TRANSMITTAL INFORMATION
REVISION 1 TO SERVICE BULLETIN 72-0113
Revision 1 is issued to update paragraph 2., MATERIAL INFORMATION.
The original was issued December 28, 2012. Revision bars in the left margin identify changes.
1.PLANNING INFORMATION
A.Effectivity
* * * FOR GEnx-1B54, -1B58, -1B64, -1B67, -1B70, -1B54/P1, -1B58/P1, -1B64/P1, -1B67/P1, -1B70/P1, -1B70/72/P1, -1B70/75/P1, -1B74/75/P1, -1B75/P1
This Service Bulletin is applicable to all GEnx-1B engines.
B.Description
This Service Bulletin provides a quick turn (Q/T) method to remove and replace the mid fan shaft.
C.Compliance
Category 7
GE recommends that you do this Service Bulletin at customer's convenience.
NOTE:
This Service Bulletin can be accomplished in shop.
D.Concurrent Requirements
None.
E.Reason
(1)Objective:
To enhance shop turn around time.
(2)Condition:
Some engines in service are being removed at low cycles since new (CSN) for mid fan shaft repair.
(3)Cause:
Replacement of the mid fan shaft.
(4)Improvement:
The procedures defined within this Service Bulletin are optimized for repair of the mid fan shaft and verification of the modular serviceability.
(5)Substantiation:
Substantiation is by analysis.
F.Approval
This Service Bulletin has been reviewed by the FAA and the repair(s) and modification(s) herein comply with the applicable Federal Aviation Regulations and are FAA APPROVED for installation in the model(s) listed in this Service Bulletin.
G.Manpower
After you get access to the engine, you will need approximately 465 man-hours for each engine.
H.Weight and Balance
Weight and balance are not changed.
I.References (Use the latest version of these documents)
GEK 9250, Commercial Engine Standard Practices Manual (SPM)
GEK 112851, GEnx-1B Engine Manual (EM)
GEK 112862, GEnx-1B Cleaning, Inspection, and Repair Manual (CIR)
GEK 112864, GEnx-1B Engine Illustrated Parts Catalog (EIPC)
GEK 112866, GEnx-1B Illustrated Tool and Equipment Manual (ITEM)
Boeing 787 Aircraft Maintenance Manual (AMM)
GEnx-1B S/B 72-0114, ENGINE - Mid Fan Shaft Assembly (72-58-00) - Introduction of the New Mid Fan Shaft and Forward Lock Nut
J.Publications Affected
None.
K.Interchangeability
Replace the forward lock nut and mid fan shaft, from the old part numbers to the new part numbers. The old part numbers are not to be reinstalled. New parts are introduced by S/B 72-0114.
L.Software Accomplishment Summary
Not applicable.
2.MATERIAL INFORMATION
A.Material - Price and Availability
(1)Parts necessary to do this Service Bulletin:
 
Part Number
Qty/ Eng
Part Name
Unit ($) Price
Pkg Qty
Lead Time Days
 
J1438P177
(1)
Packing
45.25
(1)
30
 
J1437P013
(1)
Packing, Preformed
212.25
(1)
30
 
AS1895/23-100*
(1)
Seal, Ring
NP
(X)
NP
 
2331M67P02
(1)
Ring, Seal
1,077.00
(1)
30
 
1767M65G05
(1)
Seal Assembly
612.00
(1)
20
 
2331M87P01
(1)
Packing, Preformed
359.00
(1)
30
 
AS1895/7-125*
(1)
Seal, Ring
NP
(X)
NP
 
J1437P010
(1)
Packing, Preformed
116.00
(1)
10
 
2331M32P01
(38)
Nut, Main Shaft
230.00
(1)
Quote
 
* Part not supplied by GE Engine Services Distribution L.L.C.
 
