GEnx-1B - SB 72 -0107N06ENGINE - Mid Fan Shaft Assembly (72-58-00)

	GEnx-1B SERVICE BULLETIN - 72-0107 R06	Revised: 11/13/2015
	SB 72-0107 R06 ENGINE - Mid Fan Shaft Assembly (72-58-00) - Inspection of Mid Fan Shaft	Issued: 08/17/2012

	GE PROPRIETARY INFORMATION
	The information contained in this document is GE proprietary information and is disclosed in confidence. It is the property of GE and shall not be used, disclosed to others or reproduced without the express written consent of GE, including, but without limitation, it is not to be used in the creation, manufacture, development, or derivation of any repairs, modifications, spare parts, designs, or configuration changes or to obtain FAA or any other government or regulatory approval to do so. If consent is given for reproductionin whole or in part, this notice and the notice set forth on each page of this document shall appear in any such reproduction in whole or in part.
	This technical data is considered EAR controlled pursuant to 15 CFR Parts 730-774 respectively. Transfer of this data by any means to a Non-US Person, whether in the United States or abroad, without the proper U.S. Government authorization (e.g., License, exemption, NLR, etc.), is strictly prohibited.
	GEAE authorizes the Federal Aviation Administration to incorporate this document by reference in an Airworthiness Directive.
	Copyright (2015) General Electric Company, U.S.A.

TRANSMITTAL INFORMATION

REVISION 6 TO SERVICE BULLETIN 72-0107

Revision 6 is issued to update paragraphs 1.C., Compliance, 1.F., Approval, and 2.A., Material - Price and Availability.

Revision 5 was issued May 11, 2015. Revision 4 was issued October 17, 2014. Revision 3 was issued June 16, 2014. Revision 2 was issued September 14, 2012. Revision 1 was issued August 24, 2012. The original was issued August 17, 2012. Revision bars in the left margin identify changes.

PLANNING INFORMATION

Effectivity

* * * FOR GEnx-1B54, -1B54/P1, -1B58, -1B58/P1, -1B64, -1B64/P1, -1B67, -1B67/P1, -1B70, -1B70/72/P1, -1B70/75/P1, -1B70/P1, -1B74/75/P1, -1B75/P1

This Service Bulletin is applicable to all GEnx-1B engines.

Description

This Service Bulletin provides an inspection procedure of the mid fan shaft in an assembled engine.

Compliance

Category 2

Deleted.

GE recommends that you do this Service Bulletin as soon as possible without effect on revenue service but before 30 days from the issue date of this Service Bulletin revision.

For engines that have complied with a prior revision of GEnx-1B S/B 72-0107, or that have been inspected prior to aircraft delivery, reinspect within 365 days from completion date of the initial inspection and then at a maximum 365-day interval thereafter.

NOTE:

This Service Bulletin can be accomplished on wing and/or in shop.

This Service Bulletin is offered to improve the reliability or performance of your GE product, or to help prevent the occurrence of the event or condition described in this Service Bulletin. If the operator elects not to participate in the bulletin, that decision will be taken into consideration by GE in evaluating future product performance issues that may arise in the operators fleet.

Concurrent Requirements

None.

Reason

(1)

Objective:

Ultrasonic inspection of the installed mid fan shaft forward end for the presence of cracks.

(2)

Condition:

A GEnx engine experienced a fracture in the forward threaded end of the mid fan shaft prior to aircraft delivery.

(3)

Cause:

Environmentally assisted cracking.

(4)

Improvement:

None.

(5)

Substantiation:

Engineering analysis and metallurgical evaluation of field hardware.

Approval

The data contained in this Service Bulletin has been reviewed by the appropriate governmental authority and the repair(s) and modification(s) herein comply with the applicable Aviation Regulations and are APPROVED for installation in the model(s) listed in this Service Bulletin.

Revision 6 of this Service Bulletin is approved by the Manager, Engine Certification Office, ANE-140, by letter dated November 05, 2015, as an Alternative Method of Compliance (AMOC) to Airworthiness Directive (AD) 2012-19-08, paragraphs (f)(2), (f)(4), and (j)(2)(i).

