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GE AIRCRAFT ENGINES
CUSTOMER TECHNICAL EDUCATION CENTER

FAN STATOR REMOVAL/INSTALLATION
BOEING 777
GEK 109976 SEP 05

GE90
110B & 115B

GE Aircraft Engine PROPRIETARY

.

1. Introduction

-115B GE PROPRIETARY INFORMATION 71-00-05 Page 1-1 Sep 05 .GE AIRCRAFT ENGINES GE90 TRAINING MANUAL GE90 Fan Stator Removal/Installation g Document: GEK 109976 Issued: Sep 05 Published by: Customer Training Services GE Aircraft Engines Customer Technical Education Center 123 Merchant Street Cincinnati. Ohio 45246 EFFECTIVITY B777/GE90-110B.

-115B GE PROPRIETARY INFORMATION 71-00-05 Page 1-2 Sep 05 .GE AIRCRAFT ENGINES GE90 TRAINING MANUAL THIS PAGE INTENTIONALLY LEFT BLANK EFFECTIVITY B777/GE90-110B.

however. -115B GE PROPRIETARY INFORMATION 71-00-05 Page 1-3 Sep 05 . re-exported.S. This product is considered GE Aircraft Engines technical data information and therefore is exported under U. The foregoing is subject to any rights the U.S. For authorized maintenance practices and specifications. Government Export License Regulations. Copyright 2005 GE Aircraft Engines EFFECTIVITY B777/GE90-110B. diverted. Government. Government may have acquired as such information. If consent is given for reproduction in whole or in part. or it's product may not be resold. in whole or in part.S. trans-shipped. This information is accurate at the time of compilation. Proprietary Information Notice The information contained in this document is disclosed in confidence.GE AIRCRAFT ENGINES GE90 TRAINING MANUAL This publication is for TRAINING PURPOSES ONLY. It is issued to the user under specific conditions that. It is the property of GE and shall not be used (except for evaluation). no update service will be furnished to maintain accuracy. or used in any other country without prior written approval of the U. disclosed to others. transferred. or reproduced without the expressed written consent of GE. this notice shall appear on any such reproduction. consult the pertinent Maintenance Publication. the contained data.

-115B GE PROPRIETARY INFORMATION 71-00-05 Page 1-4 Sep 05 .GE AIRCRAFT ENGINES GE90 TRAINING MANUAL THIS PAGE INTENTIONALLY LEFT BLANK EFFECTIVITY B777/GE90-110B.

............. 10 ..56 4.. Sep/05 ............ 1 ............................................. Sep/05 ................ 1 ............. 8 .............14 5...............9C6030 Transfer System ........................................ Fan Stator Module Removal/Installation ............GE AIRCRAFT ENGINES GE90 TRAINING MANUAL TABLE OF CONTENTS Section Topic Revised Page Numbers 1. Fan Stator Module R & I ...................................... 1 ........18 3.. Introduction Table of Contents ...9 Fan Stator Module Removal/Installation Introduction ........... Sep/05 ......................................Engine Preparation ...............................12 2.......................... 1 .....7 Engine General .................... Sep/05 .... Replacement Engine Test ...............................5 Acronyms and Abbreviations ................. 6 ....................... Sep/05 ................................... Fan Stator Module Removal/Installation ..................... Sep/05 ............................4 EFFECTIVITY B777/GE90-110B.... 1 ....... -115B GE PROPRIETARY INFORMATION 71-00-05 Page 1-5 Sep 05 ................... Sep/05 ..... Sep/05 ...............Equipment ................

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GE AIRCRAFT ENGINES GE90 TRAINING MANUAL ABBREVIATIONS & ACRONYMS ALF AMM CTEC EAI EBU EDP EEC FHF FLA FADEC GEAE HMU HPT IDG LH LPT MFP OGV PRSOV RH R&I QEC VBV VSV Aft Looking Forward Aircraft Maintenance Manual Customer Technical Education Center Engine Anti-Ice Engine Buildup Unit Engine Driven Pump Electronic Engine Control (also FADEC) Fan Hub Frame Forward Looking Aft Full Authority Digital Engine Control (also EEC) GE Aircraft Engines HydroMechanical Unit High Pressure Turbine Integrated Drive Generator Left Hand Low Pressure Turbine Main Fuel Pump Outlet Guide Vane(s) Pressure Regulating Shut Off Valve Right Hand Removal & Installation Quick Engine Change Variable Bleed Valve Variable Stator Vanes EFFECTIVITY B777/GE90-110B. -115B GE PROPRIETARY INFORMATION 71-00-05 Page 1-7 Sep 05 .

24 inches (8. and 33% lower emissions over previous commercial turbofan engines. -115B GE PROPRIETARY INFORMATION Arrangement: Turbofan engine Two spool axial airflow Clockwise (AFT looking Forward) Compressors: .Nominal length: 287.Nominal weight (dry): 18.Engine (no EBU or inlet): .Fan: . axial-flow turbofan propulsion system designed to meet high thrust commercial jet engine requirements of advanced aircraft manufactured during the mid 1990's and beyond.Low pressure turbine: Single stage Four stages Nine stages Dual-dome annular Two stages Six stages Dimensions: . In addition.High pressure turbine: .210 m) .86 inches (3.High pressure compressor: Combustion chamber: Turbines: . A higher overall pressure ratio than current engines gives higher thermal efficiencies.Nominal width: 166.300 m) . Type of engine: The GE90 is an ultrahigh bypass (9:1).36 inches (7. The specific fuel consumption (SFC) improvement is achieved through a higher efficiency engine cycle.000 lbs ( and more ).291 lbs (8314 kg) .425 m) .Nominal weight (dry): 18. its reduced noise level permits operation at the most noise sensitive airports in the world. variable stator.Nominal width: 134. The GE90 is designed for ease of maintainability and high overall system reliability.GE AIRCRAFT ENGINES GE90 TRAINING MANUAL ENGINE GENERAL The GE90 has been designed to power the BOEING 777 and future airplanes. EFFECTIVITY B777/GE90-110B.Nominal length: 323.46 inches (4. while the higher bypass ratio (BPR) provides improved propulsion efficiency. Rotation: (both rotors) The 75K to 115K+ lbs thrust family of engines is designed to provide 10% improvement in specific fuel consumption (SFC). Many of the components were derived from proven designs on existing engines.982 lbs (8628 kg) 71-00-05 72-00-00 Page 1-8 Sep 05 .228 m) . This derivative heritage provides a sound foundation for the components and systems of the GE90.000 lbs it has a growth capability up to 115.Powerplant (with EBU and inlet): . With an initial thrust of 76.Booster: .

(4.524 2 M) FAN STATOR DIAMETER = 134. -115B GE PROPRIETARY INFORMATION 72-00-00 71-00-05 Page 1-9 Sep 05 . (3.300 M) POWERPLANT OVERALL LENGTH = 323. (8. (4.847 M) INSTALLABLE SPARE ENGINE LENGTH = 287.228 M) GE AIRCRAFT ENGINES SPARE ENGINE LENGTH = 190. (7.24 IN.46 IN.210 M) GE90 PROPULSION SYSTEM EFFECTIVITY B777/GE90-110B. (3.86 IN.425 M) POWER PLANT HEIGHT = 166.84 IN.GE90 TRAINING MANUAL FAN DIAMETER = 128 IN.36 IN.

The fan stator module . the engine is designed around the principle of the fan stator module removal into two parts: .GE AIRCRAFT ENGINES GE90 TRAINING MANUAL FAN STATOR MODULE REMOVAL/INSTALLATION INTRODUCTION The GE90 is designed for high overall system reliability and maintainability based on the relevant experience on different successful programs. Due to its size. -115B GE PROPRIETARY INFORMATION 71-00-05 Page 1-10 Sep 05 .The engine propulsor This removal increases the engine transportability and reduces the number and the cost of the spare parts by reusing some engine hardware. EFFECTIVITY B777/GE90-110B.

