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Copyright (2013) General Electric Company, U.S.A.
TRANSMITTAL INFORMATION
REVISION 1 TO SERVICE BULLETIN 72-0088
Revision 1 is issued to update paragraphs 1.I., References
, 2., MATERIAL INFORMATION
, and 3.,ACCOMPLISHMENT INSTRUCTIONS
.
The original was issued on the October 16, 2012. Revision bars in the left margin identify changes.
1.PLANNING INFORMATION
A.Effectivity
* * * FOR GEnx-1B64, -1B70
This Service Bulletin is applicable to these GEnx-1B engines:
•
GEnx-1B engines, serial numbers 956-102 thru 956-106 and 956-109 thru 956-178.
This Service Bulletin has been introduced in production to these GEnx-1B engines:
•
GEnx-1B engines, serial numbers 956-179 and up.
All engines retrofitted at Boeing prior to entry into service.
The old VFSG1 power feeder harness (power feeder cable) P/N 506002-3, VFSG2 power feeder harness (power feeder cable) P/N 506003-3, and associated hardware are affected by this Service Bulletin.
B.Description
This Service Bulletin releases a new power feeder cable P/N 513392-1, power feeder cable P/N 513397-1, and associated hardware.
C.Compliance
Category 9
Information only.
All engines were upgraded before delivery.
NOTE:
This Service Bulletin can be accomplished on wing.
D.Concurrent Requirements
None.
E.Reason
(1)Objective:
To introduce new parts.
(2)Condition:
Low level of EMI/HIRF protection.
(3)Cause:
The initial designed power feeder harness did not meet the aircraft level EMI/HIRF protection requirements.
(4)Improvement:
The new harness provides additional shielding and grounding path for the engine installation.
(5)Substantiation:
Substantiation is by analysis and test.
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
No additional man-hours are required to comply with this Service Bulletin.
H.Weight and Balance
The complete compliance with this Service Bulletin increases weight by 6.5 lb (2.9 kg).
I.References (Use the latest version of these documents)
GEK 9250, Commercial Engine Standard Practices Manual (SPM)
GEK 112851, GEnx-1B Engine Manual (EM)
GEK 112864, GEnx-1B Engine Illustrated Parts Catalog (EIPC)
GEK 114013, GEnx-1B Power Feeder Harness, Component Maintenance Manuals (CMM)
GEnx-1B, Boeing 787 Aircraft Maintenance Manual (AMM):
•
DMC-B787-A-24-21-05-01B-720A-A
•
DMC-B787-A-24-21-05-02B-720A-A
  NOTE:
The reference documents listed below are for the engine manufacturer's internal use only:
 
CID: 573442 and 573442-3
 
BPP: 11-72-00-19
J.Publications Affected
GEK 112851, GEnx-1B Engine Manual (EM)
GEK 112864, GEnx-1B Engine Illustrated Parts Catalog (EIPC)
GEK 114013, GEnx-1B Power Feeder Harness, CMM
K.Interchangeability
All parts must be incorporated concurrently.
L.Software Accomplishment Summary
Not applicable.
2.MATERIAL INFORMATION
A.Material - Price and Availability
(1)Parts necessary to do this Service Bulletin:
 