Manpower

You will need approximately 9 man-hours to accomplish this service bulletin.

Weight and Balance

Weight and balance are not changed.

References (Use the latest version of this document)

Boeing 787 Aircraft Maintenance Manual (AMM)

NAS-410, Certification and Qualification of Non-destructive Test Personnel Aerospace Industries Association - National Aerospace Standard (Latest Revision)

Airworthiness Directive (AD) 2012-19-08

Publications Affected

None.

Interchangeability

Not applicable.

Software Accomplishment Summary

Not applicable.

MATERIAL INFORMATION

Material - Price and Availability

(1)

Parts necessary to do this Service Bulletin:

None.

(2)

Other Spare Parts:

Part Number

Qty/ Eng

Part Name

Unit ($) Price

Pkg Qty

Lead Time Days

J1438P177

(1)

Packing, Preformed

48.25

(1)

NOTE:

Prices are provided for planning purposes and are subject to change.

(3)

Consumables:

Code Number

Description

C02-019

Oil, Engine Lubricating (engine oil) - couplant

C02-023

Oil, Engine Lubricating (engine oil) - couplant

C05-003

Marking Pens

Absorbent Rags

Syringe

Industry Support Information

Contact your Customer Support Manager (CSM).

Configuration Chart

None.

Parts Disposition

None.

Tooling - Price and Availability

Tool Number

Description

9C3020P09*

Removal Bar (alternative to 11C4654G01)

11C3084G02*

Fan Disk Bore Protector (recommended)

11C3304G01*

Installation Tool Forward Retainer and Lock Plate (alternative to 11C3304G02)

11C3304G02*

Installation Tool Forward Retainer and Lock Plate (recommended)

11C3421G02*

Fan Shaft Cover Fixture

11C3421G03*

Fan Shaft Cover Fixture (alternative to 11C3421G02 to be used without removal of the aft support ring)

11C4514G01

Protector Set - Fan Stator (protector set)

11C4654G01

LPT Shaft I/R Fixture (recommended)

GE-FQAP-660

Ultrasonic Inspection Kit

**Fan Disk Bore Protector (alternative to 11C3084G02)

*Orders for 9C and 11C engine tooling should be made to Rhinestahl Corporation at sales@rhinestahl.com. Mark: Purchase Order with GEnx FMS Inspection Service Bulletin 72-0107.

**Alternative disk bore protection can be used to protect the bore from contact damage (rubber sheeting minimum 0.100 inch (2.54 mm) in thickness).

The following items are supplied with the inspection kit GE-FQAP-660

Part Number

Description

Qty

389-082-170

Ultrasonic Transducer Assembly

(2)

387-010-618

Reference Standard Assembly

(1)

389-082-180

Transducer Switch Box

(2)

022-509-749

Lemo to BNC Adaptor

(2)

USMGo Ultrasonic Instrument

(1)

Brush - Applicator

(1)

Approved Marker on Extension Handle

(1)

Storage Case

(1)

To obtain an ultrasonic kit, additional items, or replacement items, contact the GE Inspection Technologies Group via the following method:

GE Inspection Technologies

50 Industrial Park Road

Lewistown, PA 17044

Attn: NDE Kit Coordinator

email: ndttooling@ge.com

ACCOMPLISHMENT INSTRUCTIONS

Alternative Procedure Available. Removal with the 11C3421G02 fan shaft cover fixture.

(1)

Remove the spinner fan (20-010, 72-00-00) and the spinner assembly aft support ring (20-101) as follows:

(a)

If removal process of the spinner fan and the spinner assembly aft support ring is done on wing, refer to GEnx-1B Boeing 787 AMM Task 72-22-01-00A-520A-A.

(b)

If removal process of the spinner fan and the spinner assembly aft support ring is done in shop, refer to the GEnx-1B EM, 72-00-01, REMOVAL 001, Subtask 72-00-01-020-002.

(2)

Remove the fan shaft cover (20-290, 72-00-02) as follows. Refer to Figure 1.

(a)

Compress and remove the retainer ring (20-280) manually.

