Fan Removal

e
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
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
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GE AIRCRAFT ENGINES
GE90
TRAINING MANUAL
THIS PAGE INTENTIONALLY LEFT BLANK
EFFECTIVITY
B777/GE90-110B, -115B
71-00-05
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GE AIRCRAFT ENGINES
GE90
TRAINING MANUAL
This publication is for TRAINING PURPOSES ONLY. This information is accurate at the time of compilation; however, no
update service will be furnished to maintain accuracy. For authorized maintenance practices and specifications, consult the
pertinent Maintenance Publication.
This product is considered GE Aircraft Engines technical data information and therefore is exported under U.S. Government
Export License Regulations. It is issued to the user under specific conditions that; the contained data, or it's product may not
be resold, diverted, transferred, trans-shipped, re-exported, or used in any other country without prior written approval of the
U.S. Government.
Proprietary Information Notice
The information contained in this document is disclosed in confidence. It is the property of GE and shall not be used (except
for evaluation), disclosed to others, or reproduced without the expressed written consent of GE. If consent is given for
reproduction in whole or in part, this notice shall appear on any such reproduction, in whole or in part. The foregoing is subject
to any rights the U.S. Government may have acquired as such information.
Copyright 2005 GE Aircraft Engines
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GE AIRCRAFT ENGINES
GE90
TRAINING MANUAL
EFFECTIVITY
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GE AIRCRAFT ENGINES
GE90
TRAINING MANUAL
TABLE OF CONTENTS
Section
Topic
Revised
Page Numbers
1.
Introduction
Table of Contents ........................................................................ Sep/05 ................................ 1 - 5
Acronyms and Abbreviations ..................................................... Sep/05 ................................ 6 - 7
Engine General ............................................................................ Sep/05 ................................ 8 - 9
Fan Stator Module Removal/Installation Introduction .............. Sep/05 ............................ 10 - 12
2.
Fan Stator Module Removal/Installation - Equipment .................... Sep/05 .............................. 1 - 18
3.
Fan Stator Module Removal/Installation - Engine Preparation ..... Sep/05 .............................. 1 - 56
4.
Fan Stator Module R & I - 9C6030 Transfer System ....................... Sep/05 .............................. 1 - 14
5.
Replacement Engine Test ................................................................ Sep/05 ................................ 1 - 4
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GE AIRCRAFT ENGINES
GE90
TRAINING MANUAL
EFFECTIVITY
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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
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GE AIRCRAFT ENGINES
GE90
TRAINING MANUAL
ENGINE GENERAL
The GE90 has been designed to power the BOEING 777
and future airplanes. With an initial thrust of 76,000 lbs it
has a growth capability up to 115,000 lbs ( and more ).
Type of engine:
The GE90 is an ultrahigh bypass (9:1), variable stator,

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.
Rotation: (both rotors)
The 75K to 115K+ lbs thrust family of engines is designed

to provide 10% improvement in specific fuel consumption
(SFC), and 33% lower emissions over previous
commercial turbofan engines. In addition, its reduced
noise level permits operation at the most noise sensitive
airports in the world.
The specific fuel consumption (SFC) improvement is
achieved through a higher efficiency engine cycle. A
higher overall pressure ratio than current engines gives
higher thermal efficiencies, while the higher bypass ratio
(BPR) provides improved propulsion efficiency.
The GE90 is designed for ease of maintainability and high
overall system reliability. Many of the components were
derived from proven designs on existing engines. This
derivative heritage provides a sound foundation for the
components and systems of the GE90.
EFFECTIVITY
B777/GE90-110B, -115B
Arrangement:
Turbofan engine
Two spool axial airflow
Clockwise (AFT looking
Forward)
Compressors:
- Fan:
- Booster:
- High pressure compressor:
Combustion chamber:
Turbines:
- High pressure turbine:
- Low pressure turbine:
Single stage
Four stages
Nine stages
Dual-dome annular
Two stages
Six stages
Dimensions:
- Engine (no EBU or inlet):
- Nominal length:
287.36 inches (7.300 m)
- Nominal width:
134.86 inches (3.425 m)
- Nominal weight (dry):
18,291 lbs (8314 kg)
- Powerplant (with EBU and inlet):
- Nominal length:
323.24 inches (8.210 m)
- Nominal width:
166.46 inches (4.228 m)
- Nominal weight (dry):
18,982 lbs (8628 kg)
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GE90
TRAINING MANUAL
FAN DIAMETER = 128 IN. (3.524

2 M)
FAN STATOR DIAMETER = 134.86 IN. (3.425 M)
POWER PLANT HEIGHT = 166.46 IN. (4.228 M)
GE AIRCRAFT ENGINES
SPARE ENGINE LENGTH = 190.84 IN. (4.847 M)

INSTALLABLE SPARE ENGINE LENGTH = 287.36 IN. (7.300 M)
POWERPLANT OVERALL LENGTH = 323.24 IN. (8.210 M)
GE90 PROPULSION SYSTEM

EFFECTIVITY
B777/GE90-110B, -115B
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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, the engine is designed around the principle
of the fan stator module removal into two parts:
- The fan stator module
- 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.
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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