GE AIRCRAFT ENGINES GE90 FAN STATOR MODULE TRAINING MANUAL ENGINE PROPULSOR 9C6025 SHIPPING AND INSTALLATION STAND 9C6030 FAN STATOR MODULE TRANSFER CARRIAGE FAN STATOR MODULE REMOVAL/INSTALLATION EQUIPMENT EFFECTIVITY B777/GE90-110B. -115B GE PROPRIETARY INFORMATION 71-00-05 Page 1-11 Sep 05 .

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2. Equipment .

-115B GE PROPRIETARY INFORMATION 71-00-05 Page 2-1 Sep 05 ..GE AIRCRAFT ENGINES GE90 TRAINING MANUAL FAN STATOR MODULE REMOVAL/INSTALLATION . identify the tooling required for fan stator module removal/installation EFFECTIVITY B777/GE90-110B.EQUIPMENT Objectives: At the completion of this section a student should be able to: ..

9C6031 component shipping container .9C6025 shipping and installation stand .9C6014 personnel stand .9C6031 component shipping container .9C6030 fan stator module transfer system .GE AIRCRAFT ENGINES GE90 TRAINING MANUAL FAN STATOR MODULE REMOVAL/INSTALLATION EQUIPMENT The equipment to do the fan stator module removal is as follows: .9C6025 shipping and installation stand . -115B GE PROPRIETARY INFORMATION The equipment to do the fan stator module installation is as follows: .9C6030 fan stator module transfer system .9C6014 personnel stand .9C1277 guide pin set .9C1202 fan blade spacer removal tool or 9C3001 fan blade spacer removal tool .9C6028 fan blade shipping container 71-00-05 Page 2-2 Sep 05 .9C6028 fan blade shipping container EFFECTIVITY B777/GE90-110B.

-115B GE PROPRIETARY INFORMATION 71-00-05 Page 2-3 Sep 05 .GE AIRCRAFT ENGINES GE90 FAN STATOR MODULE TRAINING MANUAL ENGINE PROPULSOR 9C6025 SHIPPING AND INSTALLATION STAND 9C6030 FAN STATOR MODULE TRANSFER CARRIAGE FAN STATOR MODULE REMOVAL/INSTALLATION EQUIPMENT EFFECTIVITY B777/GE90-110B.

Two aft cradle to engine support adapters and two forward cradle to engine support adapters allow for the support of the propulsor or engine. EFFECTIVITY B777/GE90-110B. .the base. . The hydraulic jacks are controlled from a central hydraulic hand pump located on the left side of the stand. It is made up of two main parts: .GE AIRCRAFT ENGINES GE90 TRAINING MANUAL 9C6025 INSTALLATION AND SHIPPING STAND The 9C6025 stand allows: .the cradle . Forklift tubes are positioned within the base and usable from either side of the stand. -115B GE PROPRIETARY INFORMATION 71-00-05 Page 2-4 Sep 05 . There are hydraulic jacks near each wheel of the stand.the removal and installation of the engine to the airplane wing.the removal and installation of the fan stator case from the propulsor. There is a hand operated hyraulic pump attached to the base for raising and lowering of the cradle on the base.the air and ground transportation of the propulsor.

-115B GE PROPRIETARY INFORMATION 71-00-05 Page 2-5 Sep 05 .GE AIRCRAFT ENGINES GE90 FORWARD ENGINE SUPPORT ADAPTERS TRAINING MANUAL CRADLE ASSEMBLY AFT ENGINE SUPPORT ADAPTERS HYDRAULIC JACK (DEPLOYED) TOW BAR STOW BASE ASSEMBLY STORAGE BOX HYDRAULIC HAND PUMP FORKLIFT TUBE STEERING BAR STOW 9C6025 INSTALLATION AND SHIPPING STAND EFFECTIVITY B777/GE90-110B.

EFFECTIVITY B777/GE90-110B. All four wheels of the side frames are individually adjustable up and down. The 9C6030 has two Aft Adapters. two 94B Forward Adapter Plates and two Side Frames. To align the fan stator module to the propulsor. all adjustments are made to the fan stator module using the 9C6030 fan stator module transfer system. two Forward Adapters. The 9C6030 transfer system is attached to the GE90 fan stator module and is used to remove or intall the fan stator module onto the propulsor.GE AIRCRAFT ENGINES GE90 TRAINING MANUAL 9C6030 FAN STATOR MODULE TRANSFER SYSTEM The 9C6030 fan stator module transfer system supports the fan stator module. -115B GE PROPRIETARY INFORMATION 71-00-05 Page 2-6 Sep 05 .

GE AIRCRAFT ENGINES GE90 FORWARD ADAPTER (LEFT) FORWARD ADAPTER (RIGHT) SIDE FRAME (LEFT) TRAINING MANUAL AFT ADAPTER (RIGHT) AFT ADAPTER (LEFT) SIDE FRAME (RIGHT) 9C6030 FAN STATOR MODULE TRANSFER SYSTEM EFFECTIVITY B777/GE90-110B. -115B GE PROPRIETARY INFORMATION 71-00-05 Page 2-7 Sep 05 .

move the slide hammer aft and forward to remove the fan blade spacer. -115B GE PROPRIETARY INFORMATION 71-00-05 Page 2-8 Sep 05 .GE AIRCRAFT ENGINES GE90 TRAINING MANUAL 9C1202 FAN BLADE SPACER REMOVAL TOOL The 9C1202 fan blade spacer removal tool is used to remove the fan blade spacer. . Fan Blade Spacer Removal: . EFFECTIVITY B777/GE90-110B.Place the detail pin in the bolt hole of the fan blade spacer.

GE AIRCRAFT ENGINES GE90 TRAINING MANUAL 9C1202 FAN BLADE SPACER REMOVAL TOOL EFFECTIVITY B777/GE90-110B. -115B GE PROPRIETARY INFORMATION 71-00-05 Page 2-9 Sep 05 .

Place the fan blade spacer removal tool detail pin into the fan blade spacer bolt hole and use hydraulic pressure to remove the fan blade spacer. Fan Blade Spacer Removal: . -115B GE PROPRIETARY INFORMATION 71-00-05 Page 2-10 Sep 05 .GE AIRCRAFT ENGINES GE90 TRAINING MANUAL FAN BLADE SPACER REMOVAL/INSTALLATION TOOLS The 9C3001 fan blade spacer removal tool is used to remove the fan blade spacers. EFFECTIVITY B777/GE90-110B.

-115B GE PROPRIETARY INFORMATION 71-00-05 Page 2-11 Sep 05 .GE AIRCRAFT ENGINES GE90 TRAINING MANUAL 9C3001FAN BLADE SPACER REMOVAL TOOL EFFECTIVITY B777/GE90-110B.

Forklift tubes are positioned within the stand and usable from the front side of the stand.GE AIRCRAFT ENGINES GE90 TRAINING MANUAL 9C6014 PERSONNEL STAND The 9C6014 personnel stand allows for access to the fan stator module forward flange bolts. The stand is made up of three parts and is placed into the fan stator module after the fan blades have been removed. -115B GE PROPRIETARY INFORMATION 71-00-05 Page 2-12 Sep 05 . EFFECTIVITY B777/GE90-110B. the 9C6014 personnel stand provide steps for the mechanic to reach the upper bolts of the fan stator module forward bolt flange. When assembled.

GE AIRCRAFT ENGINES GE90 TRAINING MANUAL B A 9C6014 STAND B 9C6014 PERSONNEL STAND EFFECTIVITY B777/GE90-110B. -115B GE PROPRIETARY INFORMATION 71-00-05 Page 2-13 Sep 05 .