(b)

Remove the fan shaft cover (20-290) with 11C3421 fan shaft cover fixture as follows:

Install removal cover (item 2) to the fan shaft cover.

Align the tabs on tool 11C3421 fan shaft cover fixture with the slots in the fan shaft cover and turn the tool to engage the tabs on the fan shaft cover (20-290).

Install the cross bar puller (item 12) on the forward end of the removal cover (item 2).

CAUTION:

MAKE SURE NOT TO DAMAGE THE FAN ROTOR DISK SURFACE WHEN THE CROSS BAR PULLER IS ATTACHED.

Attach the cross bar puller (item 12) to the fan rotor disk (01-050, 72-22-00) with lock pins (item 15) and hand knobs (item 13).

Install sleeve (items 14) and torque arm plate (item 3) to the removal cover (item 2).

Make sure that the removal cover (item 2) stays fully engaged in the fan shaft cover and turn the torque arm plate (item 3) to remove the fan shaft cover (20-290, 72-00-02).

Remove 11C3421 fan shaft cover fixture from the fan rotor and remove fan shaft cover from the fixture (item 2).

(3)

Remove packing (20-300) from the fan shaft cover (20-290) and discard the packing.

(4)

Remove the retainer ring (20-310) and nut lock plate (20-320) as follows. Refer to Figure 2.

(a)

Use the 11C4654 LPT shaft I/R fixture or a screw driver to engage the tip of retainer ring (20-310) in order to move it in and disengage it from the slot in the mid fan shaft (01-010, 72-58-00).

(b)

Use a C05-003 marking pen to put a mark on the nut lock plate (20-320, 72-00-02) to align it with the forward fan shaft (01-170, 72-24-00) and remove the nut lock plate.

NOTE:

Oil will be applied to the forward shaft and nut surface during the inspection. Do not put marks on these locations for indexing purposes of the inspection.

(c)

Install 11C3084 fan disk bore protector or alternative.

NOTE:

A piece of rubber sheeting with a minimum of 0.100 inch (2.54 mm) in thickness can be used for protection on the bore surface to prevent contact damage as an alternative to the 11C3084 bore protector tool.

Alternative Procedure. Removal with the 11C3421G03 fan shaft cover fixture.

(1)

Remove the spinner fan (20-010, 72-00-00) with the 11C3421G03 fan shaft cover fixture as follows:

CAUTION:

MAKE SURE TO PUT A PROTECTIVE MAT IN THE INLET COWL. THIS WILL PREVENT DAMAGE TO THE INLET COWL OR ENGINE IF THE TOOLS, PARTS, OR UNWANTED MATERIALS FALL ON THE INLET COWL SURFACE.

(a)

Put the 11C4514 protector set in the lower half of the inlet cowl to protect the inlet cowl and engine.

(b)

Remove the spinner fan as follows:

CAUTION:

DO NOT LOOSEN OR REMOVE THE BALANCE WEIGHT BOLTS, UNLESS THE SPINNER FAN IS REPLACED. AN UNBALANCED CONDITION CAN OCCUR IF THE SPINNER FAN IS INSTALLED WITH LOOSE OR REMOVED BALANCE WEIGHT BOLTS.

Remove the 18 bolts (20-020) that attach the spinner fan (20-010) to the aft spinner ring (20-100) or (20-101).

CAUTION:

MAKE SURE THE FAN ROTOR SPINNER DOES NOT FALL WHEN IT IS REMOVED FROM THE AFT SPINNER RING. DAMAGE TO THE FAN ROTOR SPINNER CAN OCCUR.

Remove the spinner fan (20-010).

Put the spinner fan in a protective cover.

(c)

Remove the fan shaft cover (20-290, 72-00-02). Refer to Figure 1 and do as follows:

Compress and remove the retainer ring (20-280) manually.

Remove the fan shaft cover (20-290) with the 11C3421 fan shaft cover fixture as follows:

Install the removal cover (item 2) to the fan shaft cover.

Align the tabs on the 11C3421 fan shaft cover fixture with the slots in the fan shaft cover and turn the tool to engage the tabs on the fan shaft cover (20-290).