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GE90
TRAINING MANUAL
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2. Equipment
GE AIRCRAFT ENGINES
GE90
TRAINING MANUAL
FAN STATOR MODULE REMOVAL/INSTALLATION - EQUIPMENT
Objectives:
At the completion of this section a student should be able to:
... identify the tooling required for fan stator module removal/installation
EFFECTIVITY
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GE AIRCRAFT ENGINES
GE90
TRAINING MANUAL

The equipment to do the fan stator module removal is as
follows:
- 9C6025 shipping and installation stand
- 9C6030 fan stator module transfer system
- 9C6014 personnel stand
- 9C1202 fan blade spacer removal tool
or 9C3001 fan blade spacer removal tool
- 9C6031 component shipping container
- 9C6028 fan blade shipping container
EFFECTIVITY
B777/GE90-110B, -115B
The equipment to do the fan stator module installation is

as follows:
- 9C6025 shipping and installation stand
- 9C6030 fan stator module transfer system
- 9C6014 personnel stand
- 9C1277 guide pin set
- 9C6031 component shipping container
- 9C6028 fan blade shipping container
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GE AIRCRAFT ENGINES
GE90
FAN STATOR
MODULE
TRAINING MANUAL
ENGINE PROPULSOR
9C6025 SHIPPING AND

INSTALLATION STAND
9C6030 FAN STATOR

MODULE TRANSFER
CARRIAGE

EFFECTIVITY
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GE AIRCRAFT ENGINES
GE90
TRAINING MANUAL
9C6025 INSTALLATION AND SHIPPING STAND

The 9C6025 stand allows:
- the removal and installation of the engine to the
airplane wing.
- the removal and installation of the fan stator case
from the propulsor.
- the air and ground transportation of the propulsor.
It is made up of two main parts:
- the cradle
- the base.
Two aft cradle to engine support adapters and two
forward cradle to engine support adapters allow for the
support of the propulsor or engine.
There are hydraulic jacks near each wheel of the stand.
The hydraulic jacks are controlled from a central hydraulic
hand pump located on the left side of the stand.
There is a hand operated hyraulic pump attached to the
base for raising and lowering of the cradle on the base.
Forklift tubes are positioned within the base and usable
from either side of the stand.
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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

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GE AIRCRAFT ENGINES
GE90
TRAINING MANUAL
9C6030 FAN STATOR MODULE TRANSFER SYSTEM

The 9C6030 fan stator module transfer system supports
the fan stator module. 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.
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.
The 9C6030 has two Aft Adapters, two Forward
Adapters, two 94B Forward Adapter Plates and two Side
Frames. All four wheels of the side frames are
individually adjustable up and down.
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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
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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:
- Place the detail pin in the bolt hole of the fan blade
spacer.
- move the slide hammer aft and forward to remove
the fan blade spacer.
EFFECTIVITY
B777/GE90-110B, -115B
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GE AIRCRAFT ENGINES
GE90
TRAINING MANUAL

EFFECTIVITY
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GE AIRCRAFT ENGINES
GE90
TRAINING MANUAL
FAN BLADE SPACER REMOVAL/INSTALLATION

TOOLS
remove the fan blade spacers.
- 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.
EFFECTIVITY
B777/GE90-110B, -115B
71-00-05
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Sep 05
GE AIRCRAFT ENGINES
GE90
TRAINING MANUAL
9C3001FAN BLADE SPACER REMOVAL TOOL

EFFECTIVITY
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71-00-05
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Sep 05
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. When assembled, the 9C6014 personnel stand
provide steps for the mechanic to reach the upper bolts of
the fan stator module forward bolt flange.
Forklift tubes are positioned within the stand and usable
from the front side of the stand.
EFFECTIVITY
B777/GE90-110B, -115B
71-00-05
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Sep 05
GE AIRCRAFT ENGINES
GE90
TRAINING MANUAL
9C6014
STAND
B

EFFECTIVITY
B777/GE90-110B, -115B
71-00-05
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Sep 05
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.
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
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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

EFFECTIVITY
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Sep 05
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, in a safe and secure manner.
Each is made up of two main parts:
- the fiberglass cover
- the metal base assembly.
A document storage receptacle and a view port are
provided.
Hoist rings are built into the cover for removal
and installation of the cover. Forklift tubes are positioned
within the base and usable from either side of the unit.
- fan blade retainers

- spinner
- support ring
- acoustic panels
- air bleed deflector panels
- blankoff panels
- lower bifurcation module
- drain module
- center vent tube extension
- starter air duct
- booster anti-ice tubes
- booster splitter fairing.
9C6028 Fan Blade Shipping Container holds:
- fan blades
The interior is divided in several areas to ensure proper

support of items during all container motions. The
container has been designed to ship the following
items:
9C6031 Components Shipping Container holds:
- fan blade platforms
- fan blade spacers
- dovetail key
EFFECTIVITY
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Sep 05
GE AIRCRAFT ENGINES
GE90
TRAINING MANUAL
9C6031
CONTAINER
FIBERGLASS
COVER
FAN
BLADES
FIBERGLASS
COVER
BASE
BASE
9C6028
CONTAINER
BASE
9C6031 FAN BLADES, SPINNER AND

