ENGINE - Mid Fan Shaft Assembly (72-58-00) - Inspection of Mid Fan Shaft

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 reproduction in 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.

Copyright (2012) General Electric Company, U.S.A.

August 17, 2012 GEnx-1B S/B 72-0107

Revision 02, September 14, 2012 PAGE 1 of 32
ENGINE - Mid Fan Shaft Assembly (72-58-00) - Inspection of Mid Fan Shaft

TRANSMITTAL INFORMATION

REVISION 2 TO SERVICE BULLETIN 72-0107

Revision 2 is issued to update paragraphs 1.A., Effectivity, 1.B., Description, 1.C., Compliance,

1.E., Reason, and 3., Accomplishment Instructions.

The original was issued on the August 17, 2012. Revision 1 was issued August 24, 2012. Revision

bars in the left margin identify changes.

1. PLANNING INFORMATION

A. Effectivity

GEnx-1B64, -1B67, -1B70, -1B64/P1, -1B67/P1, -1B70/P1, -1B70/75/P1

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

B. Description

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

assembled engine.

C. Compliance

Category 2

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 previously complied with GEnx-1B SB 72-0107 Revision 0 or

Revision 1, or that have been inspected prior to aircraft delivery, reinspect within

90 days from completion date of the initial inspection and then at a maximum 90

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 operator’s fleet.

D. Concurrent Requirements

None.

August 17, 2012 GEnx-1B S/B 72-0107

Revision 02, September 14, 2012 PAGE 2

GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.
ENGINE - Mid Fan Shaft Assembly (72-58-00) - Inspection of Mid Fan Shaft

E. 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.

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

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

H. Weight and Balance

Weight and balance are not changed.

I. 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)

J. Publications Affected

None.

K. Interchangeability

Not applicable.

August 17, 2012 GEnx-1B S/B 72-0107

Revision 02, September 14, 2012 PAGE 3

GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.
ENGINE - Mid Fan Shaft Assembly (72-58-00) - Inspection of Mid Fan Shaft

L. Software Accomplishment Summary

Not applicable.

2. MATERIAL INFORMATION

A. 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

Quote (X) Quote

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

B. Industry Support Information

Contact your Customer Support Manager (CSM).

C. Configuration Chart

None.

D. Parts Disposition

None.

E. Tooling - Price and Availability

August 17, 2012 GEnx-1B S/B 72-0107

Revision 02, September 14, 2012 PAGE 4

GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.
ENGINE - Mid Fan Shaft Assembly (72-58-00) - Inspection of Mid Fan Shaft

Tool Number Description

9C3020P09* Removal Bar (recommended)

11C3084G02* Fan Disk Bore Protector

(recommended)

11C3304G01* Installation Tool Forward Retainer and

Lock Plate

11C3421G02* Fan Shaft Cover Fixture

11C4654G01 LPT Shaft I/R Fixture (alternative to

9C3020P09)

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

August 17, 2012 GEnx-1B S/B 72-0107

Revision 02, September 14, 2012 PAGE 5

GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.
ENGINE - Mid Fan Shaft Assembly (72-58-00) - Inspection of Mid Fan Shaft

Attn: NDE Kit Coordinator

email: ndttooling@ge.com

3. ACCOMPLISHMENT INSTRUCTIONS

A. Removal

(1) Remove the spinner fan (20-010, 72-00-00) and the spinner assembly aft

support ring (20-101).

(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:

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

2 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).

3 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.

4 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).

5 Install sleeve (items 14) and torque arm plate (item 3) to the removal

cover (item 2).

6 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).

7 Remove 11C3421 fan shaft cover fixture from the fan rotor and

remove fan shaft cover from the fixture (item 2).

August 17, 2012 GEnx-1B S/B 72-0107

Revision 02, September 14, 2012 PAGE 6

GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.
ENGINE - Mid Fan Shaft Assembly (72-58-00) - Inspection of Mid Fan Shaft

(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 9C3020P09 removal bar or a screw driver to engage the tip of

retainer ring (20-310) to move it inward and to disengage it from the slot

in the mid fan shaft (01-010, 72-58-00).

(b) Use a marking pen (C05-003) to put a mark on the nut lock plate

(20-320, 72-00-02) to align it with the mid fan shaft (01-010, 72-58-00)

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.