The guide pin set contains eight guides pins. The guide pins are installed by hand into the fan stator module aft bolt flange.Install the guides pins at equal distances around the aft fan stator module bolt flange. EFFECTIVITY B777/GE90-110B.GE AIRCRAFT ENGINES GE90 TRAINING MANUAL 9C1277 GUIDE PIN SET The 9C1277 guide pin set is used align the fan stator module bolt flanges onto the propulsor bolt flanges. -115B GE PROPRIETARY INFORMATION 71-00-05 Page 2-14 Sep 05 . .

-115B GE PROPRIETARY INFORMATION 71-00-05 Page 2-15 Sep 05 .GE AIRCRAFT ENGINES AFT FAN STATOR MODULE FLANGE GE90 TRAINING MANUAL FAN STATOR MODULE OUTLET GUIDE VANES 9C1277 GUIDE PIN (8 LOCATIONS) FORWARD FAN STATOR MODULE FLANGE GUIDE PIN FAN HUB FRAME 9C1277 GUIDE PIN SET EFFECTIVITY B777/GE90-110B.

lower bifurcation module .fan blade platforms .GE AIRCRAFT ENGINES GE90 TRAINING MANUAL 9C6031 SPINNER AND COMPONENTS SHIPPING CONTAINER & 9C6028 FAN BLADES SHIPPING CONTAINER The purpose of these containers is to ensure the transportation and the storage of the fan case module reusable hardware.dovetail key EFFECTIVITY B777/GE90-110B.drain module .fan blade retainers .booster splitter fairing.center vent tube extension .booster anti-ice tubes . Each is made up of two main parts: .the metal base assembly. Hoist rings are built into the cover for removal and installation of the cover.support ring . 9C6028 Fan Blade Shipping Container holds: .acoustic panels . A document storage receptacle and a view port are provided.fan blades The interior is divided in several areas to ensure proper support of items during all container motions.spinner . -115B GE PROPRIETARY INFORMATION 71-00-05 Page 2-16 Sep 05 .the fiberglass cover .air bleed deflector panels .blankoff panels . in a safe and secure manner. The container has been designed to ship the following items: 9C6031 Components Shipping Container holds: . .starter air duct .fan blade spacers . Forklift tubes are positioned within the base and usable from either side of the unit.

SPINNER AND COMPONENTS SHIPPING CONTAINER EFFECTIVITY B777/GE90-110B.GE AIRCRAFT ENGINES GE90 TRAINING MANUAL 9C6031 CONTAINER FIBERGLASS COVER FAN BLADES FIBERGLASS COVER BASE BASE 9C6028 CONTAINER BASE 9C6031 FAN BLADES. -115B GE PROPRIETARY INFORMATION 9C6028 FAN BLADE SHIPPING CONTAINER 71-00-05 Page 2-17 Sep 05 .

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Engine Preparation .3.

identify the engine items removed for fan stator module removal/installation EFFECTIVITY B777/GE90-110B. -115B GE PROPRIETARY INFORMATION 71-00-05 Page 3-1 Sep 05 ..GE AIRCRAFT ENGINES GE90 TRAINING MANUAL FAN STATOR MODULE REMOVAL/INSTALLATION .ENGINE PREPARATION Objectives: At the completion of this section a student should be able to: ..

71-00-05 Page 3-2 Sep 05 .install the drain and service module assembly . Complete the engine preparation after the fan stator module as been installed on the engine propulsor.GE AIRCRAFT ENGINES GE90 TRAINING MANUAL ENGINE PREPARATION FOR FAN STATOR MODULE REMOVAL/INSTALLATION Prepare the engine for removal of the fan stator module from the engine propulsor.install the upper and lower bifurcation bridges .install the splitter fairing and booster anti-ice tubes .disconnect the EAI duct .remove the drain and service module assembly .install the fan blade platforms .remove the upper and lower bifurcation bridges . Note: The steps of engine preparation can be done with the engine on wing or in the installation/shipping stand.install the bleed air deflector panels .connect the electrical harnesses to the fan stator module assembly .install the lower hydraulic bifurcation assembly .connect the seal pressurization and oil tank vent tube .install the acoustic panels .remove the upper and lower fillet fairings .remove the air bleed defector panels . -115B GE PROPRIETARY INFORMATION .drain the oil from the engine. Note: The steps of engine preparation can be done with the engine in the installation/shipping stand or on wing.disconnect the seal pressurization and oil tank vent tube .remove the lower hydraulic bifurcation assembly .remove the fan blades and mounting hardware .install the upper and lower fillet fairings .remove the spinner and support ring . IDG and Backup Generator .install the support ring and spinner .install the fan blades and mounting hardware .remove the acoustic panels .remove the fan blade platforms . Following are the main steps of engine preparation for the engine fan stator removal: Following are the main steps of engine preparation after the engine fan stator module installation: .remove the booster anti-ice tubes and splitter fairing EFFECTIVITY B777/GE90-110B.remove the blank off panels .fill the oil of the engine.connect the EAI duct .install the blank off panels . IDG and Backup Generator.disconnect the electrical harnesses from the fan stator assembly .

-115B GE PROPRIETARY INFORMATION 71-00-05 Page 3-3 Sep 05 .GE AIRCRAFT ENGINES GE90 BLEED AIR DEFLECTOR PANELS TRAINING MANUAL ENGINE PROPULSOR BOOSTER SPLITTER FAIRING ENGINE PREPARATION FOR FAN STATOR MODULE REMOVAL/INSTALLATION EFFECTIVITY B777/GE90-110B.

1 gallon or 4 quarts low. .the 4/4 mark means that 1 gallon (4 quarts) needs to be added . EFFECTIVITY B777/GE90-110B. The oil tank is drained by using the two quick disconnect ports in the oil supply and scavenge return lines and a bucket.GE AIRCRAFT ENGINES GE90 TRAINING MANUAL ENGINE OIL (CHANGE) SERVICING WARNING: DO NOT LET HOT OIL GET ON YOU. Note: There is no need to service the oil tank unless it is at or below the 4/4 mark . HOT OIL CAN BURN YOU. The manual fill port cap has a dipstick attached to it. The drain ports are located in the oil supply and scavenge returns lines at the 6:00 position off the fan case.the 5/4 mark means that 1. This dipstick indicated the amount of oil that needs to be added to bring the oil level to full. The oil tank dipstick reads in gallons: Oil Tank Draining: .the 1/2 mark means that 1/2 gallon (2 quarts) needs to be added. -115B GE PROPRIETARY INFORMATION 71-00-05 12-22-01 Page 3-4 Sep 05 .connect locally manufactured drain tube to the drain ports and catch the oil (11 gallons or 42 liters) in a container. Oil Tank Servicing: The oil tank is manually filled by hand pouring quart cans of oil into the oil tank at the manual fill port. .the 3/4 mark means that 3/4 gallon (3 quarts) needs to be added .25 gallon (5 quarts) needs to be added.

GE AIRCRAFT ENGINES GE90 TRAINING MANUAL ENGINE OIL (CHANGE) SERVICING EFFECTIVITY B777/GE90-110B. -115B GE PROPRIETARY INFORMATION 12-22-01 71-00-05 Page 3-5 Sep 05 .

aft face of the accessory gearbox.pressure servicing the IDG through the remote service lines. EFFECTIVITY B777/GE90-110B.removing the IDG case drain plug and catching the oil (1.GE AIRCRAFT ENGINES GE90 TRAINING MANUAL INTEGRATED DRIVE GENERATOR .5 gallons or 6 liters) in a container. -115B GE PROPRIETARY INFORMATION 71-00-05 12-22-07 Page 3-6 Sep 05 . The generator remote oil service lines are attached to the aft side of the engine drain lines.installing the IDG case drain plug The Integrated Drive Generator is located on the left. . HOT OIL CAN BURN YOU. . The IDG oil is serviced by: .attaching a hose to the overfill remote service line to relieve any pressure in the system. IDG Oil Servicing: .SERVICING (OIL CHANGE) WARNING: DO NOT LET HOT OIL GET ON YOU.