COMPONENTS SHIPPING CONTAINER
EFFECTIVITY
B777/GE90-110B, -115B
9C6028 FAN BLADE SHIPPING CONTAINER
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GE AIRCRAFT ENGINES
GE90
TRAINING MANUAL
EFFECTIVITY
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Sep 05
3. Engine Preparation
GE AIRCRAFT ENGINES
GE90
TRAINING MANUAL
FAN STATOR MODULE REMOVAL/INSTALLATION - ENGINE PREPARATION
Objectives:
... identify the engine items removed for fan stator module removal/installation
EFFECTIVITY
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Sep 05
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.
Complete the engine preparation after the fan stator

module as been installed on the engine propulsor.
Note: The steps of engine preparation can be done with

the engine on wing or in the installation/shipping stand.
Note: The steps of engine preparation can be done with

the engine in the installation/shipping stand or on wing.
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:
- drain the oil from the engine, IDG and Backup

Generator
- remove the drain and service module assembly
- disconnect the electrical harnesses from the fan stator
assembly
- remove the lower hydraulic bifurcation assembly
- remove the blank off panels
- remove the upper and lower fillet fairings
- remove the air bleed defector panels
- remove the upper and lower bifurcation bridges
- disconnect the seal pressurization and oil tank vent
tube
- disconnect the EAI duct
- remove the spinner and support ring
- remove the fan blade platforms
- remove the fan blades and mounting hardware
- remove the acoustic panels
- remove the booster anti-ice tubes and splitter fairing
EFFECTIVITY
B777/GE90-110B, -115B
- install the splitter fairing and booster anti-ice tubes

- install the acoustic panels
- install the fan blades and mounting hardware
- install the fan blade platforms
- install the support ring and spinner
- connect the EAI duct
- connect the seal pressurization and oil tank vent tube
- install the upper and lower bifurcation bridges
- install the bleed air deflector panels
- install the upper and lower fillet fairings
- install the blank off panels
- install the lower hydraulic bifurcation assembly
- connect the electrical harnesses to the fan stator
module assembly
- install the drain and service module assembly
- fill the oil of the engine, IDG and Backup Generator.
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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
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Sep 05
GE AIRCRAFT ENGINES
GE90
TRAINING MANUAL
ENGINE OIL (CHANGE) SERVICING

WARNING: DO NOT LET HOT OIL GET ON YOU. HOT
OIL CAN BURN YOU.
The oil tank is drained by using the two quick disconnect
ports in the oil supply and scavenge return lines and a
bucket.
The drain ports are located in the oil supply and scavenge
returns lines at the 6:00 position off the fan case.
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 manual fill port cap has a dipstick attached to it. 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:

- connect locally manufactured drain tube to the drain
ports and catch the oil (11 gallons or 42 liters) in a
container.
- the 1/2 mark means that 1/2 gallon (2 quarts) needs to

be added.
- the 3/4 mark means that 3/4 gallon (3 quarts) needs to
be added
- the 4/4 mark means that 1 gallon (4 quarts) needs to
be added
- the 5/4 mark means that 1.25 gallon (5 quarts) needs
to be added.
Note: There is no need to service the oil tank unless it is
at or below the 4/4 mark - 1 gallon or 4 quarts low.
EFFECTIVITY
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GE AIRCRAFT ENGINES
GE90
TRAINING MANUAL
ENGINE OIL (CHANGE) SERVICING

EFFECTIVITY
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GE AIRCRAFT ENGINES
GE90
TRAINING MANUAL
INTEGRATED DRIVE GENERATOR - SERVICING (OIL

CHANGE)
OIL CAN BURN YOU.
The IDG oil is serviced by:

- installing the IDG case drain plug
The Integrated Drive Generator is located on the left, aft

face of the accessory gearbox.
- pressure servicing the IDG through the remote service

lines.
IDG Oil Servicing:

- attaching a hose to the overfill remote service line to
relieve any pressure in the system.
- removing the IDG case drain plug and catching the oil
(1.5 gallons or 6 liters) in a container.
The generator remote oil service lines are attached to the
aft side of the engine drain lines.
EFFECTIVITY
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GE AIRCRAFT ENGINES
GE90
TRAINING MANUAL
INTEGRATED DRIVE GENERATOR - SERVICING (OIL CHANGE)

EFFECTIVITY
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GE AIRCRAFT ENGINES
GE90
TRAINING MANUAL
BACKUP GENERATOR - SERVICING (OIL CHANGE)

OIL CAN BURN YOU.
The Backup Generator is located on the left, forward face
of the accessory gearbox.
The Backup Generator oil is serviced by:

- installing the Backup Generator case drain plug
- pressure servicing the Backup Generator through the
remote service lines.
Backup Generator Oil Draining:

- attach a hose to the overfill remote service line to
relieve any pressure in the system.
- remove the Backup Generator case drain plug and
catching the oil (1 gallon or 3.7 liters) in a container.
The generator remote oil service lines are attached to the
aft side of the engine drain lines.
EFFECTIVITY
B777/GE90-110B, -115B
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Sep 05
GE AIRCRAFT ENGINES
GE90
TRAINING MANUAL
BACKUP GENERATOR - SERVICING (OIL CHANGE)

EFFECTIVITY
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12-22-09
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Sep 05
GE AIRCRAFT ENGINES
GE90
TRAINING MANUAL
DRAIN AND SERVICE MODULE ASSEMBLY