Part Number
Qty/ Eng
Part Name
Unit ($) Price
Pkg Qty
Lead Time Days
 
2508M97G01
(1)
Bracket, Oil Tube
Quote
(-)
Quote
 
513392-1*
(1)
Harness, VFSG1 Power Feeder
NP
(-)
--
 
513397-1*
(1)
Harness, VFSG2 Power Feeder
NP
(-)
--
 
ER8043P01*
(3)
Clamp, Block
NP
(-)
--
 
ER8042P01*
(8)
Clamp, Hinged
NP
(-)
--
 
J1432P06
(2)
Clamp, Cushioned Loop
Quote
(-)
Quote
 
ER8041G01*
(2)
Bracket
NP
(-)
--
 
MS9556-12*
(2)
Bolt, Machine
NP
(-)
--
 
AS3237-08*
(6)
Bolt, Machine
NP
(-)
--
 
MS9556-08*
(4)
Bolt, Machine
NP
(-)
--
 
513305-6*
(1)
Strap, Ground
Quote
(-)
Quote
 
513305-7*
(1)
Strap, Ground
Quote
(-)
Quote
 *Part not supplied by GE Engine Services Distribution L.L.C. To procure parts, contact the following:
 Unison Industries Inc.
 7575 Baymeadows Way
 Jacksonville, FL 32256
 U.S.A.
NP = Not Provisioned
NOTE:
Prices are provided for planning purposes and are subject to change.
(2)Other Spare Parts:
None.
(3)Consumables:
 
Code Number
Description
 
C01-006
RTV, Silicone Elastomer (MIL-A-46106 Type I) (RTV 103 or RTV 106)
 
C03-092
Conversion Coating, Chromated (coating)
 
C04-035
Solvent, General (isopropyl alcohol)
 
C10-182
Cloth, Cleaning for Aircraft Structural (SAE-AMS 3819, BMS 15-5) (lint-free cloth)
B.Industry Support Information
None.
C.Configuration Chart
 
New Part Number
Qty/ Eng
Part Name
Old Part Number/ IPC Location
Qty/ Eng
Op Code
Chg/ Sprt Code
 
2376M20G05-G08
(X)
Propulsor Module Assembly
2376M20G05-G08
(X)
RM
-/-
 
.2508M97G01
05-101, 79-22-30
(1)
Bracket, Oil Tube
(SIN 46110)
.2451M49G01
05-090, 79-22-30
(1)
RE
5/A
 
.513392-1
65-031, 72-00-02
(1)
Harness, VFSG1 Power Feeder
(SIN 68000)
.506002-3
65-030, 72-00-02
(1)
RE
5/A
 
.513397-1
65-041, 72-00-02
(1)
Harness, VFSG2 Power Feeder
(SIN 68001)
.506003-3
65-040, 72-00-02
(1)
RE
5/A
 
.ER8043P01
65-091, 72-00-02
(3)
Clamp, Block
(SIN 68080)
.ER3852G01
65-090, 72-00-02
(3)
RE
5/A
 
.ER8042P01
65-101, 72-00-02
(8)
Clamp, Hinged
(SIN 68085)
.ER4378G01
65-100, 72-00-02
(8)
RE
5/A
 
.J1432P06
10-060A, 73-21-66
15-050A, 73-21-66
(4)
Clamp, Cushioned Loop
(SIN 68885)
.J1432P06
10-060, 73-21-66
15-050, 73-21-66
(2)
QTC
5/-
 
.ER8041G01
10-090, 73-21-66
15-080, 73-21-66
(2)
Bracket
(SIN 69911)
--
(-)
AD
5/-
 
.MS9556-12
10-080, 73-21-66
15-070, 73-21-66
(2)
Bolt, Machine
(SIN 69921)
--
(-)
AD
5/-
 
.AS3237-08

65-055, 72-00-02
(4)
Bolt, Machine
(SIN 69922)
--
(-)
AD
5/-
 
.MS9556-08
10-070, 73-21-66
15-060, 73-21-66
(4)
Bolt, Machine
(SIN 69923)
--
(-)
AD
5/-
 