Install the cross bar puller (item 12) on the forward end of the removal cover (item 2).

CAUTION:

MAKE SURE NOT TO DAMAGE THE FAN ROTOR DISK SURFACE WHEN THE CROSS BAR PULLER IS ATTACHED.

Attach the cross bar puller (item 12) to the fan rotor disk (01-050, 72-22-00) with the lock pins (item 15), locking bracket (item 17), threaded posts (item 18), and hand knobs (item 19).

Install the sleeve (items 14) and torque arm plate (item 3) to the removal cover (item 2).

Make sure that the removal cover (item 2) stays fully engaged in the fan shaft cover (20-290, 72-00-02).

Turn the torque arm plate (item 3) to remove the fan shaft cover (20-290).

Remove the 11C3421 fan shaft cover fixture from the fan rotor and remove fan shaft cover from the removal cover (item 2).

(d)

Remove packing (20-300) from the fan shaft cover (20-290) and discard the packing.

(e)

Remove the retainer ring (20-310) and nut lock plate (20-320) as follows. Refer to Figure 2.

Use the 11C4654 LPT shaft I/R fixture or a screw driver to engage the tip of retainer ring (20-310) in order to move it in and disengage it from the slot in the mid fan shaft (01-010, 72-58-00).

Use a C05-003 marking pen to put a mark on the nut lock plate (20-320, 72-00-02) in order to align it with the forward fan shaft (01-170, 72-24-00) and remove the nut lock plate.

NOTE:

Oil will be applied to the forward shaft and nut surface during the inspection. Do not put marks on these locations for indexing purposes of the inspection.

Install the 11C3084 fan disk bore protector or alternative.

NOTE:

Inspection

(1)

Scope

(a)

This Service Bulletin describes the technique, equipment, and procedure required for conducting an on-engine manual ultrasonic inspection of the mid fan shaft (01-010, 72-58-00) for the detection of localized cracks. Refer to Figure 5.

(b)

The inspection must be done on-engine with the spinner fan (20-010, 72-00-00), fan shaft cover (20-290, 72-00-02), and coupling nut lock rings removed. Refer to Figure 1.

(c)

This inspection is done with a dedicated ultrasonic probe assembly with four transducers that point an ultrasonic beam through the top and bottom of the castellations on the forward end of the mid fan shaft (01-010, 72-58-00). Refer to Figure 13.

(d)

For specific cases where the procedures or equipment described herein cannot be applied in total, specific exceptions must be obtained in writing from the appropriate technical function prior to any inspection of hardware.

(2)

Applicable Documents

(a)

NAS-410 (latest revision).

(b)

Applicable manufacturers equipment users manual.

(3)

Personnel Requirements

(a)

Personnel must be certified in accordance with NAS-410, American Society of Nondestructive Testing (ASNT-TC-1A), or local certification process to do this inspection.

(b)

It is strongly recommended that personnel that will do this inspection receive practical training in the use of this procedure and must demonstrate proficiency in the calibration, inspection, and evaluation routines before accept/reject authority is delegated.

(c)

Any training which can be provided regarding the performance of this inspection does not imply that the personnel who receive that training have met the requirements for inspector certification in accordance with NAS-410, the appropriate certification document.

(4)

Initial Equipment Setup

NOTE:

Refer to the manufacturers equipment manual for the particular ultrasonic instrument used for this inspection if any questions arise about the instrument.

(a)

Connect the ultrasonic instrument to the appropriate power source and switch the instrument power ON. Let the instrument warm up for at least 10 minutes or the manufacturers recommended warm up time.

(b)

Connect the four transducer cables from the inspection fixture to the appropriate connectors on the transducer switchbox as marked.

(c)

Connect the transducer switch box to the instrument.

WARNING:

REFER TO THE PRODUCT LABEL AND THE MANUFACTURERS (MATERIAL) SAFETY DATA SHEET FOR INSTRUCTIONS ON THE HAZARDS, STORAGE, SAFE HANDLING AND PROPER USE OF THIS PRODUCT.

CAUTION:

ONLY APPROVED ENGINE OIL CAN BE USED AS COUPLANT ON THE GENX FAN MID SHAFT.