B. 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 manufacturer’s equipment user’s manual.

August 17, 2012 GEnx-1B S/B 72-0107

Revision 02, September 14, 2012 PAGE 7

GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.
ENGINE - Mid Fan Shaft Assembly (72-58-00) - Inspection of Mid Fan Shaft

(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 manufacturer’s 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 manufacturer’s 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

MANUFACTURER’S (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

August 17, 2012 GEnx-1B S/B 72-0107

Revision 02, September 14, 2012 PAGE 8

GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.
ENGINE - Mid Fan Shaft Assembly (72-58-00) - Inspection of Mid Fan Shaft

(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.

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

Refer to Figure 1 .

2 Castellation No. 1 will be in line with the stage 1 fan blade dovetail.

Rotate the castellation No. 1 to the 6 o’clock position. Refer to

Figure 2 .

NOTE: The No. 1 fan blade can be identified with a number 1

marked on the fan disk.

3 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.B.(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

MANUFACTURER’S (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.

August 17, 2012 GEnx-1B S/B 72-0107

Revision 02, September 14, 2012 PAGE 9

GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.
ENGINE - Mid Fan Shaft Assembly (72-58-00) - Inspection of Mid Fan Shaft

(f) Apply engine oil to the transducer with the syringe.

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

1 Adjust the transducer switchbox to position 2 (transducer 2 - lower

castellation).

2 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 .

3 Record the calibration settings on the worksheet in Figure 15 .

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

1 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 .

2 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.B.(4),

paragraph 3.B.(5), and paragraph 3.B.(6).

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

1 Set the transducer switchbox to position 2. Adjust the instrument

gain setting to number 2 transducer gain level.

2 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

MANUFACTURER’S (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.

3 Apply engine oil (C02-019) or engine oil (C02-023) to the upper and

lower castellations on the FMS with a brush.

4 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 o’clock position.

August 17, 2012 GEnx-1B S/B 72-0107

Revision 02, September 14, 2012 PAGE 10

GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.
ENGINE - Mid Fan Shaft Assembly (72-58-00) - Inspection of Mid Fan Shaft

5 Apply engine oil to the transducer with the syringe.

6 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.B.(9).

7 Record the maximum amplitude within the gate on Form 2194-1.

Refer to Figure 15 .

8 Pull back the transducer assembly and turn it counterclockwise

(CCW) forward looking aft (FLA) to the next castellation position.

9 Turn the shaft clockwise (CW) FLA to the 6 o’clock position.

10 Do paragraph 3.B.(7)(b)(5) thru paragraph 3.B.(7)(b)(9) again until

all 16 lower castellation positions are completed.

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

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

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

3 Set the transducer switchbox to position 1.

4 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

MANUFACTURER’S (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.

5 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 o’clock position. Refer to Figure 2 and Figure

13 .

6 Apply engine oil (C02-019) or engine oil (C02-023) to the transducers

with the syringe.

7 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.B.(9).

8 Record the maximum amplitude within the gate for each transducer.

9 Pull back the transducer assembly and turn it CCW FLA to the next

castellation position.

August 17, 2012 GEnx-1B S/B 72-0107

Revision 02, September 14, 2012 PAGE 11

GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.
ENGINE - Mid Fan Shaft Assembly (72-58-00) - Inspection of Mid Fan Shaft

10 Turn the shaft CW FLA to the 6 o’clock position.

11 Do paragraph 3.B.(7)(C)(6) thru paragraph 3.B.(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:

1 Confirm that the calibration is acceptable. Refer to paragraph

3.B.(8).

August 17, 2012 GEnx-1B S/B 72-0107

Revision 02, September 14, 2012 PAGE 12

GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.
ENGINE - Mid Fan Shaft Assembly (72-58-00) - Inspection of Mid Fan Shaft

2 Identify with which transducer the indication was associated.

WARNING: REFER TO THE PRODUCT LABEL AND THE

MANUFACTURER’S (MATERIAL) SAFETY DATA

SHEET FOR INSTRUCTIONS ON THE HAZARDS,

STORAGE, SAFE HANDLING AND PROPER USE OF

THIS PRODUCT.

3 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.

4 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 .

5 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.