-115B GE PROPRIETARY INFORMATION 71-00-05 12-22-07 Page 3-7 Sep 05 .GE AIRCRAFT ENGINES GE90 TRAINING MANUAL INTEGRATED DRIVE GENERATOR .SERVICING (OIL CHANGE) EFFECTIVITY B777/GE90-110B.

forward face of the accessory gearbox. EFFECTIVITY B777/GE90-110B. Backup Generator Oil Draining: .installing the Backup Generator case drain plug . The Backup Generator is located on the left.remove the Backup Generator case drain plug and catching the oil (1 gallon or 3. -115B GE PROPRIETARY INFORMATION 71-00-05 12-22-09 Page 3-8 Sep 05 . . The generator remote oil service lines are attached to the aft side of the engine drain lines.attach a hose to the overfill remote service line to relieve any pressure in the system. The Backup Generator oil is serviced by: .GE AIRCRAFT ENGINES GE90 TRAINING MANUAL BACKUP GENERATOR . HOT OIL CAN BURN YOU.SERVICING (OIL CHANGE) WARNING: DO NOT LET HOT OIL GET ON YOU.pressure servicing the Backup Generator through the remote service lines.7 liters) in a container.

-115B GE PROPRIETARY INFORMATION 12-22-09 71-00-05 Page 3-9 Sep 05 .SERVICING (OIL CHANGE) EFFECTIVITY B777/GE90-110B.GE AIRCRAFT ENGINES GE90 TRAINING MANUAL BACKUP GENERATOR .

remove the drain assembly.connect the eight drain tubes .connect the manual override flexible cable from the starter .disconnect the eight drain tubes . The drain module takes engine accessory gearbox drive pad. Drain Module Removal: .disconnect the IDG and Backup Generator remote service lines . The service module contains the engine oil lines.GE AIRCRAFT ENGINES GE90 TRAINING MANUAL DRAIN AND SERVICE MODULE ASSEMBLY REMOVAL/INSTALLATION Drain Module Installation: The drain and service module assembly is located on the aft side of the fan stator module at the 6:00 position.disconnect the forward lower fire detector .disconnect the manual override flexible cable from the starter .connect the forward lower fire detector.install the drain assembly .connect the IDG and Backup Generator remote service lines . -115B GE PROPRIETARY INFORMATION 71-00-05 Page 3-10 Sep 05 . . EFFECTIVITY B777/GE90-110B. air lines and electrical harnesses that run between the fan stator and propulsor. fuel driven actuator and fuel driven valve internal leakage overboard.

-115B GE PROPRIETARY INFORMATION 71-00-05 71-00-05 Page3-11 3-11 Page Jan05 03 Sep .GE AIRCRAFT ENGINES GE90 TRAINING MANUAL IDG FILL TUBE BACKUP GENERATOR FILL TUBE BACKUP GENERATOR OVERFLOW TUBE IDG OVERFLOW TUBE FORWARD LOWER FIRE DETECTOR (NOT SHOWN) B SERVICE MODULE DRAIN AND SERVICE MODULE ASSEMBLY REMOVAL/INSTALLATION (SHEET 1) EFFECTIVITY B777/GE90-110B.

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MANUAL OVERRIDE FLEXIBLE CABLE GE AIRCRAFT ENGINES GE90 TRAINING MANUAL B DRAIN AND SERVICE MODULE ASSEMBLY REMOVAL/INSTALLATION (SHEET 2) EFFECTIVITY B777/GE90-110B. -115B GE PROPRIETARY INFORMATION 71-00-05 Page 3-13 Sep 05 .

disconnect the electrical harness connectors at the bottom of the fan case .install the bottom of the fire seal .install the electrical harnesses into the springs clips and quarter turn clamps .GE AIRCRAFT ENGINES GE90 TRAINING MANUAL ELECTRICAL HARNESS REMOVAL/INSTALLATION Electrical Harness Removal: .remove the bottom of the fire seal . Electrical Harness Installation: . EFFECTIVITY B777/GE90-110B. -115B GE PROPRIETARY INFORMATION 71-00-05 Page 3-14 Sep 05 .install the heatshield blanket. Tie the electrical harnesses out of the way on the propulsor.remove the heatshield blanket .remove the electrical connectors from the springs clips and quarter turn clamps.connect the electrical harness connectors at the bottom of the fan case .

GE AIRCRAFT ENGINES GE90 TRAINING MANUAL ELECTRICAL HARNESSES REMOVAL/INSTALLATION (SHEET 1) EFFECTIVITY B777/GE90-110B. -115B GE PROPRIETARY INFORMATION 71-00-05 Page 3-15 Sep 05 .

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-115B GE PROPRIETARY INFORMATION 71-00-05 Page 3-17 Sep 05 .GE AIRCRAFT ENGINES GE90 TRAINING MANUAL ELECTRICAL HARNESSES REMOVAL/INSTALLATION (SHEET 2) EFFECTIVITY B777/GE90-110B.

-115B GE PROPRIETARY INFORMATION 71-00-05 Page 3-18 Sep 05 .GE AIRCRAFT ENGINES GE90 TRAINING MANUAL W729 HEATSHIELD BLANKET W722 W724 FIRE SEAL W728 SEE E W738 BOLTS (2 LOCATIONS) SAFETY CLIPS (3 LOCATIONS) FWD D ELECTRICAL HARNESSES REMOVAL/INSTALLATION (SHEET 3) EFFECTIVITY B777/GE90-110B.

-115B GE PROPRIETARY INFORMATION 71-00-05 Page 3-19 Sep 05 .GE AIRCRAFT ENGINES GE90 TRAINING MANUAL E 1134065-05-A ELECTRICAL HARNESSES REMOVAL/INSTALLATION (SHEET 4) EFFECTIVITY B777/GE90-110B.

connect the eight pressure air tubes in front of the lower bifurcation fire seal and at 12:00 position at the upper end of the service module.GE AIRCRAFT ENGINES GE90 TRAINING MANUAL LOWER HYDRAULIC BIFURCATION ASSEMBLY REMOVAL/INSTALLATION Lower Hydraulic Bifurcation Assembly Removal: .connect the oil tank and oil return tubes in front of the lower bifurcation fire seal and at 12:00 position at the upper end of the service module . Lower Hydraulic Bifurcation Assembly Installation: . EFFECTIVITY B777/GE90-110B.disconnect the eight pressure air tubes in front of the lower bifurcation fire seal and at 12:00 position at the upper end of the service module .install the lower hydraulic bifurcation assembly . -115B GE PROPRIETARY INFORMATION 71-00-05 Page 3-20 Sep 05 .remove the lower hydraulic bifurcation assembly.disconnect the oil tank and oil return tubes in front of the lower bifurcation fire seal and at 12:00 position at the upper end of the service module .

GE AIRCRAFT ENGINES GE90 TRAINING MANUAL LOWER HYDRAULIC BIFURCATION ASSEMBLY REMOVAL/INSTALLATION (SHEET 1) EFFECTIVITY B777/GE90-110B. -115B GE PROPRIETARY INFORMATION 71-00-05 Page 3-21 Sep 05 .

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-115B GE PROPRIETARY INFORMATION 71-00-05 Page 3-23 Sep 05 .GE AIRCRAFT ENGINES GE90 TRAINING MANUAL C LOWER HYDRAULIC BIFURCATION ASSEMBLY REMOVAL/INSTALLATION (SHEET 2) EFFECTIVITY B777/GE90-110B.