(d)

Fill the inspection fixture syringe with an approved engine oil (C02-019) or engine oil (C02-023) for the ultrasonic couplant.

(e)

Adjust the ultrasonic instrument to the basic settings. Refer to Figure 14.

(5)

Pre-inspection Preparation

(a)

Engines have to be prepared for inspection as follows (use appropriate technical data to accomplish):

CAUTION:

EXCESSIVE TEMPERATURES CAN CAUSE DAMAGE TO THE TRANSDUCERS AND ASSEMBLIES USED FOR THIS INSPECTION. IF THE ENGINE IS REMOVED FROM OPERATION TO PERFORM THIS INSPECTION, SUFFICIENT TIME FOR COOLING MUST BE ALLOWED BEFORE THE INSPECTION CAN BE ACCOMPLISHED. AS A GENERAL RULE, THE ENGINE HARDWARE TO BE INSPECTED MUST BE COOL ENOUGH TO TOUCH. THE USE OF A PORTABLE FAN OR EQUIVALENT EQUIPMENT TO BLOW AIR INTO THE BORE NEAR THE INSPECTION AREA IS AN ACCEPTABLE METHOD TO REDUCE METAL TEMPERATURES MORE QUICKLY.

Get access to the forward end of mid fan shaft (01-010, 72-58-00). Refer to Figure 1.

Castellation No. 1 will be in line with the stage 1 fan blade dovetail. Rotate the castellation No. 1 to the 6 oclock position. Refer to Figure 2.

NOTE:

The No. 1 fan blade can be identified with a number 1 marked on the fan disk.

Put the rags forward of the mid fan shaft (01-010) to absorb unwanted oil run-off.

(6)

Equipment Calibration

(a)

Prepare the ultrasonic instrument and probe according to paragraph 3.C.(4).

(b)

Set the transducer switchbox to position 1 (transducer 1 - upper castellation). Refer to Figure 6.

(c)

Adjust range and delay so that the leading edge of the second delay multiple is at the first major division on the instrument baseline and the leading edge of the third delay multiple is at the ninth major division. Refer to Figure 7 and Figure 8.

WARNING:

REFER TO THE PRODUCT LABEL AND THE MANUFACTURERS (MATERIAL) SAFETY DATA SHEET FOR INSTRUCTIONS ON THE HAZARDS, STORAGE, SAFE HANDLING AND PROPER USE OF THIS PRODUCT.

CAUTION:

ONLY APPROVED ENGINE OIL CAN BE USED AS COUPLANT ON THE GENX FAN MID SHAFT.

(d)

Apply engine oil (C02-019) or engine oil (C02-023) to the upper and lower castellations on the inspection standard with a brush.

(e)

Put the probe assembly safely on the inspection standard and maximize the response from the side drilled hole.

(f)

Apply engine oil to the transducer with the syringe.

(g)

For transducer 2 (lower castellation), do as follows:

Adjust the transducer switchbox to position 2 (transducer 2 - lower castellation).

Adjust the gain to set the amplitude of the response from the side drilled hole to 80 percent of full screen height (FSH). Refer to Figure 9.

Record the calibration settings on the worksheet in Figure 15.

(h)

For transducers 1,3, and 4 (upper castellation), do as follows:

Adjust to add 3dB of gain to the transducer 2 calibration gain and make sure that the backwall response from each of the transducers 1, 3, and 4 is above 80 percent FSH. Refer to Figure 10.

Record the calibration settings on the worksheet in Figure 15.

(7)

Inspection

NOTE:

Two different gain settings will be used for this inspection.

(a)

Make sure that the initial equipment setup, pre-inspection preparation, and system calibration are complete. Refer to paragraph 3.C.(4), paragraph 3.C.(5), and paragraph 3.C.(6).

(b)

For transducer 2 (lower castellation), do as follows:

Set the transducer switchbox to position 2. Adjust the instrument gain setting to number 2 transducer gain level.

Put the gate from 3.2 - 5.0 on horizontal base line at 30 percent (FSH). Refer to Figure 11.