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.
The drain module takes engine accessory gearbox drive
pad, fuel driven actuator and fuel driven valve internal
leakage overboard.
The service module contains the engine oil lines, air lines
and electrical harnesses that run between the fan stator and
propulsor.
- install the drain assembly

- connect the eight drain tubes
- connect the IDG and Backup Generator remote
service lines
- connect the manual override flexible cable from the
starter
- connect the forward lower fire detector.
Drain Module Removal:

- disconnect the forward lower fire detector
- disconnect the manual override flexible cable from the
starter
- disconnect the IDG and Backup Generator remote
service lines
- disconnect the eight drain tubes
- remove the drain assembly.
EFFECTIVITY
B777/GE90-110B, -115B
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Sep 05
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
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Jan05
03
Sep
GE AIRCRAFT ENGINES
GE90
TRAINING MANUAL
EFFECTIVITY
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Sep 05
MANUAL OVERRIDE
FLEXIBLE CABLE
GE AIRCRAFT ENGINES
GE90
TRAINING MANUAL
DRAIN AND SERVICE MODULE ASSEMBLY REMOVAL/INSTALLATION (SHEET 2)

EFFECTIVITY
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Sep 05
GE AIRCRAFT ENGINES
GE90
TRAINING MANUAL
ELECTRICAL HARNESS REMOVAL/INSTALLATION

Electrical Harness Removal:
- disconnect the electrical harness connectors at the
bottom of the fan case
- remove the heatshield blanket
- remove the bottom of the fire seal
- remove the electrical connectors from the springs clips
and quarter turn clamps. Tie the electrical
harnesses out of the way on the propulsor.
Electrical Harness Installation:

- install the electrical harnesses into the springs clips
and quarter turn clamps
- connect the electrical harness connectors at the
bottom of the fan case
- install the bottom of the fire seal
- install the heatshield blanket.
EFFECTIVITY
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Sep 05
GE AIRCRAFT ENGINES
GE90
TRAINING MANUAL
ELECTRICAL HARNESSES REMOVAL/INSTALLATION (SHEET 1)

EFFECTIVITY
B777/GE90-110B, -115B
71-00-05
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Sep 05
GE AIRCRAFT ENGINES
GE90
TRAINING MANUAL
EFFECTIVITY
B777/GE90-110B, -115B
71-00-05
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Sep 05
GE AIRCRAFT ENGINES
GE90
TRAINING MANUAL

EFFECTIVITY
B777/GE90-110B, -115B
71-00-05
Page 3-17
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

EFFECTIVITY
B777/GE90-110B, -115B
71-00-05
Page 3-18
Sep 05
GE AIRCRAFT ENGINES
GE90
TRAINING MANUAL
1134065-05-A

EFFECTIVITY
B777/GE90-110B, -115B
71-00-05
Page 3-19
Sep 05
GE AIRCRAFT ENGINES
GE90
TRAINING MANUAL
LOWER HYDRAULIC BIFURCATION ASSEMBLY

Lower Hydraulic Bifurcation Assembly Removal:
- 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
- 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
- remove the lower hydraulic bifurcation assembly.
Lower Hydraulic Bifurcation Assembly Installation:
- install the lower hydraulic bifurcation assembly
- connect the oil tank and oil return tubes in front of the
the upper end of the service module
- connect the eight pressure air tubes in front of the
the upper end of the service module.
EFFECTIVITY
B777/GE90-110B, -115B
71-00-05
Page 3-20
Sep 05
GE AIRCRAFT ENGINES
GE90
TRAINING MANUAL
LOWER HYDRAULIC BIFURCATION ASSEMBLY REMOVAL/INSTALLATION (SHEET 1)

EFFECTIVITY
B777/GE90-110B, -115B
71-00-05
Page 3-21
Sep 05
GE AIRCRAFT ENGINES
GE90
TRAINING MANUAL
EFFECTIVITY
B777/GE90-110B, -115B
71-00-05
Page 3-22
Sep 05
GE AIRCRAFT ENGINES
GE90
TRAINING MANUAL

EFFECTIVITY
B777/GE90-110B, -115B
71-00-05
Page 3-23
Sep 05
GE AIRCRAFT ENGINES
GE90
TRAINING MANUAL

EFFECTIVITY
B777/GE90-110B, -115B
71-00-05
Page 3-24
Sep 05
GE AIRCRAFT ENGINES
GE90
TRAINING MANUAL

EFFECTIVITY
B777/GE90-110B, -115B
71-00-05
Page 3-25
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.
To help during installation, the blank off panel installation
positions are etched into the panels (Example - POS 1&5).
The panels are numbered from aft looking forward starting
at 12:00 o'clock of the engine.
Blank Off Panel Removal:
- remove the screws from the blank off panels and
remove the panels
Blank Off Panel Installation:
- install the blank off panels by position number and
install the screws.
EFFECTIVITY
B777/GE90-110B, -115B
71-00-05
Page 3-26
Sep 05
GE AIRCRAFT ENGINES
GE90
TRAINING MANUAL
BLANK OFF PANELS REMOVAL/INSTALLATION

