 | GEnx-1B SERVICE BULLETIN - 72-0154 R05 | Revised: 10/08/2021 |
| SB 72-0154 R05 ENGINE - General (72-00-00) - GEnx-1B Pre-PIP2 Engine Upgrade to GEnx-1B/P2 (Collector Bulletin) | Issued: 11/06/2013 | |
| GEnx-1B SERVICE BULLETIN - 72-0154 R05 | Revised: 10/08/2021 |
| SB 72-0154 R05 ENGINE - General (72-00-00) - GEnx-1B Pre-PIP2 Engine Upgrade to GEnx-1B/P2 (Collector Bulletin) | Issued: 11/06/2013 | |
| GE Designated: -CONFIDENTIAL- | |
| 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 part. | |
| This technical data is considered subject to the Export Administration Regulations (EAR) pursuant to 15 CFR Parts 730-774. Transfer of this data by any means to a Non-U.S. 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 (2021) General Electric Company, U.S.A. |
| TRANSMITTAL INFORMATION |
| REVISION 5 TO SERVICE BULLETIN 72-0154 |
| Revision 5 is issued to update paragraphs 1., PLANNING INFORMATION, 2., MATERIAL INFORMATION, and 3., ACCOMPLISHMENT INSTRUCTIONS. |
| Revision 4 was issued March 20, 2020. Revision 3 was issued December 07, 2017. Revision 2 was issued August 01, 2016. Revision 1 was issued September 24, 2014. The original was issued November 06, 2013. Revision bars in the left margin identify changes. |
| 1. | PLANNING INFORMATION |
| A. | Effectivity |
| * * * FOR GEnx-1B64, -1B64/P1, -1B64/P2, -1B67, -1B67/P1, -1B67/P2, -1B70, -1B70/75/P1, -1B70/75/P2, -1B70/P1, -1B70/P2, -1B70C/P1, -1B70C/P2, -1B74/75/P1, -1B74/75/P2, -1B76/P2, -1B76A/P2 |
| This Service Bulletin is applicable to these GEnx-1B engines: |
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| This Service Bulletin has been introduced in production to these GEnx-1B engines: |
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| These serial numbers are the best available data. |
| B. | Description |
| This Service Bulletin releases the GEnx-1B/P2 new hardware names and part numbers (P/N) information to the Engine Illustrated Parts Catalog (EIPC). This Service Bulletin also provides instructions to convert the engine from a GEnx-1BXX/G03, GEnx-1BXX/G04, or GEnx-1BXX/P1G01 to GEnx-1BXX/P2G01 configuration. |
| Revision 2 removes the acoustic liners from the upgrade kits because they can now be reworked. |
| Revision 2 releases the rake/non-rake intermix allowance for the propulsor/fan in the interchangeability statement. |
| Revision 3 of this Service Bulletin updates the testing requirements, adds reference to the new upgraded fan module assembly P/N 2305M15G12, and clarifies the deflector panel interchangeability. |
| Revision 4 of this Service Bulletin incorporates the new electronic engine control (EEC) configuration with PS3 heaters, specified in GEnx-1B S/B 73-0076, and the engine monitoring unit (EMU) kit P/N 738L787G05, specified in GEnx-1B S/B 77-0013. |
| Revision 5 of this Service Bulletin removes the new EEC configuration with PS3 heaters, specified in GEnx-1B S/B 73-0076, as this is not required for an upgrade and can be done at anytime. |
| C. | Compliance |
| Category 7 |
| GE recommends that you do this Service Bulletin at customer's convenience or option. |
| Impact E |
| This recommendation is to improve the cost of ownership, reduce maintenance requirements or is a product improvement. |
| NOTE: |
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| D. | Concurrent Requirements |
| The following Service Bulletins must be accomplished to do the conversion of the engine from a GEnx-1BXX/G03 to a GEnx-1BXX/P2G01 configuration: |