WARNING:

REFER TO THE PRODUCT LABEL AND THE MANUFACTURERS (MATERIAL) SAFETY DATA SHEET FOR INSTRUCTIONS ON THE HAZARDS, STORAGE, SAFE HANDLING AND PROPER USE OF THIS PRODUCT.

CAUTION:

ONLY APPROVED ENGINE OIL CAN BE USED AS COUPLANT ON THE GENX FAN MID SHAFT.

Apply engine oil (C02-019) or engine oil (C02-023) to the upper and lower castellations on the FMS with a brush.

Carefully insert the transducer assembly into the forward end of the mid fan shaft (01-010) until the transducer at position No. 1 is at the upper castellation at the 6 oclock position.

Apply engine oil to the transducer with the syringe.

Monitor the gate for valid responses above 30 percent FSH within the gate. If valid responses are detected, do an analysis. Refer to paragraph 3.C.(9).

Record the maximum amplitude within the gate on Form 2194-1. Refer to Figure 15.

Pull back the transducer assembly and turn it counterclockwise (CCW) forward looking aft (FLA) to the next castellation position.

Turn the shaft clockwise (CW) FLA to the 6 oclock position.

Do paragraph 3.C.(7)(b)(5) thru paragraph 3.C.(7)(b)(9) again until all 16 lower castellation positions are completed.

(c)

For transducers 1,3, and 4 (upper castellations) do as follows:

Adjust the gain level to the transducer 2 calibration gain + 3dB.

Record the final inspection gain on Form 2194-1. Refer to Figure 15.

Set the transducer switchbox to position 1.

Put the gate from 5.5 to 7.0 on the horizontal base line at 30 percent FSH. Refer to Figure 12.

WARNING:

REFER TO THE PRODUCT LABEL AND THE MANUFACTURERS (MATERIAL) SAFETY DATA SHEET FOR INSTRUCTIONS ON THE HAZARDS, STORAGE, SAFE HANDLING AND PROPER USE OF THIS PRODUCT.

CAUTION:

ONLY APPROVED ENGINE OIL MAY BE USED AS COUPLANT ON THE GENX FAN MID SHAFT.

Carefully insert the transducer assembly into the forward end of the fan mid shaft until the transducer at position 1 is at the upper castellation at the 6 oclock position. Refer to Figure 2 and Figure 13.

Apply engine oil (C02-019) or engine oil (C02-023) to the transducers with the syringe.

Select each transducer in turn using the transducer switchbox and monitor the gate for valid responses above 30 percent FSH within the gate. If valid responses are detected refer to paragraph 3.C.(9).

Record the maximum amplitude within the gate for each transducer.

Pull back the transducer assembly and turn it CCW FLA to the next castellation position.

Turn the shaft CW FLA to the 6 oclock position.

Do paragraph 3.C.(7)(C)6
thru paragraph 3.C.(7)(C)10
until all 16 upper castellation positions are completed for transducers 1, 3, and 4.

(8)

Calibration Check

(a)

A calibration check must be done after the inspection. Also, do a check of the calibration when a system component or operator is changed, after loss of power, and when the operator finds a change in the system.

(b)

If the amplitude of the response from the side drilled hole of transducer 2 has increased to more than 10 percent FSH above the calibration amplitude, the system must be calibrated again before the inspection of additional hardware is done. Do an inspection again of rejected hardware examined since the last permitted calibration when the correct calibration is done.

(c)

If the amplitude of the response from the side drilled hole of transducer 2 has decreased to more than 10 percent FSH below the calibration amplitude, the system must be calibrated again. Do an inspection again of rejected hardware examined since the last permitted calibration when the correct calibration is done.

CAUTION:

IF THE ENGINE IS REMOVED FROM OPERATION TO PERFORM THIS INSPECTION, THE INSPECTION SURFACE AND SURROUNDING SURFACES MAY BE ABOVE AMBIENT TEMPERATURES. CHECK THE ASSEMBLY TO MAKE SURE THAT THERE IS SUFFICIENT COUPLING OF TRANSDUCER IN THE PROBE ASSEMBLY. IF NECESSARY, REMOVE THE TRANSDUCER AND APPLY MINERAL OIL TO THE TRANSDUCER FACE AND RE-SEAT THE TRANSDUCER IN THE PROBE ASSEMBLY.