2305M10G03
/G06/G07
(X)
GEnx Engine Assembly
2305M10G03
/G06/G07
(X)
RM
-/-
 
.738L103G03
05-001B, 71-00-00
(1)
Kit, EBU FD
(SIN 0010J)
.738L103G02
05-001A, 71-00-00
(1)
RW
5/-
 
--
(-)
Strap, Ground
(SIN C00B1)
..513305-6
05-440, 79-22-30
(1)
DE
5/-
 
--
(-)
Strap, Ground
(SIN C00B2)
..513305-7
05-450, 79-22-30
(1)
DE
5/-
 
..513305-6
05-430, 71-00-00
(1)
Strap, Ground
(SIN C00B1)
--
(-)
AD
5/-
 
..513305-7
05-440, 71-00-00
(1)
Strap, Ground
(SIN C00B2)
--
(-)
AD
5/-
 
..AS3237-08
05-420, 71-00-00
(2)
Bolt, Machine
(SIN C00F5)
--
(-)
AD
5/-
 Operation Codes
AD=Add
RE=Replace
RM=Remains
RW=Rework
DE=Delete
QTC=Quantity Change
Change Code
5=Qualified interchangeability. Refer to paragraph 1.K., Interchangeability
Support Code
A=Old parts will no longer be supplied.
D.Parts Disposition
None.
E.Tooling - Price and Availability
None.
3.ACCOMPLISHMENT INSTRUCTIONS
A.Power Feeder Cables Removal
(1)Removal instructions for the power feeder cables (1 and 2, Figure 1, Sheet 2) have not changed. Refer to the GEnx-1B EM, 72-00-02, DISASSEMBLY 001.
B.Power Feeder Cables Installation
(1)Install the bracket (3, Figure 1, Sheet 3) in the inboard variable frequency starter generator (VFSG) (01-001, 71-00-02) as follows:
(a)Remove the hex bolt (15-030, 73-21-66, Sheet 2) that attaches the W33 harness (15-010) to the inboard VFSG with a cushioned loop clamp (15-050). Do not remove cushioned loop clamp (15-050).
(b)Inspect the two mounting bosses on the VFSG for full alodine coating as follows:
1Do a touch up of the alodine with C03-092 coating class 3 for electrical conductivity per manufacturers instructions.
WARNING:
ISOPROPYL ALCOHOL IS TOXIC AND FLAMMABLE. USE PERSONAL PROTECTION EQUIPMENT. USE IN A WELL-VENTILATED AREA.
2If no touch up is necessary, clean the contact surfaces of the mounting bosses and the bracket (3, Sheet 3) with C04-035 isopropyl alcohol.
(c)Attach the bracket (3) with one machine bolt (4) on the inboard VFSG. Hand-tighten the machine bolt (4).
(d)Move the cushioned loop clamp (15-050) on the W33 harness into position on the bracket (3).
(e)Align the boltholes of the bracket (3) with the threaded boss on the inboard VFSG and install one machine bolt (5) through the cushioned loop clamp (15-050) and bracket (3). Hand-tighten the machine bolt (5).
(f)Apply C01-006 RTV 103 or RTV 106 in 360 degrees under the bolt heads of machine bolts (4 and 5).
(g)Torque the machine bolts (4 and 5) to 32-38 lb in. (3.6-4.3 Nm).
(h)Apply C01-006 RTV 103 or RTV 106 to seal around the bolt heads of machine bolts (4 and 5). On the machine bolt (4) interface apply C01-006 RTV 103 or RTV 106 to the bracket spacer and VFSG bosses to fully cover the VFSG bosses. Refer to Figure 1, Sheet 4.
(i)Attach the W33 harness with one cushioned loop clamp (6, Sheet 3) and one machine bolt (5) to the inboard VFSG.
(j)Torque the machine bolt (5) to 32-38 lb in. (3.6-4.3 Nm).
(2)Install the bracket (3) in the outboard VFSG (01-001, 71-00-02) as follows:
(a)Remove the hex bolt (10-050, 73-21-66, Sheet 2) that attaches the W32 harness (10-010) to the outboard VFSG with a cushioned loop clamp (10-060). Do not remove cushioned loop clamp (10-060).
(b)Inspect the two mounting bosses on the VFSG for full alodine coating as follows:
1Do a touch up of the alodine with C03-092 coating class 3 for electrical conductivity per manufacturers instructions.