GE AIRCRAFT ENGINES GE90 TRAINING MANUAL LOWER HYDRAULIC BIFURCATION ASSEMBLY REMOVAL/INSTALLATION (SHEET 3) EFFECTIVITY B777/GE90-110B. -115B GE PROPRIETARY INFORMATION 71-00-05 Page 3-24 Sep 05 .

-115B GE PROPRIETARY INFORMATION 71-00-05 Page 3-25 Sep 05 .GE AIRCRAFT ENGINES GE90 TRAINING MANUAL LOWER HYDRAULIC BIFURCATION ASSEMBLY REMOVAL/INSTALLATION (SHEET 4) EFFECTIVITY B777/GE90-110B.

To help during installation. -115B GE PROPRIETARY INFORMATION 71-00-05 Page 3-26 Sep 05 .GE AIRCRAFT ENGINES GE90 TRAINING MANUAL BLANK OFF PANELS REMOVAL/INSTALLATION The eight Blank Off Panels are located between the bleed air deflector panels on the inner cowl support. The blank off panels are removed to get access to the fan stator module aft mount bolts. the blank off panel installation positions are etched into the panels (Example . Blank Off Panel Removal: .remove the screws from the blank off panels and remove the panels Blank Off Panel Installation: .POS 1&5). The panels are numbered from aft looking forward starting at 12:00 o'clock of the engine.install the blank off panels by position number and install the screws. EFFECTIVITY B777/GE90-110B.

GE AIRCRAFT ENGINES GE90 TRAINING MANUAL BLANK OFF PANELS REMOVAL/INSTALLATION EFFECTIVITY B777/GE90-110B. -115B GE PROPRIETARY INFORMATION 71-00-05 Page 3-27 Sep 05 .

Fillet Fairing Removal: . EFFECTIVITY B777/GE90-110B.install the fillet fairings and the two different length screws. -115B GE PROPRIETARY INFORMATION 71-00-05 Page 3-28 Sep 05 .remove the two different length screws of the fillet fairings and remove the fairings Fillet Fairings Installation: .GE AIRCRAFT ENGINES GE90 TRAINING MANUAL FILLET FAIRINGS REMOVAL/INSTALLATION The four Fillet Fairings are located on the bleed air deflector panels and upper (12:00 o'clock) and lower (6:00 o'clock) bifurcation firewalls. The fillet fairings are removed to get access to the fan stator module aft mount bolts.

-115B GE PROPRIETARY INFORMATION 71-00-05 Page 3-29 Sep 05 .GE AIRCRAFT ENGINES GE90 TRAINING MANUAL FILLET FAIRINGS REMOVAL/INSTALLATION EFFECTIVITY B777/GE90-110B.

The panels are numbered from aft looking forward starting at 12:00 o'clock of the engine. -115B GE PROPRIETARY INFORMATION 71-00-05 Page 3-30 Sep 05 .install the bleed air deflector panels and install the screws.GE AIRCRAFT ENGINES GE90 TRAINING MANUAL BLEED AIR DEFLECTOR PANELS REMOVAL/ INSTALLATION The ten Bleed Air Deflector Panels are located around the inner cowl support. the bleed air deflector panel installation positions are etched into the panels (Example POS 5&10). Bleed Air Deflector Panel Installation: . Bleed Air Deflector Panel Removal: . The Bleed Air Deflector Panels are removed to get access to the fan stator module aft mount bolts. To help during installation. EFFECTIVITY B777/GE90-110B.remove the screws from the bleed air deflector panels and remove the panels.

RIGHT SIDE IS OPPOSITE SCREW (29 LOCATIONS) BLEED AIR DEFLECTOR PANELS REMOVAL/INSTALLATION EFFECTIVITY B777/GE90-110B.GE AIRCRAFT ENGINES GE90 TRAINING MANUAL BLEED AIR DEFLECTOR PANEL BLEED AIR DEFLECTOR PANEL BLEED AIR DEFLECTOR PANEL FWD BLEED AIR DEFLECTOR PANEL BLEED AIR DEFLECTOR PANEL INSTALLATION POSITION LOCATION (EACH PANEL) NOTE: LEFT SIDE IS SHOWN. -115B GE PROPRIETARY INFORMATION 71-00-05 Page 3-31 Sep 05 .

install the nuts and bolts that attach the lower bifurcation bridge to the fan stator . . -115B GE PROPRIETARY INFORMATION 71-00-05 Page 3-32 Sep 05 . The lower bifurcation bridge must be removed to allow for fan stator module removal. Lower Bifurcation Bridge Removal: .remove sealant between the contact surfaces .remove the nuts and bolts that attach the lower bifurcation bridge to the fan stator .install the lower bifurcation bridge.remove the lower bifurcation bridge.GE AIRCRAFT ENGINES GE90 TRAINING MANUAL LOWER BIFURCATION BRIDGE The Lower Bifurcation Bridge is located at the top of the lower bifurcation firewall. EFFECTIVITY B777/GE90-110B.apply sealant between the contact surfaces. . Lower Bifurcation Bridge Installation: Note: Clean the lower bifurcation bridge using the Aircraft Maintenance Manual procedures before installation.

-115B GE PROPRIETARY INFORMATION 71-00-05 Page 3-33 Sep 05 .GE AIRCRAFT ENGINES GE90 TRAINING MANUAL WASHER (5 LOCATIONS) LOWER BIFURCATION BRIDGE NUT (5 LOCATIONS) BOLT (4 LOCATIONS) WASHER (4 LOCATIONS) LOWER BIFURCATION FIREWALL LOWER AND UPPER BIFURCATION BRIDGES REMOVAL/INSTALLATION (SHEET 1) EFFECTIVITY B777/GE90-110B.

install the nuts and bolts that attach the upper bifurcation bridge to the fan stator . -115B GE PROPRIETARY INFORMATION 71-00-05 Page 3-34 Sep 05 .remove sealant between the contact surfaces . Upper Bifurcation Bridge Removal: . Upper Bifurcation Bridge Installation: Note: Clean the upper bifurcation bridge using the Aircraft Maintenance Manual procedures before installation. . EFFECTIVITY B777/GE90-110B.remove upper bifurcation bridge.GE AIRCRAFT ENGINES GE90 TRAINING MANUAL UPPER BIFURCATION BRIDGE The Upper Bifurcation Bridge is located at the bottom of the upper bifurcation firewall.apply sealant between the contact surfaces. . The upper bifurcation bridge must be removed to allow for fan stator module removal.install the upper bifurcation bridge.remove the nuts and bolts that attach the upper bifurcation bridge to the fan stator .

-115B GE PROPRIETARY INFORMATION 71-00-05 Page 3-35 Sep 05 .GE AIRCRAFT ENGINES GE90 TRAINING MANUAL LOWER AND UPPER BIFURCATION BRIDGES REMOVAL/INSTALLATION (SHEET 2) EFFECTIVITY B777/GE90-110B.

These tubes must be disconnected to allow for fan stator module separation. Seal Pressurization and Oil Tank Ventilation Tube Installation: .GE AIRCRAFT ENGINES GE90 TRAINING MANUAL SEAL PRESSURIZATION AND OIL TANK VENTILATION TUBES REMOVAL/INSTALLATION The seal pressurization and oil tank ventilation tubes are located at the 12:00 position in the upper bifurcation fire wall. Seal Pressurization and Oil Tank Ventilation Tube Removal: .disconnect the seal pressurization and oil tank ventilation tubes. -115B GE PROPRIETARY INFORMATION 71-00-05 Page 3-36 Sep 05 .connect the seal pressurization and oil tank ventilation tubes. EFFECTIVITY B777/GE90-110B.

