for fan blade installation.
2Start with the number 1 fan blade slot and count in a CCW direction to find the number 5 fan disk slot.
Subtask 72-00-01-420-102
(4)Install the fan blade set as follows:
(a)Make sure that the shims (20-210 , 72-00-00) (SIN 83071) are installed fully aft before the fan blades are installed.
(b)Install the No. 1 fan blade into the No. 1 dovetail slot.
(c)Install the stage 1 retainer (retainer) (20-190 , 72-00-00) (SIN 83007) into the parts with recesses of the disk post in front of the fan blade.
(d)Install the dovetail key (20-180 , 72-00-00) (SIN 8300B) into the aft-most center position of the dovetail slot.
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.
(e)Apply the C10-215  release agent (10 percent PTFE paint on dry film lubricant) to the large, flat surfaces of the spacer (20-170 , 72-00-00) (SIN 83008) as follows:
NOTE:
As an alternative, apply four coats of C10-013   compound, release agent or C10-215  release agent to the fan blades.
1Apply C10-215  release agent (10 percent PTFE paint on dry film lubricant) to the entire spacer. Stir the solution as it is applied to make sure that the lubricant is thoroughly mixed.
2Apply a total of four coats of dry film lubricant C10-215  release agent to the spacer. Do not let it dry between applications.
3Let the lubricant dry for approximately 20 minutes and make sure that the spacer is completely covered by doing a visual inspection for remaining white powder.
NOTE:
The lubricant C10-215  release agent must not be applied to the end block (the location of the threaded bushing).
(f)Look inside the hub and down to make sure that the spacer is in the grooved slot of the dovetail key axially aligned with the center of the blade post.
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.
(g)Lubricate the threads of the bolt (20-150 , 72-00-00) (SIN 8302A) with C02-058   graphite and attach the spacer to the retainer with the bolt (20-150 , 72-00-00) (SIN 8302A).
(h)Torque the bolt to 106-124 lb in. (12-14 N.m).
(i)Install the remaining fan blades. Do the Subtask 72-00-01-420-102 (paragraph 3.O.(4)(b)) thru Subtask 72-00-01-420-102 (paragraph 3.O.(4)(h)) again.
Subtask 72-00-01-420-103
P.Make a plot of the fan platforms (20-121 , 72-00-00) (SIN 83005) and record the imbalance as follows:
(1)Use a digital scale and record the mass and serial number of each fan platform.
(2)Enter this information into the computer program.
(3)Print out a copy and save this information.
NOTE:
Fan platform imbalance must not be more than 4 grams.
Subtask 72-00-01-420-110
Q.Alternative Procedure Available. Install the fan platforms (20-121 , 72-00-00) (SIN 83005) with the 11C4645   blade spreading fixture. Refer to Figure 416 and do as follows:
(1)Do a visual inspection of the inside of each fan platform (20-121 , 72-00-00) (SIN 83005) for any foreign objects, such as carbon plugs from the manufacturing drilling process.
(2)Slowly turn the fan blades until the No. 1 fan blade is at the 6:00 o'clock position. Manually push on the root of the fan blades to turn the fan disk.
(3)Prepare the 11C4645   blade spreading fixture for use. Refer to Figure 416 and do as follows:
(a)Align the left foot (item 4) hole with the left support (item 13) hole that has the GENX-1B mark.
(b)Put the ball lock pin (item 15) through the two holes.
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.
(4)Carefully lift the 11C4645   blade spreading fixture with the handle (item 14) and put it between the fan blades so it rests on the base (item 10) on the inside surface of the fan case.
(5)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.
(6)Pull the arm (item 8) until the mark OPEN in the wedge (item 7) is totally exposed.
(7)Refer to the fan platform plot sheet and install the fan platform No. 1 between the No. 1 and No. 2 fan blades. Make sure that the aft end of the fan platform (20-121 , 72-00-00) (SIN 83005) is under the flowpath spacer (02-060 , 72-22-00) (SIN 830AM) of the fan booster assembly (20-011 , 72-00-02) (SIN 80000).
(8)Pull the arm (item 8) up with the lever arm (item 20) until the left foot (item 4) and the right foot (item 5) are fully contracted. This will put the fan blades back into the original position.
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.
(9)Apply C10-021  tape from the fan blade side to the top of each fan platform (20-121 , 72-00-00) (SIN 83005) to make sure that the fan platform does not fall.
(10)Use the handle (item 14) to lift and remove the 11C4645   blade spreading fixture.
(11)Refer to Subtask 72-00-01-420-110 (paragraph 3.Q.(4) thru paragraph 3.Q.(10)) to install the fan platform No. 2 between the No. 2 and No. 3 fan blades.
(12)Continue to install the fan platforms in numerical sequence until all 18 fan platforms are installed.
* * * FOR ALL PIP 2
Figure 416   (Sheet 1 ) Installation of the Blade Spreading Fixture, 11C4645
* * * FOR ALL PIP 2
Figure 416   (Sheet 2 ) Installation of the Blade Spreading Fixture, 11C4645
* * * FOR ALL PIP 2
Figure 416   (Sheet 3 ) Installation of the Blade Spreading Fixture, 11C4645
Subtask 72-00-01-420-104
Q.A.Alternative Procedure. Install the fan platforms (20-121 , 72-00-00) (SIN 83005). Refer to Figure 417 and do as follows:
NOTE:
Two people are necessary to install the fan platforms. One person carefully applies pressure to two fan blades at the 6:00 o'clock position to separate the blades as much as possible, while the other person inserts the fan platform between the blades.
(1)Do a visual inspection of the inside of each fan platform for foreign objects.