NP= Not Provisioned
NOTE:
Prices are provided for planning purposes and are subject to change.
(2)Other Spare Parts:
 
Part Number
Qty/ Eng
Part Name
Unit ($) Price
Pkg Qty
Lead Time Days
 
2331M30P01
(1)
Plate, Lock Nut
Quote
(X)
Quote
 
2331M28P02
(1)
Nut, Forward Lock
4,889.00
(1)
30
 
2306M63P01
(150)
Nut, Self-Locking
Quote
(X)
Quote
 
2306M52P02
(88)
Spacer, Sleeve
Quote
(X)
Quote
 
2306M49P03
(74)
Plate, LPT Lock
Quote
(X)
Quote
 
2306M49P04
(1)
Plate, LPT Lock
Quote
(X)
Quote
 
AS3217-215*
(1)
Ring, Retainer
NP
(X)
NP
 
2305M64G03
(1)
Shaft, Mid Fan
327,100.00
(1)
Quote
 
2301M59P01
(1)
Seal, Forward Brush
30,140.00
(1)
Quote
 
* Part not supplied by GE Engine Services Distribution L.L.C.
 
NP= Not Provisioned
NOTE:
Prices are provided for planning purposes and are subject to change.
(3)Consumables:
 
Code Number
Description
 
C01-007
RTV, Silicone Elastomer (RTV 106)
 
C02-019
Oil, Engine Lubricating (engine oil)
 
C02-023
Oil, Engine Lubricating (engine oil)
 
C02-058
Compound, Thread Lubricating (graphite)
 
C03-005
Primer, Epoxy, Green (epoxy primer)
 
C03-039
Paint, Sermetel, Touch-up (coating)
 
C04-002
Solvent, General (Stoddard solvent)
 
C04-003
Solvent, General, Federal Specification 0-A51 (acetone)
 
C04-035
Solvent, General (isopropyl alcohol)
 
C05-003
Marking Pen (pen)
 
C10-013
Release Agent (compound, release agent)
 
C10-071
Wire, Safety
 
C10-140
Gloves, Film Latex or Nylon/Polyethylene Disposable (gloves)
 
C10-143
Cable, Safety
 
C10-182
Cloth, Cleaning for Aircraft Structural (SAE-AMS 3819, BMS 15-5) (cloth)
 
C10-215
Release Agent
 
--
Ice, Dry (dry ice)
 
NOTE:
Consumables must be readily available at the rework location. Items such as C03-039 coating are difficult to transport as they are considered hazardous cargo, and dry ice must be readily available.
B.Industry Support Information
None.
C.Configuration Chart
None.
D.Parts Disposition
Keep the forward lock nut and mid fan shaft for possible rework.
E.Tooling - Price and Availability
 