GE AIRCRAFT ENGINES GE90 TRAINING MANUAL SEAL PRESSURIZATION AND OIL TANK VENTILATION TUBES REMOVAL/INSTALLATION EFFECTIVITY B777/GE90-110B. -115B GE PROPRIETARY INFORMATION 71-00-05 Page 3-37 Sep 05 .

disconnect the engine anti-ice duct.connect the engine anti-ice duct. EFFECTIVITY B777/GE90-110B. Engine Anti-Ice Duct Installation: . -115B GE PROPRIETARY INFORMATION 71-00-05 Page 3-38 Sep 05 . The engine anti-ice duct must be disconnected to allow for fan stator module separation. Engine Anti-Ice Duct Removal: .GE AIRCRAFT ENGINES GE90 TRAINING MANUAL ENGINE ANTI-ICE DUCT REMOVAL/INSTALLATION The Engine Anti-Ice Duct is located at the 12:00 position in the upper bifurcation fire wall.

-115B GE PROPRIETARY INFORMATION 71-00-05 Page 3-39 Sep 05 .GE AIRCRAFT ENGINES GE90 TRAINING MANUAL ENGINE ANTI-ICE DUCT REMOVAL/INSTALLATION EFFECTIVITY B777/GE90-110B.

.Align the "1" of the spinner with number "1" on the support ring to align the offset bolt holes.Remove the 22 bolts and the support ring. These number "1"s are aligned with the number "1"s marked on either side of the fan disk number 1 blade slot. NOTE: The 44 radial screws on the outer diameter of the spinner . Note: The number "1" is marked on the backside and front side of two bolt flanges of the support ring.Remove the 22 axial mount bolts on the spinner and remove the spinner.GE AIRCRAFT ENGINES GE90 TRAINING MANUAL FAN BLADE REMOVAL / INSTALLATION The spinner is attached to the front of the fan disk. EFFECTIVITY B777/GE90-110B.Align the support ring number "1"s with the number "1"s on the fan disk.and on either side of each axial mount bolt are fan assembly balance screws. To remove the spinner do the following: . Alignment of the number "1"s will align the offset bolt holes of the support ring and fan disk. The offset bolt hole is marked with an "O". -115B GE PROPRIETARY INFORMATION 71-00-05 72-21-01 Page 3-40 Sep 05 . NOTE: The number "1" is marked on the front of the support ring and on the spinner. . To install the spinners do the following: . Install the 22 bolts.

GE AIRCRAFT ENGINES GE90 TRAINING MANUAL SEE B SPINNER OFFSET BOLT HOLE FORWARD LOOKING AFT B SUPPORT RING OFFSET BOLT HOLE SPINNER CONE (ONE PIECE) REMOVAL / INSTALLATION EFFECTIVITY B777/GE90-110B. -115B GE PROPRIETARY INFORMATION 72-21-01 71-00-05 Page 3-41 Sep 05 .

Remove the fan blade from the fan disk slot. . Note: The fan blade platforms and fan blades are balance critical.Remove the retainer from the fan disk slot. NOTE: The blades are numbered counter clockwise when you are facing them. Note: Do not remove the fan disk shims. The platforms are secured in place by the spinner. . fan blades and other hardware. .Remove the blade platform on either side of the blade to be removed.Remove the spacer using the fan blade spacer removal tool (9C1202) or hydraulic removal tool (9C3001) . Record their original position. Fan Blade Spacer Removal: . NOTE: A rubber seal around the platform creates a tight fit between the blades holding the platform in place during the assembly process. The number "1" is engraved on the forward face of the fan disk.move the slide hammer aft and forward to remove the fan blade spacer.Turn the fan assembly counterclockwise to put the first fan blade to be removed at the 6 o'clock position. . Before removal use a felt tip pen and tape to mark the location of the fan blade platforms. to be sure to install them at the same location.GE AIRCRAFT ENGINES GE90 TRAINING MANUAL FAN BLADE REMOVAL The twenty-two fan blades are located in the forward end of the engine. . on either side of the number one blade slot. EFFECTIVITY B777/GE90-110B.Place the detail pin in the bolt hole of the fan blade spacer .Remove the bolt securing the spacer and the retainer together. .Number the blades and platforms before removal.Remove the dovetail key from the fan disk slot. The fan blades must be removed to allow for fan stator module separation. -115B GE PROPRIETARY INFORMATION 71-00-05 72-21-02 Page 3-42 Sep 05 . .

GE AIRCRAFT ENGINES GE90 TRAINING MANUAL FAN BLADE REMOVAL EFFECTIVITY B777/GE90-110B. -115B GE PROPRIETARY INFORMATION 72-21-02 71-00-05 Page 3-43 Sep 05 .

install the fan blade into the fan blade dovetail slot .use a soft mallet to drive the fan blade spacer into position. EFFECTIVITY B777/GE90-110B.GE AIRCRAFT ENGINES GE90 TRAINING MANUAL 9C1202 FAN BLADE SPACER REMOVAL TOOL The 9C1202 fan blade spacer removal tool is used to remove the fan blade spacer. Fan Blade Installation: . -115B GE PROPRIETARY INFORMATION 71-00-05 72-21-02 Page 3-44 Sep 05 .move the slide hammer aft and forward to remove the fan blade spacer.Place the detail pin in the bolt hole of the fan blade spacer . Fan Blade Spacer Removal: .

GE AIRCRAFT ENGINES GE90 TRAINING MANUAL FAN BLADE SPACER REMOVAL TOOL EFFECTIVITY B777/GE90-110B. -115B GE PROPRIETARY INFORMATION 72-21-02 71-00-05 Page 3-45 Sep 05 .

Fan Blade Spacer Removal: .GE AIRCRAFT ENGINES GE90 TRAINING MANUAL FAN BLADE SPACER REMOVAL/INSTALLATION TOOLS The 9C3001 fan blade spacer removal tool is used to remove the fan blade spacers. EFFECTIVITY B777/GE90-110B.Place the fan blade spacer removal tool detail pin into the fan blade spacer bolt hole and use hydraulic pressure to remove the fan blade spacer. -115B GE PROPRIETARY INFORMATION 71-00-05 Page 3-46 Sep 05 .

-115B GE PROPRIETARY INFORMATION 71-00-05 Page 3-47 Sep 05 .GE AIRCRAFT ENGINES GE90 TRAINING MANUAL FAN BLADE SPACER REMOVAL TOOL (9C3001) EFFECTIVITY B777/GE90-110B.

. . . . NOTE: A rubber seal around the platform creates a tight fit between the blades holding the platform in place during the assembly process. . Note: Be sure to clean and lubricate the fan blades and fan disk before installation.Install the blade retainer into the fan disk retainer slot.Insert the fan blade spacer between the fan blade and the dovetail key. -115B GE PROPRIETARY INFORMATION 71-00-05 72-21-02 Page 3-48 Sep 05 .Install the blade platforms on either side of the fan blade.Turn the fan assembly counterclockwise to put the fan blade slot for the fan blade to be installed at the 6 o'clock position.Hit the spacer with a plastic mallet until fully installed or use the hydraulic installation tool (9C3001). . .GE AIRCRAFT ENGINES GE90 TRAINING MANUAL FAN BLADE INSTALLATION Install the fan blades and fan blade platforms at their original locations (for balancing purposes). The platforms are secured in place by the spinner. Insert the rear of the platform under the booster flange. then push the forward part of the platform toward the fan disk.Install the dovetail key into the fan disk blade slot. . EFFECTIVITY B777/GE90-110B.Install the bolt that holds the retainer and the spacer together.Install the fan blade into the fan disk blade slot.