1 For the USMGo, freeze the screen as follows:

a Press down the F3 toggle switch (upper button on the lower

toggle). An asterik (*) icon will appear.

2 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.

August 17, 2012 GEnx-1B S/B 72-0107

Revision 02, September 14, 2012 PAGE 13

GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.
ENGINE - Mid Fan Shaft Assembly (72-58-00) - Inspection of Mid Fan Shaft

C. 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:

1 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.

(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

August 17, 2012 GEnx-1B S/B 72-0107

Revision 02, September 14, 2012 PAGE 14

GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.
ENGINE - Mid Fan Shaft Assembly (72-58-00) - Inspection of Mid Fan Shaft

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

MANUFACTURER’S (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:

1 Align the tabs on the fan shaft cover with the open slots on the

removal cover (item 2).

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.

August 17, 2012 GEnx-1B S/B 72-0107

Revision 02, September 14, 2012 PAGE 15

GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.
ENGINE - Mid Fan Shaft Assembly (72-58-00) - Inspection of Mid Fan Shaft

(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.

(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.

August 17, 2012 GEnx-1B S/B 72-0107

Revision 02, September 14, 2012 PAGE 16

GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.
ENGINE - Mid Fan Shaft Assembly (72-58-00) - Inspection of Mid Fan Shaft

RETAINING

RING

(20-280)

FORWARD

FAN SHAFT

(01-170, 72-24-00)

FAN SHAFT

COVER

(20-290)

MID FAN SHAFT

(01-010, 72-58-00)

PACKING

(20-300)

NOTES:

1. ALL IPC REFERENCES FROM 

 72-00-02 UNLESS SPECIFIED

 DIFFERENTLY.

2. SOME ITEMS NOT SHOWN

 FOR CLARITY. 1369340-00

Removal of the Retaining Ring and Forward Fan Shaft Cover

Figure 1, ( Sheet 1 of 2 )

August 17, 2012 GEnx-1B S/B 72-0107

Revision 02, September 14, 2012 PAGE 17

GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.
ENGINE - Mid Fan Shaft Assembly (72-58-00) - Inspection of Mid Fan Shaft

A-A

FORWARD

FAN SHAFT

(01-170, 72-24-00)

MID FAN

SHAFT

(01-010,

72-58-00)

FAN ROTOR DISK

(01-050, 72-22-00)

13

2

3 12

FAN SHAFT

COVER

(20-290)

LEGEND:

 2. REMOVAL COVER

 3. TORQUE ARM PLATE

12. CROSS BAR PULLER

13. HAND KNOB

14. SLEEVE

15. LOCK PINS

NOTES:

1. ALL IPC REFERENCES FROM 

 72-00-02 UNLESS SPECIFIED

 DIFFERENTLY.

2. ITEM NUMBERS AGREE WITH ITEM 

 NUMBERS OF TOOL, 11C3421. 1369341-00

A

A

14

15

Removal of the Retaining Ring and Forward Fan Shaft Cover

Figure 1, ( Sheet 2 )

August 17, 2012 GEnx-1B S/B 72-0107

Revision 02, September 14, 2012 PAGE 18

GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.
ENGINE - Mid Fan Shaft Assembly (72-58-00) - Inspection of Mid Fan Shaft

NOTE:

ALL IPC REFERENCES FROM 

72-00-02 UNLESS SPECIFIED

DIFFERENTLY.

NUT LOCK 

PLATE

(20-320)

RETAINER RING

(20-310)

FORWARD

LOCK NUT

(20-330)

MID FAN SHAFT

(01-010, 72-58-00)

A

A

1369342-00

Removal of the Retainer Ring and Nut Lock Plate

Figure 2

August 17, 2012 GEnx-1B S/B 72-0107

Revision 02, September 14, 2012 PAGE 19

GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.
ENGINE - Mid Fan Shaft Assembly (72-58-00) - Inspection of Mid Fan Shaft

RETAINER

RING

(20-310)

LEGEND:

 2. GUIDE

 4. LOCKPLATE INSTALLER

 5. NUT

 6. SNAP RING HOLDER

 7. SNAP RING NUT

 8. PUSHER

 9. PUSHER NUT

10. LOCKPLATE HOLDER

13. CAPSCREW

NOTES:

1. ALL IPC REFERENCES FROM 

 72-00-02 UNLESS SPECIFIED

 DIFFERENTLY.