WARNING:
ISOPROPYL ALCOHOL IS TOXIC AND FLAMMABLE. USE PERSONAL PROTECTION EQUIPMENT. USE IN A WELL-VENTILATED AREA.
2If no touch up is necessary, clean the contact surfaces of the mounting bosses and the bracket (3, Sheet 3) with C04-035 isopropyl alcohol.
(c)Attach the bracket (3) with one machine bolt (4) on the outboard VFSG. Hand-tighten the machine bolt (4).
(d)Move the cushioned loop clamp (10-060) on the W32 harness into position on the bracket (3).
(e)Align the boltholes of the bracket (3) with the threaded boss on the outboard VFSG and install one machine bolt (5) through the cushioned loop clamp (10-060) and bracket (3). Hand-tighten the machine bolt (5).
(f)Apply C01-006 RTV 103 or RTV 106 in 360 degrees under the bolt heads of machine bolts (4 and 5).
(g)Torque the machine bolts (4 and 5) to 32-38 lb in. (3.6-4.3 Nm).
(h)Apply C01-006 RTV 103 or RTV 106 to seal around the bolt heads of machine bolts (4 and 5). On the machine bolt (4) interface apply C01-006 RTV 103 or RTV 106 to the bracket spacer and VFSG bosses to fully cover the VFSG bosses. Refer to Figure 1, Sheet 4.
(i)Attach the W32 harness with one cushioned loop clamp (6, Sheet 3) and one machine bolt (5) to the outboard VFSG.
(j)Torque the machine bolt (5) to 32-38 lb in. (3.6-4.3 Nm).
(3)Replace the oil tube bracket (bracket) (7, Sheet 5) as follows:
(a)Remove the machine bolt (15-070, 73-11-40) that attaches the signal fuel tube/hose (tube/hose) (15-010) to the bracket (7) with a cushioned loop clamp (15-100). Do not remove the cushioned loop clamp (15-100) from the tube/hose.
(b)Remove two machine bolts (05-400, 79-22-30) that attach the oil tube (05-030) to the bracket (7) with a P-clamp (05-410). Do not remove the P-clamp (05-410) from the oil tube.
(c)Remove two machine bolts (05-060) that attach the bracket (7) to the support bracket (33-290, 72-00-02).
(d)Remove the bracket (7) from the engine.
WARNING:
ISOPROPYL ALCOHOL IS TOXIC AND FLAMMABLE. USE PERSONAL PROTECTION EQUIPMENT. USE IN A WELL-VENTILATED AREA.
(e)Clean the areas of the new bracket (7, Sheet 6) and support bracket (33-290), with C04-035 isopropyl alcohol and a C10-182 lint-free cloth or equivalent.
(f)Put the bracket (7) on the support bracket (33-290) and align the boltholes.
(g)Install two machine bolts (05-060, 79-22-30) through the bracket (7) and into the nut plates on the support bracket (33-290, 72-00-02).
(h)Torque the machine bolts (05-060, 79-22-30) to 106-124 lb in. (12.0-14.0 Nm).
(i)Attach the oil tube with the P-clamp (05-410) and two machine bolts (05-400) to the bracket (7).
(j)Torque the machine bolts (05-400) to 51-59 lb in. (5.8-6.7 Nm).
(k)Align the cushioned loop clamp (15-100, 73-11-40) attached to the tube/hose with the nut plate on the bracket (7) and install the machine bolt (15-070).
(l)Torque the machine bolt (15-070) to 32-38 lb in. (3.6-4.3 Nm).
 (4)Attach the ground straps (05-430, 71-00-00) and (05-440), (Figure 1, Sheet 6) to the bracket (7) as follows:
WARNING:
ISOPROPYL ALCOHOL IS TOXIC AND FLAMMABLE. USE PERSONAL PROTECTION EQUIPMENT. USE IN A WELL-VENTILATED AREA.
(a)Clean the surfaces of the ground strap lugs and face of the bracket (7) with C04-035 isopropyl alcohol and a C10-182 lint-free cloth or equivalent.