-115B GE PROPRIETARY INFORMATION 72-21-02 71-00-05 Page 3-49 Sep 05 .GE AIRCRAFT ENGINES GE90 TRAINING MANUAL FAN BLADE INSTALLATION EFFECTIVITY B777/GE90-110B.

install the acoustic panels.Install the screws that attach the acoustic panels to the fan booster.remove the acoustic panels. .Remove the screws that attach the acoustic panels to the fan booster . Acoustic Panel Removal: . The acoustic panels are removed to get access to the fan stator module forward mount bolts. EFFECTIVITY B777/GE90-110B. There are six acoustic panels. -115B GE PROPRIETARY INFORMATION 71-00-05 Page 3-50 Sep 05 . Acoustic Panel Installation: .GE AIRCRAFT ENGINES GE90 TRAINING MANUAL ACOUSTIC PANEL REMOVAL/INSTALLATION The Acoustic Panels are located around the fan booster.

GE AIRCRAFT ENGINES GE90 TRAINING MANUAL FAN STATOR MODULE (OGVS) ACOUSTIC PANEL REMOVAL/INSTALLATION EFFECTIVITY B777/GE90-110B. -115B GE PROPRIETARY INFORMATION 71-00-05 Page 3-51 Sep 05 .

Install the booster splitter fairing.install the bolts that attach the booster splittler fairing to the low pressure compressor leading edge. EFFECTIVITY B777/GE90-110B.remove the booster splitter fairing. .Remove the bolts that attach the booster splittler fairing to the low pressure compressor leading edge. The Booster Splitter Fairing is removed to provide clearance between the pressure compressor case and fan stator while removing and installing the fan stator. Booster Splitter Faiting Installation: . -115B GE PROPRIETARY INFORMATION 71-00-05 Page 3-52 Sep 05 .GE AIRCRAFT ENGINES GE90 TRAINING MANUAL BOOSTER SPLITTER FAIRING The Booster Splitter Fairing is attached to the leading edge of the low pressure compressor case. . Booster Splitter Fairing Removal: .

GE AIRCRAFT ENGINES

GE90

*

TRAINING MANUAL

*

BOOSTER
SPLITTER
FAIRING
FAN
BOOSTER

*

*

BOOSTER
SPLITTER
FAIRING

A

FAN STATOR
MODULE (OGVS)

SEE B

SCREW
(50 LOCATIONS)
* SEE C

A-A

BOOSTER SPLITTER FAIRING
EFFECTIVITY
B777/GE90-110B, -115B
GE PROPRIETARY INFORMATION

LPC ANTI-ICE TUBE ATTACHMENT
POINTS WILL NOT EXIST ON NON
ANTI-ICED BOOSTER SPLITTER
FAIRING

71-00-05

Page 3-53
Sep 05

GE AIRCRAFT ENGINES

GE90

TRAINING MANUAL

LOW PRESSURE COMPRESSOR (LPCAI) ANTI-ICE
TUBES
GE SB 75-003 deleted the Low pressure compressor antiice system and was introduced in production on engines
900-129 and up.
Reason for service bulletin introduction:
Engine tests indicate that the LPC Anti-Ice system is not
required.

LPC Anti-IceTube Installation:
- connect the two bolts that attach the tube to the
booster splitter fairing at the forward end, the nut at
the aft end and the clamp.

For those engines that still have the LPC Anti-Ice Tubes
they are located at four locations around the booster
module. The acoustic panels much be removed to get
access to them.
The LPC Anti-Ice Tubes delivers seventh stage HPC air to
the booster splitter fairing. The tubes must be removed to
allow for fan stator removal.
LPC Anti-IceTube Removal:
- disconnect the two bolts that attach the tube to the
booster splitter fairing at the forward end, the nut at
the aft end and the clamp.

EFFECTIVITY
B777/GE90-110B, -115B
GE PROPRIETARY INFORMATION

71-00-05

Page 3-54
Sep 05

GE AIRCRAFT ENGINES

GE90

TRAINING MANUAL

*

* LPC ANTI-ICE TUBES DELETED BY SB 75-003

LOW PRESSURE COMPRESSOR ANTI-ICE TUBES
EFFECTIVITY
B777/GE90-110B, -115B
GE PROPRIETARY INFORMATION

71-00-05

Page 3-55
Sep 05

-115B GE PROPRIETARY INFORMATION 71-00-05 Page 3-56 Sep 05 .GE AIRCRAFT ENGINES GE90 TRAINING MANUAL THIS PAGE INTENTIONALLY LEFT BLANK EFFECTIVITY B777/GE90-110B.

9C6030 System .4.

9C6030 TRANSFER SYSTEM Objectives: At the completion of this section a student should be able to: .. -115B GE PROPRIETARY INFORMATION 71-00-05 Page 4-1 Sep 05 .GE AIRCRAFT ENGINES GE90 TRAINING MANUAL FAN STATOR REMOVAL & INSTALLATION .. identify the tooling required for fan stator module removal/installation EFFECTIVITY B777/GE90-110B.

Note: If using9C6000 Installation and Shipping Stand make sure that the fan hub frame mount support adapters are installed first. can be done with the engine in the 9C6000 or 9C6025 Installation and Shipping Stands. using the 9C6030 Transfer System. Fan Stator Module Installation: . . The fan stator module must be removed to perform a normal engine change.attach the left and right 9C6030 Aft Adapters to the aft fan case ground handling mounts . EFFECTIVITY B777/GE90-110B. -115B GE PROPRIETARY INFORMATION Fan Stator Module Removal: .attach the right 9C6030 Side Frame to the right Forward Adapter and Aft Adapter. . The fan stator module removal/installation.install the 9C1277 guide pin set into the fan stator module aft flange 71-00-05 Page 4-2 Sep 05 .attach the left and right 9C6030P01 Forward Adapters to the fan case flange. The fan stator module can be removed and installed with or without the inlet cowl installed.attach the left 9C6030 Side Frame to the left Forward Adapter and Aft Adapter.GE AIRCRAFT ENGINES GE90 TRAINING MANUAL FAN STATOR MODULE REMOVAL/INSTALLATION 9C6030 TRANSFER SYSTEM The Fan Stator Module is located on the front of the engine.

LEFT SIDE OPPOSITE) FAN STATOR MODULE REMOVAL/INSTALLATION . -115B GE PROPRIETARY INFORMATION 71-00-05 Page 4-3 Sep 05 .9C6030 TRANSFER SYSTEM EFFECTIVITY B777/GE90-110B.GE AIRCRAFT ENGINES GE90 TRAINING MANUAL FORWARD ADAPTER MOUNT AFT ADAPTER MOUNT FRAME HEIGHT ADJUSTING HANDLE FRAME HEIGHT ADJUSTING HANDLE SIDE FRAME (RIGHT SIDE SHOWN.

9C6030 TRANSFER SYSTEM EFFECTIVITY B777/GE90-110B. RIGHT SIDE OPPOSITE) FAN STATOR MODULE REMOVAL/INSTALLATION . -115B GE PROPRIETARY INFORMATION 71-00-05 Page 4-4 Sep 05 .GE AIRCRAFT ENGINES GE90 TRAINING MANUAL FAN STATOR (AFT LOOKING FORWARD) FRAME HEIGHT ADJUSTING HANDLE FORWARD ADAPTER SIDE FRAME FORWARD ADAPTER SIDE FRAME SIDE BEAM AND FORWARD ADAPTERS (LEFT SIDE SHOWN.

LEFT SIDE OPPOSITE) FAN STATOR MODULE REMOVAL/INSTALLATION .9C6030 TRANSFER SYSTEM EFFECTIVITY B777/GE90-110B. -115B GE PROPRIETARY INFORMATION 71-00-05 Page 4-5 Sep 05 .GE AIRCRAFT ENGINES GE90 TRAINING MANUAL AFT ADAPTER PAD AFT ADAPTER PAD AFT ADAPTER FAN STATOR (AFT LOOKING FORWARD) SIDE FRAME FRAME HEIGHT ADJUSTING HANDLE AFT ADAPTER SIDE FRAME FAN STATOR AFT MOUNT SIDE FRAME AND AFT ADAPTER (RIGHT SIDE SHOWN.