2. ITEM NUMBERS AGREE WITH ITEM 

 NUMBERS OF TOOL, 11C3304.

3. FORWARD LOCK NUT (20-330) IS

 ALREADY INSTALLED.

2

FAN BOOSTER

ASSEMBLY

(20-010)

5

7

9

6

8

4

10

13 (4 LOCATIONS)

NUT LOCK

PLATE

(20-320)

FORWARD

LOCK NUT

(20-330)

1369343-00

Installation of the Lock plate and the Retainer Ring

Figure 3

August 17, 2012 GEnx-1B S/B 72-0107

Revision 02, September 14, 2012 PAGE 20

GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.
ENGINE - Mid Fan Shaft Assembly (72-58-00) - Inspection of Mid Fan Shaft

RETAINING

RING

(20-280)

PACKING

(20-300)

FAN SHAFT

COVER

(20-290)

2

3

13

12

FAN BOOSTER

ASSEMBLY

(20-010)

LEGEND:

 2. REMOVAL COVER

 3. TORQUE ARM PLATE

12. CROSS BAR PULLER

13. HAND KNOB

NOTES:

1. ALL IPC REFERENCES FROM 

 72-00-02 UNLESS SPECIFIED

 DIFFERENTLY.

2. ITEM NUMBERS AGREE WITH ITEM 

 NUMBERS OF TOOL, 11C3421.

3. ITEMS 3, 12, AND 13 NOT REQUIRED

 FOR INSTALLATION OF THE

 FORWARD FAN SHAFT COVER.

1369344-00

Installation of the Forward Fan Shaft Cover

Figure 4

August 17, 2012 GEnx-1B S/B 72-0107

Revision 02, September 14, 2012 PAGE 21

GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.
ENGINE - Mid Fan Shaft Assembly (72-58-00) - Inspection of Mid Fan Shaft

FORWARD

FAN SHAFT

(01-170, 72-24-00) MID FAN 

SHAFT

(01-010)

CENTER 

VENT TUBE

(01-020)

INSPECTION 

TARGET LOCATION

1369500-00

A-A

A

A

NOTE:

ALL IPC REFERENCES FROM 

72-58-00 UNLESS SPECIFIED

DIFFERENTLY.

Crack Location in the Mid Fan Shaft

Figure 5

August 17, 2012 GEnx-1B S/B 72-0107

Revision 02, September 14, 2012 PAGE 22

GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.
ENGINE - Mid Fan Shaft Assembly (72-58-00) - Inspection of Mid Fan Shaft

1369700-00

1

2 3 4

3 2 1 4

A

B

A

INSPECTION COVERAGE

TRANDUCER #1 - UPPER CASTELLATION - RIGHT SIDE

TRANDUCER #2 - BOTTOM CASTELLATION

TRANDUCER #3 - UPPER CASTELLATION - LEFT SIDE

TRANDUCER #4 - UPPER CASTELLATION - CENTER

TRANSDUCER

SWITCHBOX

1

2 3

4

B

INSPECTION FIXTURE

Inspection Fixture

Figure 6

August 17, 2012 GEnx-1B S/B 72-0107

Revision 02, September 14, 2012 PAGE 23

GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.
ENGINE - Mid Fan Shaft Assembly (72-58-00) - Inspection of Mid Fan Shaft

1369701-00

FIRST DELAY MULTIPLE

SECOND DELAY MULTIPLE

THIRD DELAY 

MULTIPLE

Delay Multiples

Figure 7

August 17, 2012 GEnx-1B S/B 72-0107

Revision 02, September 14, 2012 PAGE 24

GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.
ENGINE - Mid Fan Shaft Assembly (72-58-00) - Inspection of Mid Fan Shaft

1369702-00

SECOND DELAY MULTIPLE

THIRD DELAY 

MULTIPLE

Positioning of Delay Multiples

Figure 8

August 17, 2012 GEnx-1B S/B 72-0107

Revision 02, September 14, 2012 PAGE 25

GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.
ENGINE - Mid Fan Shaft Assembly (72-58-00) - Inspection of Mid Fan Shaft