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| The following Service Bulletins must be accomplished to do the conversion of the engine from a GEnx-1BXX/G04 to a GEnx-1BXX/P2G01 configuration: |
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| The following Service Bulletins must be accomplished to do the conversion of the engine from a GEnx-1BXX/P1G01 to a GEnx-1BXX/P2G01 configuration: |
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| E. | Reason |
| (1) | Objective: |
| To introduce the new GEnx-1B/PIP2 engine model and associated new parts to the Engine Illustrated Parts Catalog (EIPC) and provide configuration conversion instructions. |
| (2) | Condition: |
| The GEnx-1B/P2 model includes upgrades to improve performance and durability. |
| (3) | Cause: |
| Product improvement. |
| (4) | Improvement: |
| This Service Bulletin introduces the GEnx-1B/P2 configuration which improves fuel efficiency of the GEnx-1B engine. Depending on engine operating characteristics and configuration, this Service Bulletin can improve specific fuel consumption (SFC) of the GEnx-1B and GEnx-1B/P1 engines. |
| (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 |
| The man hours required to accomplish this Service Bulletin are equivalent to the time required to perform a full performance restoration workscope. |
| H. | Weight and Balance |
| The complete compliance with this Service Bulletin for the conversion from GEnx-1BXX/G03 to the GEnx-1BXX/P2G01 configuration increases weight by 47 lb (21.32 kg). The complete compliance with this Service Bulletin for the conversion from GEnx-1BXX/G04 or GEnx-1BXX/P1G01 to the GEnx-1BXX/P2G01 configuration does not change the weight. The balance for all configurations has not changed. |
| I. | References (Use the latest version of these documents) |
| GEK 112851, GEnx-1B Engine Manual (EM) |
| GEK 112862, GEnx-1B Cleaning, Inspection, and Repair Manual (CIR) |
| GEK 112864, GEnx-1B Engine Illustrated Parts Catalog (EIPC) |
| GEnx-1B Boeing 787 Aircraft Maintenance Manual (AMM) |
| GEK 108792, GE Standard Practice Manual (SPM) |
| GEnx-1B S/B 72-0037, ENGINE - Stage 1 Blades and Spinner (72-00-00) - Release of New Fan Platform |
| GEnx-1B S/B 72-0050, ENGINE - Cowl Support Rings (72-00-02) - Introduction of New Cowl Supports |
| GEnx-1B S/B 72-0058, ENGINE - General (72-00-00) - Introduction of Improved Drain Manifold Assembly Seal Gasket |
| GEnx-1B S/B 72-0123, ENGINE - Fan Stator Module, Lower Bifurcation, and Related Parts (72-00-00) - Introduction of New Support Strap and Machine Bolts |
| GEnx-1B S/B 72-0155, ENGINE - General (72-40-00) - GEnx-1B/P2 Hardware Release (CDN Module) |
| GEnx-1B S/B 72-0156, ENGINE - General (72-00-00) - GEnx-1B/P2 Hardware Release (Fan Module) |
| GEnx-1B S/B 72-0157, ENGINE - HPC Rotor Assembly (72-31-00) - GEnx-1B/P2 Hardware Release (HPC Rotor Module) |
| GEnx-1B S/B 72-0158, ENGINE - General (72-30-00 and 72-32-00) - GEnx-1B/P2 Hardware Release (HPC Stator Module) |
| GEnx-1B S/B 72-0159, ENGINE - High Pressure Turbine Module (72-52-00 & 72-53-00) - GEnx-1B/P2 Hardware Release (HPT Module) |
| GEnx-1B S/B 72-0160, ENGINE - General (72-00-00) - GEnx-1B/P2 Hardware Release (LPT Module) |
| GEnx-1B S/B 72-0161, ENGINE - General (72-00-00) - GEnx-1B/P2 Hardware Release (Propulsor Module) |
| GEnx-1B S/B 72-0162, ENGINE - General (72-00-00) - GEnx-1B/P2 Hardware Release (TCF Module) |
| GEnx-1B S/B 72-0175, ENGINE - Combustion Chamber Assembly (72-42-00) - Repair of Engines to Replace or Repair Combustor |
| GEnx-1B S/B 72-0198, ENGINE - General (71-00-00) - PIP 2 Fire Support Nozzle Redesign |