EFFECTIVITY
B777/GE90-110B, -115B
71-00-05
Page 3-27
Sep 05
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.
Fillet Fairing Removal:
- remove the two different length screws of the fillet
fairings and remove the fairings
Fillet Fairings Installation:
- install the fillet fairings and the two different length
screws.
EFFECTIVITY
B777/GE90-110B, -115B
71-00-05
Page 3-28
Sep 05
GE AIRCRAFT ENGINES
GE90
TRAINING MANUAL
FILLET FAIRINGS REMOVAL/INSTALLATION

EFFECTIVITY
B777/GE90-110B, -115B
71-00-05
Page 3-29
Sep 05
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 Panels are removed to get access
to the fan stator module aft mount bolts.
To help during installation, the bleed air deflector panel
installation positions are etched into the panels (Example POS 5&10). The panels are numbered from aft looking
forward starting at 12:00 o'clock of the engine.
Bleed Air Deflector Panel Removal:
- remove the screws from the bleed air deflector panels
and remove the panels.
Bleed Air Deflector Panel Installation:
- install the bleed air deflector panels and install the
screws.
EFFECTIVITY
B777/GE90-110B, -115B
71-00-05
Page 3-30
Sep 05
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,
RIGHT SIDE IS OPPOSITE
SCREW
(29 LOCATIONS)
BLEED AIR DEFLECTOR PANELS REMOVAL/INSTALLATION

EFFECTIVITY
B777/GE90-110B, -115B
71-00-05
Page 3-31
Sep 05
GE AIRCRAFT ENGINES
GE90
TRAINING MANUAL
LOWER BIFURCATION BRIDGE

The Lower Bifurcation Bridge is located at the top of the
lower bifurcation firewall.
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
- remove the lower bifurcation bridge.
Lower Bifurcation Bridge Installation:
Note: Clean the lower bifurcation bridge using the Aircraft
Maintenance Manual procedures before installation.
- install the lower bifurcation bridge.
- install the nuts and bolts that attach the lower
- apply sealant between the contact surfaces.
EFFECTIVITY
B777/GE90-110B, -115B
71-00-05
Page 3-32
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, -115B
71-00-05
Page 3-33
Sep 05
GE AIRCRAFT ENGINES
GE90
TRAINING MANUAL
UPPER BIFURCATION BRIDGE

The Upper Bifurcation Bridge is located at the bottom of
the upper bifurcation firewall.
The upper bifurcation bridge must be removed to allow for
fan stator module removal.
Upper Bifurcation Bridge Removal:
- remove sealant between the contact surfaces
- remove the nuts and bolts that attach the upper
- remove upper bifurcation bridge.
Upper Bifurcation Bridge Installation:
Note: Clean the upper bifurcation bridge using the Aircraft
Maintenance Manual procedures before installation.
- install the upper bifurcation bridge.
- install the nuts and bolts that attach the upper
- apply sealant between the contact surfaces.
EFFECTIVITY
B777/GE90-110B, -115B
71-00-05
Page 3-34
Sep 05
GE AIRCRAFT ENGINES
GE90
TRAINING MANUAL
LOWER AND UPPER BIFURCATION BRIDGES REMOVAL/INSTALLATION (SHEET 2)

EFFECTIVITY
B777/GE90-110B, -115B
71-00-05
Page 3-35
Sep 05
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.
These tubes must be disconnected to allow for fan stator
module separation.
Seal Pressurization and Oil Tank Ventilation Tube
Removal:
- disconnect the seal pressurization and oil tank
ventilation tubes.
Seal Pressurization and Oil Tank Ventilation Tube
Installation:
- connect the seal pressurization and oil tank ventilation
tubes.
EFFECTIVITY
B777/GE90-110B, -115B
71-00-05
Page 3-36
Sep 05
GE AIRCRAFT ENGINES
GE90
TRAINING MANUAL
SEAL PRESSURIZATION AND OIL TANK VENTILATION TUBES REMOVAL/INSTALLATION

EFFECTIVITY
B777/GE90-110B, -115B
71-00-05
Page 3-37
Sep 05
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.
The engine anti-ice duct must be disconnected to allow for
fan stator module separation.
Engine Anti-Ice Duct Removal:
- disconnect the engine anti-ice duct.
Engine Anti-Ice Duct Installation:
- connect the engine anti-ice duct.
EFFECTIVITY
B777/GE90-110B, -115B
71-00-05
Page 3-38
Sep 05
GE AIRCRAFT ENGINES
GE90
TRAINING MANUAL
ENGINE ANTI-ICE DUCT REMOVAL/INSTALLATION

EFFECTIVITY
B777/GE90-110B, -115B
71-00-05
Page 3-39
Sep 05
GE AIRCRAFT ENGINES
GE90
TRAINING MANUAL
FAN BLADE REMOVAL / INSTALLATION

The spinner is attached to the front of the fan disk.
- Align the "1" of the spinner with number "1" on the

support ring to align the offset bolt holes.
To remove the spinner do the following:

- Remove the 22 axial mount bolts on the spinner and
remove the spinner.
NOTE: The number "1" is marked on the front of the

support ring and on the spinner.
NOTE: The 44 radial screws on the outer diameter of

the spinner - and on either side of each axial mount bolt are fan assembly balance screws.
- Remove the 22 bolts and the support ring.
To install the spinners do the following:
- Align the support ring number "1"s with the number
"1"s on the fan disk. Install the 22 bolts.
Note: The number "1" is marked on the backside and front
side of two bolt flanges of 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. The offset bolt
hole is marked with an "O". Alignment of the number "1"s
will align the offset bolt holes of the support ring and fan
disk.
EFFECTIVITY
B777/GE90-110B, -115B
71-00-05
72-21-01
Page 3-40
Sep 05
GE AIRCRAFT ENGINES
GE90
TRAINING MANUAL
SEE B
SPINNER
OFFSET
BOLT
HOLE
FORWARD
LOOKING AFT
SUPPORT
RING OFFSET
BOLT HOLE
SPINNER CONE (ONE PIECE) REMOVAL / INSTALLATION

EFFECTIVITY
B777/GE90-110B, -115B
72-21-01
71-00-05
Page 3-41
Sep 05
GE AIRCRAFT ENGINES
GE90
TRAINING MANUAL
FAN BLADE REMOVAL

The twenty-two fan blades are located in the forward end of
the engine.
The fan blades must be removed to allow for fan stator
module separation.
NOTE: The blades are numbered counter clockwise when
you are facing them. The number "1" is engraved on the
forward face of the fan disk, on either side of the number
one blade slot.
Note: The fan blade platforms and fan blades are balance
critical. Before removal use a felt tip pen and tape to mark
the location of the fan blade platforms, fan blades and other
hardware.
NOTE: A rubber seal around the platform creates a tight fit

between the blades holding the platform in place during the
assembly process. The platforms are secured in place by
the spinner.
- Remove the bolt securing the spacer and the
retainer together.
- Remove the spacer using the fan blade spacer
removal tool (9C1202) or hydraulic removal tool
(9C3001)
spacer
- Number the blades and platforms before removal.

- Turn the fan assembly counterclockwise to put the first
fan blade to be removed at the 6 o'clock position.
- move the slide hammer aft and forward to remove the

fan blade spacer.
- Remove the dovetail key from the fan disk slot.
- Remove the blade platform on either side of the

blade to be removed. Record their original position,
to be sure to install them at the same location.
- Remove the retainer from the fan disk slot.

- Remove the fan blade from the fan disk slot.
Note: Do not remove the fan disk shims.
EFFECTIVITY
B777/GE90-110B, -115B
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
72-21-02
71-00-05
Page 3-43
Sep 05
GE AIRCRAFT ENGINES
GE90
TRAINING MANUAL

remove the fan blade spacer.
spacer
- move the slide hammer aft and forward to remove the
fan blade spacer.
Fan Blade Installation:
- 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, -115B
71-00-05
72-21-02
Page 3-44
Sep 05
GE AIRCRAFT ENGINES
GE90
TRAINING MANUAL
FAN BLADE SPACER REMOVAL TOOL

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

TOOLS
remove the fan blade spacers.
- 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.
EFFECTIVITY
B777/GE90-110B, -115B
71-00-05
Page 3-46
Sep 05
GE AIRCRAFT ENGINES
GE90
TRAINING MANUAL
FAN BLADE SPACER REMOVAL TOOL (9C3001)

EFFECTIVITY
B777/GE90-110B, -115B
71-00-05
Page 3-47
Sep 05
GE AIRCRAFT ENGINES
GE90
TRAINING MANUAL
FAN BLADE INSTALLATION

Install the fan blades and fan blade platforms at their
original locations (for balancing purposes).
- Turn the fan assembly counterclockwise to put the
fan blade slot for the fan blade to be installed at the
6 o'clock position.
Note: Be sure to clean and lubricate the fan blades and fan
disk before installation.
- Install the fan blade into the fan disk blade slot.
- Install the bolt that holds the retainer and the spacer
together.
- Install the blade platforms on either side of the fan
blade. Insert the rear of the platform under the
booster flange, then push the forward part of the
platform toward the fan disk.
NOTE: A rubber seal around the platform creates a tight fit
between the blades holding the platform in place during the
assembly process. The platforms are secured in place by
the spinner.
- Install the blade retainer into the fan disk retainer

slot.
- Install the dovetail key into the fan disk blade slot.
- Insert the fan blade spacer between the fan blade
and the dovetail key.
- Hit the spacer with a plastic mallet until fully
installed or use the hydraulic installation tool
(9C3001).
EFFECTIVITY
B777/GE90-110B, -115B
71-00-05
72-21-02
Page 3-48
Sep 05
GE AIRCRAFT ENGINES
GE90
TRAINING MANUAL
FAN BLADE INSTALLATION

EFFECTIVITY
B777/GE90-110B, -115B
72-21-02
71-00-05
Page 3-49
Sep 05
GE AIRCRAFT ENGINES
GE90
TRAINING MANUAL
ACOUSTIC PANEL REMOVAL/INSTALLATION

The Acoustic Panels are located around the fan booster.
The acoustic panels are removed to get access to the fan
stator module forward mount bolts.
There are six acoustic panels.
Acoustic Panel Removal:
- Remove the screws that attach the acoustic panels to
the fan booster
- remove the acoustic panels.
Acoustic Panel Installation:

- install the acoustic panels.
- Install the screws that attach the acoustic panels to the
fan booster.
EFFECTIVITY
B777/GE90-110B, -115B
71-00-05
Page 3-50
Sep 05
GE AIRCRAFT ENGINES
GE90
TRAINING MANUAL
FAN STATOR
MODULE (OGVS)
ACOUSTIC PANEL REMOVAL/INSTALLATION

EFFECTIVITY
B777/GE90-110B, -115B
71-00-05
Page 3-51
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.
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 Fairing Removal:
- Remove the bolts that attach the booster splittler
fairing to the low pressure compressor leading
edge.
- remove the booster splitter fairing.
Booster Splitter Faiting Installation:

- 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, -115B
71-00-05
Page 3-52
Sep 05
GE AIRCRAFT ENGINES
GE90
TRAINING MANUAL
BOOSTER
SPLITTER
FAIRING
FAN
BOOSTER
BOOSTER
SPLITTER
FAIRING
FAN STATOR
MODULE (OGVS)
SEE B
SCREW
(50 LOCATIONS)
* SEE C
A-A
BOOSTER SPLITTER FAIRING

EFFECTIVITY
B777/GE90-110B, -115B
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
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
71-00-05
Page 3-55
Sep 05
GE AIRCRAFT ENGINES
GE90
TRAINING MANUAL
EFFECTIVITY
B777/GE90-110B, -115B
71-00-05
Page 3-56
Sep 05
4. 9C6030 System
GE AIRCRAFT ENGINES
GE90
TRAINING MANUAL
FAN STATOR REMOVAL & INSTALLATION - 9C6030 TRANSFER SYSTEM
Objectives:
... identify the tooling required for fan stator module removal/installation
EFFECTIVITY
B777/GE90-110B, -115B
71-00-05
Page 4-1
Sep 05
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.
The fan stator module must be removed to perform a
normal engine change. The fan stator module can be
removed and installed with or without the inlet cowl
installed.
The fan stator module removal/installation, using the
9C6030 Transfer System, can be done with the engine in
the 9C6000 or 9C6025 Installation and Shipping Stands.
Note: If using9C6000 Installation and Shipping Stand
make sure that the fan hub frame mount support adapters
are installed first.
EFFECTIVITY
B777/GE90-110B, -115B
Fan Stator Module Removal:

- attach the left and right 9C6030P01 Forward
Adapters to the fan case flange.
- attach the left and right 9C6030 Aft Adapters to the
aft fan case ground handling mounts
- attach the left 9C6030 Side Frame to the left
Forward Adapter and Aft Adapter.
- attach the right 9C6030 Side Frame to the right
Forward Adapter and Aft Adapter.
Fan Stator Module Installation:

- install the 9C1277 guide pin set into the fan stator
module aft flange
71-00-05
Page 4-2
Sep 05
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, LEFT SIDE OPPOSITE)
FAN STATOR MODULE REMOVAL/INSTALLATION - 9C6030 TRANSFER SYSTEM

EFFECTIVITY
B777/GE90-110B, -115B
71-00-05
Page 4-3
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, RIGHT SIDE OPPOSITE)

EFFECTIVITY
B777/GE90-110B, -115B
71-00-05
Page 4-4
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, LEFT SIDE OPPOSITE)

EFFECTIVITY
B777/GE90-110B, -115B
71-00-05
Page 4-5
Sep 05
GE AIRCRAFT ENGINES
GE90
TRAINING MANUAL
EFFECTIVITY
B777/GE90-110B, -115B
71-00-05
Page 4-6
Sep 05
GE AIRCRAFT ENGINES
GE90
TRAINING MANUAL
FRAME HEIGHT
ADJUSTING
HANDLE
(4 LOCATIONS)

EFFECTIVITY
B777/GE90-110B, -115B
71-00-05
Page 4-7
Sep 05
GE AIRCRAFT ENGINES
GE90
TRAINING MANUAL
FAN STATOR MODULE REMOVAL/INSTALLATION 9C6030 TRANSFER SYSTEM (CONT.)

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, lubricate and torque fan stator module

flanges and bolts as stated in the Aircraft Maintenance
Manual.
- adjust the left 9C6030 side frame forward wheel

handle "down" until the wheel is off the ground.
- adjust the left 9C6030 side beam aft wheel handle
"down" until there is a gap between the Aft Adapter
Pad and the fan stator.
- 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
- adjust the 9C6030 Side Frame "up" one full turn of
the handle.
Fan Stator Bolt Removal:
- remove the bolts from the forward flange of the fan
stator module at the fan hub frame. Use the
9C6014 personnel stand as necessary.
- remove the bolts from the aft flange of the fan stator
module at the fan hub frame.
- move the 9C6030 and fan stator, by hand, away
from the propulsor.
EFFECTIVITY
B777/GE90-110B, -115B
- apply lubricant to the threads of the bolts.