1369703-00

SIDE DRILL HOLE RESPONSE 

SET TO 80% STANDARD

Transducer 2 Sensitivity

Figure 9

August 17, 2012 GEnx-1B S/B 72-0107

Revision 02, September 14, 2012 PAGE 26

GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.
ENGINE - Mid Fan Shaft Assembly (72-58-00) - Inspection of Mid Fan Shaft

1369704-00

STANDARD BACK SURFACE

RESPONSE AT CALIBRATION 

+ 3dB 80% OR GREATER

Transducer 1,3 and 4 Sensitivity

Figure 10

August 17, 2012 GEnx-1B S/B 72-0107

Revision 02, September 14, 2012 PAGE 27

GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.
ENGINE - Mid Fan Shaft Assembly (72-58-00) - Inspection of Mid Fan Shaft

1369705-01

GATE 3.2-5.0

THRESHOLD 30%

Transducer 2

Figure 11

August 17, 2012 GEnx-1B S/B 72-0107

Revision 02, September 14, 2012 PAGE 28

GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.
ENGINE - Mid Fan Shaft Assembly (72-58-00) - Inspection of Mid Fan Shaft

1369706-00

GATE 5.5 - 7.0

THRESHOLD 30%

Gate - Transducer 1,3,4

Figure 12

August 17, 2012 GEnx-1B S/B 72-0107

Revision 02, September 14, 2012 PAGE 29

GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.
ENGINE - Mid Fan Shaft Assembly (72-58-00) - Inspection of Mid Fan Shaft

FORWARD

FAN SHAFT

(01-170, 72-24-00)

MID FAN

SHAFT

(01-010)

FAN ROTOR DISK

(01-050, 72-22-00)

NOTE:

ALL IPC REFERENCES FROM 

72-58-00 UNLESS SPECIFIED

DIFFERENTLY. 1369707-00

Engine Access

Figure 13

August 17, 2012 GEnx-1B S/B 72-0107

Revision 02, September 14, 2012 PAGE 30

GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.
ENGINE - Mid Fan Shaft Assembly (72-58-00) - Inspection of Mid Fan Shaft

GAIN

RANGE

VEL

DISPLAY DELAY

PROBE DELAY

FREQUENCY

REJECT

RECTIFICATION

DUAL

PULSER TYPE

PULSER ENERGY

DAMPING

VOLTAGE

PRF MODE

50 dB

5.000

0.2323 in/us

0.00

0.00

10 MHz

0%

FULLWAVE

OFF

SPIKE

LOW

50 OHM

HIGH

AUTO LOW 400 HZ

USM GO

TABLE 1. BASIC INSTRUMENT SETTINGS.

MAIN MENU

FILE NAME

ACTION

REPORT

IMAGE IN REPORT

PARAM IN REPORT

VIDEO

SOURCE/DEST

CONFIG2

FUNCTION1

FUNCTION2

FMS

STORE REPORT

YES

YES

SD CARD

FREEZE/NONE

NONE/COPY

1369501-00

Preliminary Instrument Settings

Figure 14

August 17, 2012 GEnx-1B S/B 72-0107

Revision 02, September 14, 2012 PAGE 31

GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.
ENGINE - Mid Fan Shaft Assembly (72-58-00) - Inspection of Mid Fan Shaft

FORM 2194-1 CALIBRATION AND INSPECTION LOG

DATE: SITE:

ENGINE SN INSPECTOR

INSTRUMENT S/N INSPECTION FIXTURE SN

STANDARD S/N:

CASTELLATION TRAN 2 TRANS 1 TRANS 3 TRANS 4 COMMENTS

1

2

3

4

5

6

7

8

9

10

11

12

13

14

15

16

POST CALIBRATION: ACCEPT / REJECT 

DISPOSITION: ACCEPT / REJECT (CIRCLE ONE)

INSPECTOR:

COMMENTS:

DATE:

FILE NAME

INSPECTION GAIN 

TRANS 2 (CAL)

INSPECTION GAIN 

TRANS 1/3/4 

CAL +3 dB

RANGE

VEL

DISPLAY DELAY

PROBE DELAY

1369502-00

Form 2194-1 - Calibration and Inspection Log

Figure 15

August 17, 2012 GEnx-1B S/B 72-0107

Revision 02, September 14, 2012 PAGE 32

GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.