(d)

If the amplitude of the backwall responses from the calibration standard for transducers 1, 3, and 4 at calibration gain + 3dB has fallen below 80 percent, the system must be calibrated again and all hardware examined since the last permitted calibration or calibration check must be examined again.

(9)

Indication Evaluation

(a)

Any indication(s) that equals or is more than 30 percent FSH must be evaluated as follows:

Confirm that the calibration is acceptable. Refer to paragraph 3.C.(8).

Identify with which transducer the indication was associated.

WARNING:

REFER TO THE PRODUCT LABEL AND THE MANUFACTURERS (MATERIAL) SAFETY DATA SHEET FOR INSTRUCTIONS ON THE HAZARDS, STORAGE, SAFE HANDLING AND PROPER USE OF THIS PRODUCT.

Clean the surface of the inspection area with a clean cloth to remove all oil and reapply fresh engine oil (C02-019) or engine oil (C02-023) to the inspection surface with the brush provided.

For transducer 2, do an inspection of the area in question again. If the indication is not more than 30 percent, then the indication is acceptable. If the signal is equal to or is more than 30 percent FSH, inspect the suspect area again. If the indication is still present, repeat the inspection with a second operator if available to confirm that the indication is still present. If the indication is still present, contact GEnx PSE before continuing. Record the results on the data sheet Form 2194-1. Refer to Figure 15.

For transducers 1, 3, or 4, do an inspection of the area in question again with the inspection gain at calibration gain + 3dB. If the indication is not more than 30 percent, then the indication is acceptable. If the signal is equal to or is more than 30 percent FSH, inspection with a second operator if available to confirm that the indication is still present. If the indication is still present, contact GEnx PSE before continuing. Record the results on the data sheet Form 2194-1. Refer to Figure 15.

(10)

Documentation

(a)

All calibration and inspection data must be recorded on the appropriate log. Refer to Figure 15.

(b)

Capture three screen shots of all indications that are 30 percent or greater, one from the indication, one from the screen display from the adjacent castellation slot CW and one from the screen display from the adjacent castellation slot CCW.

For the USMGo, freeze the screen as follows:

Press down the F3 toggle switch (upper button on the lower toggle). An asterik (*) icon will appear.

Press F4 for 2 seconds (lower button on lower toggle) until the screen image is saved.

(c)

Record the file name on the data sheet.

(d)

Forward Form 2194-1 along with supporting electronic files to the appropriate GE Representative.

Installation

(1)

Install the nut lock plate (20-320, 72-00-02) and retainer ring (20-310) with the 11C3304 installation tool forward retainer and lock plate as follows. Refer to Figure 3.

(a)

Install the threaded guide (guide) (item 2) through the fan rotor disk (01-050, 72-22-00) as follows:

Turn the guide (item 2) into the forward end of the mid fan shaft (01-010, 72-58-00) until it is installed on the forward face of the vent center tube (01-020).

(b)

Install the nut lock plate (20-320, 72-00-02) onto the four tabs on the lockplate holder (item 10).

NOTE:

The lock plate holder is attached to the lockplate installer (item 4) with capscrews (item 13).

(c)

Install the lockplate installer (item 4), the lock plate holder (item 10), and the lock plate (20-320) on the guide (item 2). Use the matched marks to align the lock plate (20-320) outer diameter tabs with the castellations on the forward lock nut, and the inner diameter tabs with the castellations on the mid shaft fan.

CAUTION:

MAKE SURE THAT THE LOCK PLATE IS ALIGNED CORRECTLY WITH THE MATCH MARK THAT SPECIFIES ITS ORIGINAL POSITION OR DAMAGE TO THE LOCK PLATE CAN OCCUR.

(d)

Install the lock plate installer nut (nut) (item 5) on the forward threaded end of the guide (item 2) until the lock plate installer (item 4) and the nut lock plate (20-320) are against the forward lock nut (20-330).