| GEnx-1B S/B 73-0003, ENGINE - Engine Monitoring Unit (77-32-10) - Introduction of New Engine Monitoring Unit |
| GEnx-1B S/B 73-0007, ENGINE FUEL AND CONTROL - Electronic Engine Control (73-21-20) - Release of EEC Software Hardware Kit |
| GEnx-1B S/B 73-0011, ENGINE FUEL AND CONTROL - Flow Splitting Valve (73-21-30) - Fuel Accumulator Hardware Release |
| Deleted |
| GEnx-1B S/B 73-0054, ENGINE FUEL AND CONTROL - Electronic Engine Control (73-21-20) - Release of EEC Software (Version B195) |
| GEnx-1B S/B 73-0076, ENGINE FUEL AND CONTROL - Electronic Engine Control (EEC) (73-21-20) - Introduction of New EEC Configuration with PS3 Heater |
| Deleted |
| GEnx-1B S/B 73-0085, ENGINE FUEL AND CONTROL - Electronic Engine Control (73-21-20) - Release of EEC Software (Version B205) |
| Deleted |
| Deleted |
| Deleted |
| GEnx-1B S/B 75-0013, AIR SYSTEM - Air Anti-Ice Manifold - (75-11-40) - Booster Anti-Ice Manifold Improvement |
| GEnx-1B S/B 75-0035, AIR - PS25 Pressure Sense Tubes (75-42-15) - Removal of the PS25 Sense Tube and P25 Hose Tube from the Fan Case Module Assembly |
| Deleted |
| GEnx-1B S/B 77-0013, ENGINE INDICATING - Engine Monitoring Unit (77-32-10) - Introduction of New EMU Software Version EA65 |
| GEnx-1B S/B 79-0018, OIL - Fuel/Oil Heat Exchanger (79-21-00) - Improved Main Fuel/Oil Heat Exchanger with Indicating Capability |
| Repair Document (RD) 842-011 (P1 or higher), Fan Stator Assembly - Inner Acoustic Liners - Alteration - Bushing Replacement for Upgrade to PIP Configuration |
| NOTE: |
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| J. | Publications Affected |
| GEK 112851, GEnx-1B Engine Manual (EM) |
| GEK 112862, GEnx-1B Cleaning, Inspection, and Repair Manual (CIR) |
| GEK 112864, GEnx-1B Engine Illustrated Parts Catalog (EIPC) |
| DMC-B787-A-00-40-06-00A-018A-A, Boeing 747-8 Interactive Fault Isolation Manual |
| DMC-B787-A-00-40-01-00A-00UA-D, GEnx-1B Boeing 787 Aircraft Maintenance Manual (AMM) |
| K. | Interchangeability |
| Qualified interchangeability. Refer to paragraph 1.D., Concurrent Requirements for other required Services Bulletins. |
| It is permissible to intermix any GEnx engine assemblies P/N 2447M10G01, P/N 2447M10G02, and P/N 2447M10G03 with any propulsor module assemblies P/N 2447M20G01 and P/N 2447M20G02 or P/N 2447M20G03. |
| Deleted. |
| For GEnx-1B PIP2 engines, the deflector panel and blankoff panels must be replaced as a set in an upgrade to obtain the SFC benefit. |
| For field GEnx-1B PIP2 engines, it is permitted to intermix the old and new part numbers for SIN 9500A, SIN 9500B, SIN 9500C, SIN 9500D, SIN 9500E, SIN 9500F, SIN 9500G, SIN 9500H, and SIN 9500L at customer's convenience but without the proposed SFC improvements. |
| Active clearance control (ACC) inlet flow shield P/N 2323M89G01 or P/N 2500M61G01 (SIN 9500L). |
| Leading edge splitter P/N 2446M85G02 (SIN 84202) must be installed as a set. Refer to GEnx-1B S/B 75-0013. |
| The connector cap P/N 2563M83P01 (SIN 65K02) is interchangeable as a set. Refer to GEnx-1B S/B 79-0018. |
| The tube cap P/N J1315G108 (SIN 99064) is interchangeable as a set. Refer to GEnx-1B S/B 72-0198. |
| The drain manifold P/N 2437M24G01 (SIN 48700), C sump tube bracket P/N 2379M94G01 (SIN 48710), support brackets P/N 2437M28G01 (SIN 48711) and P/N 2437M27G01 (SIN 48712), machine bolt P/N AS3237-08 (SIN 48721), and tube cap P/N J1315G106 (SIN 48760) are interchangeable as a set. |
| The new tube cap P/N J1315G106 (SIN 61460) is interchangeable as a set. Refer to GEnx-1B S/B 75-0035. |
| Deleted. |
| Deleted. |