Tool Number
Description
 
9C1017G01
Variable CG Lift Beam
 
9C1156G04
Fixture, Lift Beam
 
11C3003P02**
Stand, Shipping Full Engine/Propulsor
 
11C3039G02
Bracket Set, FWD Propulsor
 
11C3084G03
Protector - Fan Disk Bore
 
11C3277G01
Fixture, Restrain - LP Turbine Rotor Lock
 
11C3278G01
Fixture, Push/Pull - LPT Install/Remove
 
11C3280G01
Adapter Set for Dolly, LPT
 
11C3281G01
Bracket Set TRF Pedestals
 
11C3281G02
Bracket Set FHF Pedestals
 
11C3281G03
Bracket Set TCF Pedestals
 
11C3281G04
Bracket Set FWD Fan Case Pedestals
 
11C3281G05
Bracket Set AFT Fan Case Pedestals
 
11C3282G01
Fixture, Guide LPT Shaft
 
11C3283G01
Fixture, Extension - LPT Mid Shaft
 
11C3288P01
Protector - Carbon Seal Runner
 
11C3296P01
Protector, Thread/Spline LPT Shaft
 
11C3304G01
Fixture, Install - FWD Ret and Lockplate
 
11C3327G01
Fixture, Guide - LPT Midshaft Extension
 
11C3328G02
Tool Set, Install/Remove No. 5 Bearing Aft Seal
 
11C3329G02
Fixture, Torque - Inner Spanner Nut
 
11C3334G01
Fixture, Torque - No. 5 Bearing Nut
 
11C3391G01
Fixture, Chill - External Duct LPT
 
11C3398G01
Fan blade Shim Removal Tool
 
11C3420G01
Tool, Install/Remove - Retaining Ring
 
11C3421G02
Fixture Install/Remove - Fan Shaft Cover
 
11C3423G02
Fixture, Torque - LPT/Fan Coupling Nut
 
11C3424G01
Gage, Mid Fan Shaft to Shaft Nut (gage)
 
11C3426G02
Dolly, LPT Module/Mid-Shaft
 
11C3437G01*
FMS Aft B-sump Seal Removal
 
11C3443P03**
Stand, Shipping Full Engine/Propulsor
 
11C3474P02
Guide-Install No. 5 Carbon Seal
 
11C3600G01*
FMS Lift Tool
 
11C3605G01
Mid Fan Shaft Truck Storage
 
11C3625G01*
Pusher, Install-Omni Seal
 
11C4266G03
LPT Light Weight Strongback 1B
 
11C4292G01
Fixture, Installation - No. 5 Carbon Seal
 
11C4323G02
Single Point Lift Beam being Upgraded G04
 
11C4486G01
Ring Fwd Fan Case Support
 
11C4487P02**
Stand, Shipping Full Engine/Propulsor
 
11C4495G02
Bracket Set, Lower Ground Handling
 
11C4514G01
Fan Case Protective Mats
 
11C4565G01*
1B Electronic FMS Nut Torque Tool - 220V
 
11C4565G02*
1B Electronic FMS Nut Torque Tool - 110V
 
11C4576P01**
Stand, Shipping Full Engine/Propulsor
 
11C4627G01**
Stanchions, Support Turbine Center Frame within Engine Stand
 
11C4655G01
Adapter to Lift LPT Nut Torque Tube
 
9429M17G01
Plate, Anti-Torque - Sweeney
 
9429M77G04
Lift Beam for 11C4266 Strong Back
 
9446M40G01
Fixture, LPT Alignment
 
9446M66P01
Fixture, Torque Reaction (50 Hz)
 
9446M66P02
Fixture, Torque Reaction (60 Hz)
 
9446M95G01
Fixture, Lift Arm-General Purpose
 
AH2543
Hydraulic Torque Multiplier
 
SPL7668
Lift Sling, Thrust Link and Aft Mount Lift Beam (Boeing tool)
 
Standard Tool
Sweeney No. 8105 and 8200 Torque Multiplier
 
Standard Tool
Pump, Hand - Hydraulic (Capacity: 20 Ton)
 
Standard Tool
Heat Gun
 
Standard Tool
Nylon Straps
 
* Denotes tools required to remove the mid fan shaft from the LPT rotor stator.
 
** Denotes tooling required to remove the LPT module with the Engine/Propulsor staying in the shipping stand.
 
NOTE:
Tools 11C4565 and AH2543 must be at the correct configuration for the voltage available at the rework location.
F.Standard Tools and Equipment
 
Description
Manufacturer
 
Gloves, Rubber
Local Purchase
 
Mallet, Soft Face
Local Purchase
 
Pliers, Teflon-Jaw
Local Purchase
 
Gauge, Clearance (Starret Taper Gauge)
Local Purchase
 
Customer Overhead Rail System (optional)
Locally Used
 
Hydra-Set Scale (6000 lb (2724 kg) minimum)
Local Purchase
 
Jack Screw, 0.250-28UNF (Qty 4)
Local Purchase
 
Picks, Long Length
Local Purchase
 
Torque Multiplier, Sweeney No. 8105 and No. 8200 (torque multiplier)
Hydratight Sweeney
 
Hydraulic Torque Multiplier, Model AH2543 (hydraulic torque multiplier)
Advance MFG Co
 