(e)

Compress the retainer ring (20-310) outside diameter and put in the groove on the aft end of the snap ring holder (item 6).

(f)

Install the snap ring holder (item 6) onto the lock plate installer (item 4) and thread the snap ring nut (item 7) onto the forward end of the guide (item 2) to seat the snap ring holder (item 6) against the forward end of the forward lock nut (20-330).

(g)

Turn the snap ring nut (item 7) onto the forward end of the guide (item 2) to install the snap ring holder (item 6) against the forward end of the forward lock nut (20-330).

(h)

Install the snap ring pusher (pusher) (item 8) on the snap ring holder (item 6).

(i)

Align the pusher so the 12 pins on the aft end go through the 12 clearance holes in the snap ring holder (item 6).

(j)

Move the pusher (item 8) aft until you can see the threads on the guide (item 2).

(k)

Install the pusher nut (item 9) on the forward end of the guide (item 2) and tighten the pusher nut (item 9) until the 12 pins push the retainer ring (20-310) out of the snap ring holder (item 6) groove and it expands into the groove in the forward end of the forward lock nut (20-330).

(l)

Remove the 11C3304 installation tool forward retainer and lock plate.

(m)

Make sure that the nut lock plate (20-320) and retainer ring (20-310) are correctly installed in the forward lock nut (20-330).

(2)

Install the fan shaft cover (20-290) as follows. Refer to Figure 4.

WARNING:

REFER TO THE PRODUCT LABEL AND THE MANUFACTURERS (MATERIAL) SAFETY DATA SHEET FOR INSTRUCTIONS ON THE HAZARDS, STORAGE, SAFE HANDLING AND PROPER USE OF THIS PRODUCT.

(a)

Use engine oil (C02-019) or engine oil (C02-023) to lubricate the lead-in chamfer and inner diameter of the forward fan shaft (01-170, 72-24-00) and a new packing (20-300, 72-00-02).

(b)

Install the packing (20-300) onto the outer groove of the fan shaft cover (20-290).

(c)

Install the fan shaft cover (20-290) on the 11C3421 fan shaft cover fixture as follows:

Align the tabs on the fan shaft cover with the open slots on the removal cover (item 2).

Turn until the tabs touch the pins on the removal cover (item 2).

(d)

Lift the fan shaft cover (20-290) with the removal cover (item 2) and put the fan shaft cover into the forward fan shaft (01-170, 72-24-00).

(e)

Push on the center of the fan shaft cover (20-290, 72-00-02) with the 11C3421 fan shaft cover fixture to fully install the fan shaft cover (20-290).

(f)

Remove the removal cover (item 2) from the fan shaft cover (20-290).

(g)

Use a shop light to do an inspection of the packing (20-300) to make sure that the packing is in the correct position (not visible).

(h)

Compress the retaining ring (20-280) to install the retaining ring (20-280) into the groove in the inner side of the bore of the forward fan shaft (01-170, 72-24-00).

(i)

Let the retaining ring (20-280, 72-00-02) expand into the groove.

(j)

Make sure that the retaining ring (20-280) is correctly installed.

(k)

Remove the 11C3084 fan disk bore protector or alternative.

(l)

Use a shop light to do an inspection for damage, FOD, and unwanted oil of the fan rotor bore and face of disk, including tool interface locations.

CAUTION:

INSTALL AGAIN THE SPINNER IN EXACTLY THE SAME ORIENTATION AS THE ORIGINAL (AS IT WAS INSTALLED BEFORE REMOVAL) TO PREVENT VIBRATION CHANGE.

(3)

Install the fan spinner (20-010, 72-00-00) and the spinner assembly aft support ring (20-101).

(a)

If the installation process of the spinner fan and the spinner assembly aft support ring is done on wing, refer to GEnx-1B Boeing 787 AMM Task 72-22-01-00A-720A-A.

(b)

If the installation process of the spinner fan and the spinner assembly aft support ring is done in shop, refer to GEnx-1B EM, 72-00-01, INSTALLATION 001, Subtask 72-00-01-420-020, and to GEnx-1B EM, 72-00-01, INSTALLATION 001, Subtask 72-00-01-420-019.