 (b)Attach the ground straps (05-430) and (05-440) leads to the bracket (7) with two machine bolts (bolt) (05-420) .
 (c)After installing the bolts (05-420) that attach the ground straps (05-430) and (05-440) to the bracket (7), put the ground straps so they point toward the left side of the engine aft locking forward (ALF) and hold in place while torquing.
 (d)Torque the bolts (05-420) to 106-124 lb in. (12.0-14.0 Nm).
(5)Install the block clamps (11, Sheet 7), hinged clamps (12, Sheet 8), and power feeder cables (1 and 2, Sheet 2). Refer to the GEnx-1B EM, 72-00-02, ASSEMBLY 006 and GEnx-1B Boeing 787 AMM DMC-B787-A-24-21-05-01B-720A-A and DMC-B787-A-24-21-05-02B-720A-A with the following exceptions:
WARNING:
ISOPROPYL ALCOHOL IS TOXIC AND FLAMMABLE. USE PERSONAL PROTECTION EQUIPMENT. USE IN A WELL-VENTILATED AREA.
(a)Clean the surfaces of the power feeder cable ground lug and surfaces on the brackets (3, Sheet 9) with C04-035 isopropyl alcohol and a C10-182 lint-free cloth or equivalent.
(b)Connect the VFSG end ground lugs to the brackets (3) with two machine bolts (13) on each bracket (3).
(c)Torque the machine bolts (13) to 106-124 lb in. (12.0-14.0 Nm).
(6)Measure the resistance of the electrical bonding between brackets (3, Sheet 3) and VFSG (01-001, 71-00-02) to make sure that it measures less than 2.5 milliohms.
(7)Measure the resistance of the electrical bonding between the bracket (33-290, 72-00-02, Sheet 6) and the engine case to make sure that it measures less than 2.5 milliohms.
(8)Measure the resistance of the electrical bonding of bracket (7) to support bracket (33-290) to make sure that it measures less than 2.5 milliohms.
 (9)Measure the resistance of the electrical bonding of ground straps (05-430, 71-00-00) and (05-440) that are attached to the bracket (7) to make sure that it measures less than 2.5 milliohms.
(10)Measure the resistance of the electrical bonding between the bolts (13, Sheet 9) in the ground lugs to the brackets (3) to make sure that it measures less than 2.5 milliohms.
(11)If the resistance level is higher than 2.5 milliohms for any of the requested electrical bonding checks, do as follows:
(a)Refer to the SPM, 70-10-00, ASSEMBLY AND DISASSEMBLY TECHNIQUES.
(b)Disassemble the affected mating surfaces that did not pass the electrical bonding check.
WARNING:
ISOPROPYL ALCOHOL IS TOXIC AND FLAMMABLE. USE PERSONAL PROTECTION EQUIPMENT. USE IN A WELL-VENTILATED AREA.
(c)Clean the mating surfaces with C04-035 isopropyl alcohol and a C10-182 lint-free cloth or equivalent.
(d)Assemble the affected mating surfaces again and apply the specified torque.
(e)Measure the resistance of the electrical bonding to make sure that it is lower than 2.5 milliohms.
Installation of New VFSG Harness Configuration
Figure 1   (Sheet 1)
Installation of New VFSG Harness Configuration
Figure 1   (Sheet 2)
Installation of New VFSG Harness Configuration
Figure 1   (Sheet 3)
Installation of New VFSG Harness Configuration
Figure 1   (Sheet 4)
Installation of New VFSG Harness Configuration
Figure 1   (Sheet 5)
Installation of New VFSG Harness Configuration
Figure 1   (Sheet 6)
Installation of New VFSG Harness Configuration
Figure 1   (Sheet 7)
Installation of New VFSG Harness Configuration
Figure 1   (Sheet 8)
Installation of New VFSG Harness Configuration
Figure 1   (Sheet 9)