| L. | Software Accomplishment Summary |
| Not applicable. |
| 2. | MATERIAL INFORMATION |
| A. | Material - Price and Availability |
| (1) | Parts necessary to do this Service Bulletin: |
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| NP= Not Provisioned |
| * Part not supplied by GE Engine Services Distribution L.L.C. Procure through local purchase. |
| ** SIN List is for Reference Only - Refer to the GEnx-1B Engine Illustrated Parts Catalog (EIPC) for the latest configuration. |
| (2) | Other Spare Parts: |
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| (3) | Consumables: |
| None. |
| B. | Industry Support Information |
| None. |
| C. | Configuration Chart |
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| Operation Codes AD=Add DE=Delete RE=Replace RM=Remains RW=Rework QTC=Quantity Change |
| Change Codes 1=One-way interchangeable. 2=Two-way interchangeable. 4=Interchangeable as a set. 5=Qualified interchangeability. Refer to paragraph 1.K., Interchangeability. |
| Support Codes A=Old parts will no longer be supplied. B=Old parts will be supplied until all old parts are sold. D=Old parts will be supplied for engines that have not been changed by this Service Bulletin. E=Old parts will be supplied, and can be used at other engine locations. |
| D. | Parts Disposition |
| Parts Disposition is described in each concurrent Service Bulletin listed in paragraph 1.D., Concurrent Requirements. Parts removed in the course of complying with this Service Bulletin, which are not reinstalled or reworked for reinstallation, may be retained by GE to support needs of the GEnx-1B configurations prior to the GEnx-1B/P2 configuration. |
| E. | Tooling - Price and Availability |
| None. |
| 3. | ACCOMPLISHMENT INSTRUCTIONS |
| A. | Removal |
| (1) | Removal instructions for the stage 1 blade (20-200, 72-00-00), acoustic liner (30-030, 72-00-00), and leading edge splitter (30-050, 72-00-00) have not changed. Refer to the GEnx-1B EM, 72-00-01, REMOVAL 001, CONFIG 01. |
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| (a) | Rework the inner acoustic liner P/N 2322M56G01 to P/N 2322M56G02. Refer to RD 842-011. |
| (2) | Removal instructions for the external hardware on the propulsor have not changed. Refer to the GEnx-1B EM, 72-00-02, DISASSEMBLY 002 and DISASSEMBLY 003. |
| (3) | Removal instructions for the low pressure turbine (LPT) module assembly have not changed. Refer to the GEnx-1B EM, 72-00-04, REMOVAL 001. |
| (4) | Disassembly instructions for the LPT module assembly have not changed. Remove the mid fan shaft. Refer to the GEnx-1B EM, 72-00-04, DISASSEMBLY 001. |
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| (5) | Disassembly instructions to remove the TCF from the HPT module assembly have not changed. Refer to the GEnx-1B EM, 72-50-00 DISASSEMBLY 001. |
| B. | Conversion Instructions of the GEnx-1BXXG03, GEnx-1BXXG04, or GEnx-1BXX/P1G01 Engine Models to the GEnx-1BXX/P2G01 Engine Model |
| (1) | Upgrade the GEnx-1BXXG03, GEnx-1BXXG04, or GEnx-1BXX/P1G01 Engine Model to the GEnx-1BXX/P2G01 engine model as follows: |
| (a) | Do the GEnx-1B S/B 72-0155 to upgrade the CDN Module to the GEnx-1B/P2 configuration. |
| (b) | Do the GEnx-1B S/B 72-0156 to upgrade the fan module to the GEnx-1B/P2 configuration. |
| (c) | Do the GEnx-1B S/B 72-0157 to upgrade the HPC rotor module to the GEnx-1B/P2 configuration. |
| (d) | Do the GEnx-1B S/B 72-0158 to upgrade the HPC stator module to the GEnx-1B/P2 configuration. |
| (e) | Do the GEnx-1B S/B 72-0159 to upgrade the HPT module to the GEnx-1B/P2 configuration. |