Pump, Hand - Hydraulic (capacity: 20 Ton)
Local Purchase
 
Torque Wrenches (different ranges)
Local Purchase
 
Micrometer 0-1 inch (0-25 mm)
Local Purchase
 
Depth Gauge 0-12 inches (0-300 mm)
Local Purchase
 
11/16 Splined Socket (for removal of FMS retaining nuts)
Local Purchase
 
NOTE:
Different size connectors are required for different hydraulic tools.
3.ACCOMPLISHMENT INSTRUCTIONS
A.General
(1)The engine disassembly procedure will start from either one of the actions that follow:
(a)The engine removed from wing as a full engine with the fan case installed (M10 configuration).
(b)The fan case removed as a propulsor (M20 configuration).
(c)The LPT module removed (M60 configuration).
NOTE:
This procedure provides instructions to repair the mid fan shaft assembly in shop with minimum engine disassembly. The engine rework per this Service Bulletin is considered to be a Q/T, continue-time shop visit workscope. All removed hardware and modules should be visually inspected for continue-time as defined for an assembled engine workscope. Refer to the GEnx-1B EM, 72-00-00, INSPECTION 001.
NOTE:
No dimensional inspection or fluorescent-penetrant inspection (FPI) (i.e. enhanced inspections) are required to complete this Service Bulletin (including no FPI required for the fan frame thrust link clevises or turbine rear frame (TRF) case) unless stated. All visual findings are to be assessed per the relevant section of the GEnx-1B EM. Additional inspection criteria to the assembled engine workscope visual inspection recommendations are provided in the paragraph 3.C., Inspection.
NOTE:
The LPT can be removed when the engine is in the 11C3003, 11C3443, 11C4487, or 11C4576 shipping stands with the 11C4627 stanchions installed on the stand to support the TCF.
B.Removal
(1)Remove and disassemble the M10 engine as follows:
(a)Put the engine in pedestals set or overhead gantry system. Refer to the GEnx-1B EM, 72-00-00, SPECIAL PROCEDURE 003. Alternatively, the LPT can be removed when the engine is in the shipping stands 11C3003, 11C3443, 11C4487, or 11C4576 with the 11C4627 stanchions installed on the stand to support the TCF. Refer to Figure 1 and Figure 2.
(b)Remove the aft mount and thrust links. Refer to the GEnx-1B, Boeing 787 AMM, B787-A-G71-21-04-00A-520A-A.
(c)Remove the spinner, platforms, and fan blades. Refer to the GEnx-1B EM, 72-00-01, REMOVAL 001.
(d)Remove the low pressure turbine (LPT) module from the engine. Refer to the GEnx-1B EM, 72-00-04, REMOVAL 001 and do as follows:
1Calculate the LPT rotor axial setting before removal of the LPT module as follows:
aRotate the LPT one time and measure the dimension R (LPT axial setting) and make a record for later comparison. Refer to the GEnx-1B EM, 72-00-04, INSTALLATION 001, Subtask 72-00-04-220-028.
2Remove the LPT module from the engine.
3Wipe the residual assembly C02-058 graphite and loose dry graphite film with an oil wetted C10-182 cloth when the LPT retaining nut is removed and before the pusher tool is installed.
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.
4Do a final wipe with a clean C10-182 cloth soaked in C04-003 acetone. Refer to the SPM 70-21-23, CLEANING METHOD 23 - HAND-WIPE DEGREASING.
(2)Remove the mid fan shaft as follows:
(a)Remove the air extension duct (extension duct) from the LPT cone shaft. Refer to the GEnx-1B EM, 72-00-04, DISASSEMBLY 001, Subtask 72-00-04-030-027.