- apply either zinc chromate primer or epoxy primer to
the fan hub frame flanges, the shank of the bolts
and to the bearing surface of the integral washers
on the bolts.
Note: Use the 9C6030 Side Frame wheels to adjust the
height of the fan module and move the 9C6030 side to
side, by hand, to adjust side clearance during installation.
- move the 9C6030 and fan stator, by hand, toward
the propulsor.
- install the bolts to the forward flange of the fan stator
module at the fan hub frame. Use the 9C6014
personnel stand as necessary.
- install the bolts to the aft flange of the fan stator
module at the fan hub frame.
71-00-05
Page 4-8
Sep 05
GE AIRCRAFT ENGINES
GE90
TRAINING MANUAL
A
B

EFFECTIVITY
B777/GE90-110B, -115B
71-00-05
Page 4-9
Sep 05
GE AIRCRAFT ENGINES
GE90
TRAINING MANUAL

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

EFFECTIVITY
B777/GE90-110B, -115B
71-00-05
Page 4-11
Sep 05
GE AIRCRAFT ENGINES
GE90
TRAINING MANUAL

The 9C1277 guide pin set is used align the fan stator
module bolt flanges onto the propulsor bolt flanges.
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.
When the fan stator and fan hub frame flanges are
together, remove the guide pins as the bolts are installed.
EFFECTIVITY
B777/GE90-110B, -115B
71-00-05
Page 4-12
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

EFFECTIVITY
B777/GE90-110B, -115B
71-00-05
Page 4-13
Sep 05
GE AIRCRAFT ENGINES
GE90
TRAINING MANUAL
EFFECTIVITY
B777/GE90-110B, -115B
71-00-05
Page 4-14
Sep 05
5. Engine Replacement Test
GE AIRCRAFT ENGINES
GE90
TRAINING MANUAL
REPLACEMENT ENGINE TEST
Objectives:
... identify the tests required for fan stator module removal/installation
EFFECTIVITY
B777/GE90-110B, -115B
71-00-05
Page 5-1
Sep 05
GE AIRCRAFT ENGINES
GE90
TRAINING MANUAL

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

EFFECTIVITY
B777/GE90-110B, -115B
71-00-00
71-00-05
Page 5-3
Sep 05
GE AIRCRAFT ENGINES
GE90
TRAINING MANUAL
EFFECTIVITY
B777/GE90-110B, -115B
71-00-05
Page 5-4
Sep 05

Fan Removal

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FAN STATOR REMOVAL/INSTALLATION

GE Aircraft Engine PROPRIETARY

GE90 Fan Stator Removal/Installation

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Fan Stator Module Removal/Installation - Equipment .................... Sep/05 .............................. 1 - 18

Fan Stator Module Removal/Installation - Engine Preparation ..... Sep/05 .............................. 1 - 56

Replacement Engine Test ................................................................ Sep/05 ................................ 1 - 4

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ABBREVIATIONS & ACRONYMS

Aft Looking Forward

The GE90 is an ultrahigh bypass (9:1), variable stator,

Rotation: (both rotors)

The 75K to 115K+ lbs thrust family of engines is designed

FAN DIAMETER = 128 IN. (3.524

FAN STATOR DIAMETER = 134.86 IN. (3.425 M)

POWER PLANT HEIGHT = 166.46 IN. (4.228 M)

SPARE ENGINE LENGTH = 190.84 IN. (4.847 M)

GE90 PROPULSION SYSTEM

FAN STATOR MODULE REMOVAL/INSTALLATION

9C6025 SHIPPING AND

9C6030 FAN STATOR

FAN STATOR MODULE REMOVAL/INSTALLATION EQUIPMENT

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FAN STATOR MODULE REMOVAL/INSTALLATION - EQUIPMENT

FAN STATOR MODULE REMOVAL/INSTALLATION EQUIPMENT

The equipment to do the fan stator module installation is

9C6025 SHIPPING AND

9C6030 FAN STATOR

FAN STATOR MODULE REMOVAL/INSTALLATION EQUIPMENT

9C6025 INSTALLATION AND SHIPPING STAND

TOW BAR STOW

9C6025 INSTALLATION AND SHIPPING STAND

9C6030 FAN STATOR MODULE TRANSFER SYSTEM

9C6030 FAN STATOR MODULE TRANSFER SYSTEM

9C1202 FAN BLADE SPACER REMOVAL TOOL

9C1202 FAN BLADE SPACER REMOVAL TOOL

FAN BLADE SPACER REMOVAL/INSTALLATION

9C3001FAN BLADE SPACER REMOVAL TOOL

9C6014 PERSONNEL STAND

9C6014 PERSONNEL STAND

9C1277 GUIDE PIN SET

AFT FAN STATOR

FAN STATOR MODULE

9C1277 GUIDE PIN

FORWARD FAN STATOR

FAN HUB FRAME

9C1277 GUIDE PIN SET

9C6031 SPINNER AND COMPONENTS SHIPPING

- fan blade retainers

The interior is divided in several areas to ensure proper

9C6031 FAN BLADES, SPINNER AND

9C6028 FAN BLADE SHIPPING CONTAINER

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FAN STATOR MODULE REMOVAL/INSTALLATION - ENGINE PREPARATION

ENGINE PREPARATION FOR FAN STATOR MODULE

Complete the engine preparation after the fan stator

Note: The steps of engine preparation can be done with

Note: The steps of engine preparation can be done with

Following are the main steps of engine preparation for the

Following are the main steps of engine preparation after

- drain the oil from the engine, IDG and Backup

- install the splitter fairing and booster anti-ice tubes