| (f) | Do the GEnx-1B S/B 72-0161 to upgrade the propulsor module to the GEnx-1B/P2 configuration. |
| (g) | Do the GEnx-1B S/B 72-0162 to upgrade the TCF module to the GEnx-1B/P2 configuration. |
| (h) | Assembly instructions for the LPT module assembly have not changed. Install the mid fan shaft. Refer to the GEnx-1B EM, 72-00-04, ASSEMBLY 001. |
| NOTE: |
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| (i) | Assembly instructions to install the TCF on the HPT module assembly have not changed. Refer to the GEnx-1B EM, 72-50-00, ASSEMBLY 001. |
| (j) | Assembly instructions for the HPT module assembly have not changed. Refer to the GEnx-1B EM, 72-00-02, ASSEMBLY 002 and ASSEMBLY 003. |
| (k) | Assembly instructions for the LPT module assembly have not changed. Refer to the GEnx-1B EM, 72-00-04, INSTALLATION 001. |
| (l) | Assembly instructions for the external hardware on the propulsor have not changed. Refer to the GEnx-1B EM, 72-00-02, ASSEMBLY 004 and ASSEMBLY 005. |
| (m) | Install the new stage 1 blade (20-201, 72-00-00), acoustic liner (30-031, 72-00-00), and leading edge splitter (30-051, 72-00-00). Refer to the GEnx-1B EM, 72-00-01, INSTALLATION 001, CONFIG 02. |
| (n) | Do a check of F1.5 clearances as specified in GEnx-1B EM, 72-00-01, SPECIAL PROCEDURE 001. |
| (o) | Replace the ID plate (nameplate) (25-570, 72-00-00). Refer to Figure 1 and do as follows: |
| 1 | Remove two machine bolts (bolts) (25-580, 72-00-00) that firmly attach the nameplate (25-570, 72-00-00) to the fan hub frame (01-490, 72-26-00) and remove the nameplate. Keep the two bolts (25-580, 72-00-00) to install it again. |
| 2 | Mark in the engine data plate a depth of 0.002-0.006 inch (0.05-0.15 mm) and a character height of 0.03-0.08 inch (0.8-2.0 mm). Refer to the SPM, 70-16-05, METAL STAMP MARKING, or 70-16-04, VIBRO-PEEN MARKING and Table in Figure 1. |
| 3 | Use the Table in Figure 1 to re-identify the engine data plate to the applicable configuration (CONFIG), takeoff thrust (TO THRUST), and maximum continuous thrust (MAX CONT). Transpose the propulsor identification (PROP IDENT) as applicable. |
| 4 | Make sure that the correct information is stamped in the applicable spaces on the engine data plate. |
| 5 | Put the replacement nameplate (25-570, 72-00-00), engraved with new model numbers from the Table in Figure 1, onto the fan hub frame (01-490, 72-26-00) with the boltholes aligned with the fan hub frame threaded inserts. |
| 6 | Install two bolts (25-580, 72-00-00) to firmly attach the nameplate (25-570, 72-00-00) to the fan hub frame (01-490, 72-26-00) and torque the bolts to 115 lb in. (13 N.m). |
| 7 | Make sure that the correct information is stamped in the applicable spaces on the engine data plate. |
| (p) | Rework the EEC. Refer to GEnx-1B S/B 73-0085. |
| C. | Test |
| (1) | Do a functional and performance test to make sure that the engine agrees with the operational and performance standards as follows: |
| (a) | The upgraded fan stator module assembly P/N 2305M15G12 must be tested with either a slave GEnx-1BXX/PIP2 propulsor or with the same engine's upgraded propulsor. |
| (b) | The upgraded propulsor module assembly P/N 2447M20GXX must be tested with either a slave GEnx-1BXX/PIP2 fan stator module assembly P/N 2305M15G11 or higher or with the same engine's upgraded fan module assembly. |
| (c) | Do an acceptance test for all GEnx-1B/P2 ratings to prove that the engine meets certified performance. Refer to the GEnx-1B EM, 72-00-00, TESTING 003. |
| (d) | Deleted |
| (e) | Deleted |