(2)Slowly turn the fan blades until the No. 1 fan blade is at the 6:00 o'clock position. Manually push on the root of the fan blades to turn the fan disk.
(3)Refer to the fan platform plot sheet and install fan platform No. 1, between the No. 1 and No. 2 fan blades.
(4)Install the number No. 2 fan platform between the No. 2 and No. 3 fan blades.
(5)Continue to install the fan platforms in numerical order until all 18 fan platforms are installed.
Subtask 72-00-01-420-105
R.Install the spinner assembly aft support ring (aft support spinner ring) (20-101 , 72-00-00) (SIN 8300A). Refer to Figure 417 and do as follows:
CAUTION:
MAKE SURE THAT THE OFFSET HOLE ON THE AFT SUPPORT SPINNER RING ALIGNS WITH THE OFFSET HOLE ON THE FAN ROTOR DISK POST. DAMAGE TO ENGINE HARDWARE CAN OCCUR.
(1)Assemble the aft support spinner ring to the fan hub disk until the 1-1 mark on the aft support spinner ring matches with the 1-1 mark on the fan rotor disk post.
(2)Make sure that the offset hole on the aft support spinner ring aligns with the offset hole on the fan rotor disk post.
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.
(3)Lubricate the threads and mating surfaces of the 18 bolts (20-110 , 72-00-00) (SIN 83021) with C02-058  graphite.
(4)Install the 18 bolts (20-110 , 72-00-00) (SIN 83021) and torque them to 79-93 lb in. (8.9-10.5 N.m) in a criss-cross pattern.
(5)Torque bolts (20-110 , 72-00-00) (SIN 83021) again to 106-124 lb in. (12-14 N.m) in a criss-cross pattern.
(6)Loosen the bolts (20-110 , 72-00-00) (SIN 83021) one half turn, then torque them again to 106-124 lb in. (12-14 N.m) in a criss-cross pattern.
(7)Do a 360-degree torque check to make sure that all bolts (20-110 , 72-00-00) (SIN 83021) are 106-124 lb in. (12-14 N.m).
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Figure 417   Installation of the Fan Platforms and Aft Support Spinner Ring
Subtask 72-00-01-420-118
S.Verify proper platform installation by ensuring proper engagement under the aft spinner support and flowpath spacer. Exposed platform wear strips is an indication of improper platform installation. Refer to Figure 418.
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Figure 418   (Sheet 1 ) Fan Platform Proper Installation
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Figure 418   (Sheet 2 ) Fan Platform Proper Installation
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Figure 418   (Sheet 3 ) Fan Platform Proper Installation
Subtask 72-00-01-420-106
T.Install the spinner fan (spinner) (20-010 , 72-00-00) (SIN 83002). Refer to Figure 419 and do as follows:
(1)Make sure that there is no FOD inside the fan hub, inside the aft support spinner ring (20-101 , 72-00-00) (SIN 8300A), and inside the spinner (20-010 , 72-00-00) (SIN 83002).
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 mating surfaces of the aft support spinner ring and the spinner with C04-035  isopropyl alcohol.
(3)Lubricate the balance weight bolt (spinner weights) (20-030 , 72-00-00) (SIN 83022) with C02-058  graphite.
NOTE:
Only spinner weights (20-030 , 72-00-00) (SIN 83022) must be used during the initial build up. Heavier spinner weights can be used later during engine test to balance the fan rotor assembly.
(4)Install the spinner weights (20-030 , 72-00-00) (SIN 83022) onto the fan rotor spinner.
(5)Torque the spinner weights to 155 lb in. (17.5 N.m).
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.
(6)Lubricate the threads and mating surfaces of 18 bolts (20-020 , 72-00-00) (SIN 8302C) with C02-058  graphite.
(7)Align the 1-1 mark on the spinner (20-010 , 72-00-00) (SIN 83002) with the 1-1 mark on the aft support spinner ring (20-101 , 72-00-00) (SIN 8300A). Attach the spinner (20-010 , 72-00-00) (SIN 83002) with 18 bolts (20-020 , 72-00-00) (SIN 8302C).
(8)Torque the 18 bolts (20-020 , 72-00-00) (SIN 8302C) to 42-45 lb in. (5.0-5.9 N.m) in a criss-cross pattern.
(9)Torque the 18 bolts (20-020 , 72-00-00) (SIN 8302C) again to 60-70 lb in. (6.8-7.9 N.m) in a criss-cross pattern.
(10)Do a 360-degree torque check on the 18 bolts (20-020 , 72-00-00) (SIN 8302C) to 60-70 lb in. (6.8-7.9 N.m).
(11)Do a 360-degree torque check of the spinner weights (20-030 , 72-00-00) (SIN 83022) to 155 lb in. (17.5 N.m).
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Figure 419   Installation of the Fan Rotor Spinner
Subtask 72-00-01-420-107
U.Put the thrust reverse cross-tie brackets (25-010 , 71-00-02) (SIN 25015), (25-020 , 71-00-02) (SIN 25016), and the other TRF brackets (25-030 , 71-00-02) (SIN 25010), (25-040 , 71-00-02) (SIN 25011), (25-050 , 71-00-02) (SIN 25012), (25-060 , 71-00-02) (SIN 25014), and (25-070 , 71-00-02) (SIN 25019) in a large, clear plastic bag, and keep the bag with the engine hardware.
NOTE:
All the TRF brackets (attached to the aft TRF flange) will be installed in a later step, during primary nozzle installation.
Subtask 72-00-01-420-108
V.Continue with the assembly of the engine. To assemble the fan stator case assembly (01-021) (SIN 00109). Refer to TASK 72-00-01-430-803 (72-00-01, ASSEMBLY 001).