(b)Remove the No. 4 bearing aft rotating seal (aft rotating seal) from the mid fan shaft assembly. Refer to the GEnx-1B EM, 72-00-04, DISASSEMBLY 001, Subtask 72-00-04-030-001.
(c)Remove the mid fan shaft assembly from the LPT module assembly. Refer to the GEnx-1B EM, 72-00-04, DISASSEMBLY 001, Subtask 72-00-04-030-004.
(d)Install the mid fan shaft assembly on the 11C3605 mid fan shaft truck storage (or alternative cradle/support). Refer to the GEnx-1B EM, 72-00-04, DISASSEMBLY 001, Subtask 72-00-04-440-002.
(e)Remove and discard the seal ring from the center vent duct. Refer to the GEnx-1B EM, 72-00-04, DISASSEMBLY 001, Subtask 72-00-04-030-028.
C.Inspection
NOTE:
All removed hardware and modules should be visually inspected for continue-time as defined for an assembled engine workscope. Refer to the GEnx-1B EM, 72-00-00, INSPECTION 001. No dimensional inspection or a FPI (i.e. enhanced inspections) are required to complete this Service Bulletin unless otherwise stated.
(1)Visually inspect the LPT/TRF module as follows:
(a)Stage 1 LPT blade:
1Looseness - any amount is permitted.
2Blade corrosion - any amount is permitted.
(b)Stage 7 LPT blade:
1Looseness - any amount is permitted.
(c)Stage 1 LPT shroud:
1Stage 1 shroud meets the inspection criteria of the GEnx-1B CIR, 72-00-04, INSPECTION 001, Subtask 72-00-04-220-034.
(d)TRF:
1FPI of the TRF case at the rear mount lug location is not required for Q/T engines as stated in the GEnx-1B CIR, 72-00-04, INSPECTION 001, Subtask 72-00-04-230-001.
(2)Visually inspect the turbine center frame (TCF) module as follows:
(a)Stage 1 LPT nozzle:
1Corrosion - any amount is permitted.
2Dents/impact damage - any amount is permitted if there is no missing material or cracking.
(b)Stage 1 nozzle retainer:
1Cracking - any amount is permitted.
2Distortion - any amount less than 0.25 inch (6.4 mm) from the TCF aft flange is permitted.
(c)Forward brush seal:
1Damper panel rivets for looseness - any amount is permitted.
2Damper panel missing rivets - none permitted.
3Damper panel cracks - none permitted.
4Brush seal bristles - general visual inspection (GVI), visibly worn bristles - none permitted.
D.Installation
(1)Install the mid fan shaft to the LPT as follows:
(a)Install the seal ring on the center vent duct of the mid fan shaft assembly. Refer to the GEnx-1B EM, 72-00-04, ASSEMBLY 001, Subtask 72-00-04-430-066.
(b)Install the mid fan shaft assembly to the LPT module assembly. Refer to the GEnx-1B EM, 72-00-04, ASSEMBLY 001, Subtask 72-00-04-430-066.
(c)Install the 11C4565 torque adapter on the mid fan shaft assembly. Refer to the GEnx-1B EM, 72-00-04, ASSEMBLY 001, Subtask 72-00-04-430-068.
(d)Torque the main shaft nuts with the 9446M66 torque reaction fixture. Refer to the GEnx-1B EM, 72-00-04, ASSEMBLY 001, Subtask 72-00-04-430-113.
(e)Use a 0.001 inch (0.03 mm) feeler stock as a no-go gage at a minimum of eight locations to make sure that the mid fan shaft assembly is against the LPT cone shaft. Refer to the GEnx- 1B EM, 72-00-04, ASSEMBLY 001, Subtask 72-00-04-430-084.
(f)Remove the 11C4565 torque adapter with an overhead hoist. Refer to the GEnx-1B EM, 72-00-04, ASSEMBLY 001, Subtask 72-00-04-430-085.
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.