GE AIRCRAFT ENGINES GE90 TRAINING MANUAL THIS PAGE INTENTIONALLY LEFT BLANK EFFECTIVITY B777/GE90-110B. -115B GE PROPRIETARY INFORMATION 71-00-05 Page 4-6 Sep 05 .

9C6030 TRANSFER SYSTEM EFFECTIVITY B777/GE90-110B. -115B GE PROPRIETARY INFORMATION 71-00-05 Page 4-7 Sep 05 .GE AIRCRAFT ENGINES GE90 TRAINING MANUAL FRAME HEIGHT ADJUSTING HANDLE (4 LOCATIONS) FAN STATOR MODULE REMOVAL/INSTALLATION .

by hand.move the 9C6030 and fan stator. Note: Use the 9C6030 Side Frame wheels to adjust the height of the fan module and move the 9C6030 side to side. .) Fan Stator Module Removal: Fan Stator Module Installation: Maintenance tip: To prevent the engine from shifting and causing damage or injury during fan stator removal do the following: Note: Clean. the shank of the bolts and to the bearing surface of the integral washers on the bolts.install the bolts to the aft flange of the fan stator module at the fan hub frame.remove the bolts from the forward flange of the fan stator module at the fan hub frame.adjust the left 9C6030 side frame forward wheel handle "down" until the wheel is off the ground. .GE AIRCRAFT ENGINES GE90 TRAINING MANUAL FAN STATOR MODULE REMOVAL/INSTALLATION 9C6030 TRANSFER SYSTEM (CONT. away from the propulsor. 71-00-05 Page 4-8 Sep 05 . lubricate and torque fan stator module flanges and bolts as stated in the Aircraft Maintenance Manual.install the bolts to the forward flange of the fan stator module at the fan hub frame. Use the 9C6014 personnel stand as necessary. .move the 9C6030 and fan stator. by hand. . Fan Stator Bolt Removal: . . to adjust side clearance during installation. Use the 9C6014 personnel stand as necessary. .remove the bolts from the aft flange of the fan stator module at the fan hub frame. -115B GE PROPRIETARY INFORMATION .apply lubricant to the threads of the bolts. . . toward the propulsor.apply either zinc chromate primer or epoxy primer to the fan hub frame flanges. by hand.adjust the left 9C6030 side beam aft wheel handle "down" until there is a gap between the Aft Adapter Pad and the fan stator. EFFECTIVITY B777/GE90-110B.adjust the 9C6030 Side Frame "up" one full turn of the handle.adjust the 9C6030 Side Frame wheel handles "up" until the forward wheel make contact with the ground and the Aft Adapter pad makes contact with the fan stator . .

-115B GE PROPRIETARY INFORMATION 71-00-05 Page 4-9 Sep 05 .GE AIRCRAFT ENGINES GE90 TRAINING MANUAL A B B A FAN STATOR MODULE REMOVAL/INSTALLATION .9C6030 TRANSFER SYSTEM EFFECTIVITY B777/GE90-110B.

-115B GE PROPRIETARY INFORMATION 71-00-05 Page 4-10 Sep 05 . The stand is made up of three parts and is placed into the fan stator module after the fan blades have been removed.GE AIRCRAFT ENGINES GE90 TRAINING MANUAL 9C6014 PERSONNEL STAND The 9C6014 personnel stand allows for access to the fan stator module forward flange bolts and acoustical panels. When assembled. the 9C6014 personnel stand provide steps for the mechanic to reach the acoustic panels and upper bolts of the fan stator module forward bolt flange. EFFECTIVITY B777/GE90-110B. Forklift tubes are positioned within the stand and usable from front side of the stand.

-115B GE PROPRIETARY INFORMATION 71-00-05 Page 4-11 Sep 05 .GE AIRCRAFT ENGINES GE90 TRAINING MANUAL B A 9C6014 STAND B 9C6014 PERSONNEL STAND EFFECTIVITY B777/GE90-110B.

The guide pins are installed by hand into the fan stator module aft bolt flange. remove the guide pins as the bolts are installed. When the fan stator and fan hub frame flanges are together.GE AIRCRAFT ENGINES GE90 TRAINING MANUAL 9C1277 GUIDE PIN SET The 9C1277 guide pin set is used align the fan stator module bolt flanges onto the propulsor bolt flanges. Install the guides pins at equal distances around the aft fan stator module bolt flange. -115B GE PROPRIETARY INFORMATION 71-00-05 Page 4-12 Sep 05 . EFFECTIVITY B777/GE90-110B. The guide pin set contains eight guides pins.

-115B GE PROPRIETARY INFORMATION 71-00-05 Page 4-13 Sep 05 .GE AIRCRAFT ENGINES AFT FAN STATOR MODULE FLANGE GE90 TRAINING MANUAL FAN STATOR MODULE OUTLET GUIDE VANES 9C1277 GUIDE PIN (8 LOCATIONS) FORWARD FAN STATOR MODULE FLANGE GUIDE PIN FAN HUB FRAME 9C1277 GUIDE PIN SET EFFECTIVITY B777/GE90-110B.

-115B GE PROPRIETARY INFORMATION 71-00-05 Page 4-14 Sep 05 .GE AIRCRAFT ENGINES GE90 TRAINING MANUAL THIS PAGE INTENTIONALLY LEFT BLANK EFFECTIVITY B777/GE90-110B.

5. Engine Replacement Test .

.GE AIRCRAFT ENGINES GE90 TRAINING MANUAL REPLACEMENT ENGINE TEST Objectives: At the completion of this section a student should be able to: .. identify the tests required for fan stator module removal/installation EFFECTIVITY B777/GE90-110B. -115B GE PROPRIETARY INFORMATION 71-00-05 Page 5-1 Sep 05 .

EEC (FADEC) Test (MAT Initiated Test) . 16 . 14 .do Test No. -115B GE PROPRIETARY INFORMATION 71-00-05 71-00-00 Page 5-2 Sep 05 . 3 .Idle Leak Test .do a check of the engine maintenance status messages on the EICAS. The replacement engine test is done to make sure that the engine will operate normally after an engine change. 10 .GE AIRCRAFT ENGINES GE90 TRAINING MANUAL REPLACEMENT ENGINE TEST The engine replacement test is located in the Power Plant Adjustment/Test section of the Aircraft Maintenance Manual chapter 71-00-00.do Test No.do the Engine Air Supply Operational Test .do Test No. do an engine depreservation .do Test No. Replacement Engine (Pretested Engine) Test: . 15 . 5 .Dry Motor Leak Test . 1 .if engine is preserved.do the Engine Fire Detection Operational Test .do Test No.Engine Fuel Driven Actuator Test (MAT Initiated Test) .Pneumatic Leak Test .do Test No.do Test No.Standard Wet Motor if not done during depreservation .do Test No.Engine Air Driven Actuator Test (MAT Initiated Test) .Low Pressure System (Fan/LPT) Vibration Survey . EFFECTIVITY B777/GE90-110B. 2 .

-115B GE PROPRIETARY INFORMATION 71-00-00 71-00-05 Page 5-3 Sep 05 .GE AIRCRAFT ENGINES GE90 TRAINING MANUAL REPLACEMENT ENGINE TEST EFFECTIVITY B777/GE90-110B.

GE AIRCRAFT ENGINES GE90 TRAINING MANUAL THIS PAGE INTENTIONALLY LEFT BLANK EFFECTIVITY B777/GE90-110B. -115B GE PROPRIETARY INFORMATION 71-00-05 Page 5-4 Sep 05 .