(g)Remove the unwanted C02-058 graphite from the main shaft nuts and the D-head bolts with C04-002 Stoddard solvent, C04-035 isopropyl alcohol, or a 50-50 blend of alcohol. Refer to the GEnx-1B EM, 72-00-04, ASSEMBLY 001, Subtask 72-00-04-430-086.
(h)Apply a minimum of three coats of C03-039 coating to the bare surfaces around the main shaft nuts on the forward face of the mid fan shaft assembly flange. Refer to the SPM 70-43-05, INORGANIC ALUMINUM PROTECTIVE COATING and GEnx-1B EM, 72-00-04, ASSEMBLY 001, Subtask 72-00-04-380-002.
(i)Install the aft rotating seal on the mid fan shaft assembly. Refer to the GEnx-1B EM, 72-00-04, ASSEMBLY 001, Subtask 72-00-04-430-087.
(j)Prepare the extension duct for installation. Refer to the GEnx-1B EM, 72-00-04, ASSEMBLY 001, Subtask 72-00-04-430-116.
(k)Install the extension duct into the LPT cone shaft. Refer to the GEnx-1B EM, 72-00-04, ASSEMBLY 001, Subtask 72-00-04-430-119.
(l)Do a seating check of the extension duct. Refer to the GEnx-1B EM, 72-00-04, ASSEMBLY 001, Subtask 72-00-04-220-032.
(2)Install the LPT as follows:
(a)Install the LPT assembly. Refer to the GEnx-1B EM, 72-00-04, INSTALLATION 001 and do as follows:
1Install the LPT module with original shim spacer installed.
CAUTION:
DO NOT APPLY MORE THAN 24 DEGREES OR 8,300 LB FT (11,253 N.M) OF TORQUE OR DAMAGE TO THE ENGINE PARTS CAN OCCUR.
2Install the LPT nut as per the GEnx-1B, SB 72-0114, with C02-019 engine oil or C02-023 engine oil and apply initial torque of 1100-1260 lb ft (1491-1708 N.m) and final torque another 20 degrees.
3Compare the LPT axial setting, dimension R, to those measured in paragraph 3.B.(1)(d)1.
aTake the measurements now, refer to the steps in 3.B.(1)(d)1.
bCompare these new measurements with the incoming results measurements recorded before the disassembly of the engine in paragraph 3.B.(1)(d)1.
cDimension R result must be within 0.015 inch (0.38 mm) tolerance of the incoming results. Refer to the GEnx-1B EM, 72-00-04, INSTALLATION 001, Subtask 72-00-04-220-028.
NOTE:
If an alternative mid fan shaft is installed, it is acceptable to use dimension R comparison or alternately compare dimension R to the previous build dimension.
(b)Complete the LPT module installation and make sure that all the hardware previously removed in paragraph 3.B. is installed.
NOTE:
The pressure check of the carbon seal can be ignored. Refer to the GEnx-1B EM, 72-00-04, INSTALLATION 001, Subtask 72-00-04-780-005. Oil consumption and oil leakage checks are done in GEnx-1B EM, 72-00-00, TESTING 002 or on wing, GEnx-1B, Boeing 787 AMM, 71-00-00, TESTING 008 for untested engine.
(c)Install the aft mount and thrust links. Refer to the GEnx-1B, Boeing 787 AMM, B787-A-G71-21-04-00A-520A-A.
E.Test
(1)Do a test either in a test cell or
on wing as follows:
(a)If the test is done in a test cell, do an acceptance test. Refer to the GEnx-1B EM 72-00-00, TESTING 001 thru 005.
(b)If the test is done on wing, refer to the GEnx-1B, Boeing 787 AMM, 71-00-00, TESTING 008 for untested engines.
Stanchions, 11C4627, to Support the TCF when the LPT is Removed within the Stand
Figure 1  
Stanchions, 11C4627, Installed within the Engine Ship Stand
Figure 2   (Sheet 1)
Stanchions, 11C4627, Installed within the Engine Ship Stand
Figure 2   (Sheet 2)
Stanchions, 11C4627, Installed within the Engine Ship Stand
Figure 2   (Sheet 3)