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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.
GE Aviation authorizes the Federal Aviation Administration to incorporate this document by reference in an Airworthiness Directive.
Copyright (2016) General Electric Company, U.S.A.
1.PLANNING INFORMATION
A.Effectivity
* * * FOR GEnx-1B64/P2, -1B67/P2, -1B70/P2, -1B70/75/P2, -1B74/75/P2
This Service Bulletin is applicable to these GEnx-1B engines:
•
GEnx-1B engines, serial numbers 956162, 956195, 956198, 956201, 956232, 956233, 956275, 956277, 956279, 956280, 956281, 956285, 956288, 956289, 956291, 956329, 956408, 956411, 956413, 956415, 956416, 956418, 956419, 956421, 956423, 956424, 956426, 956427, 956428, 956479, 956481, 956492, 956493, 956494, 956495, 956496, 956497, 956498, 956499, 956500, 956503, 956514, 956516, 956543, 956618, 956622, 956628, 956636, 956646, 956647, 956651, 956665, 956672, and 956677.
No combination of the affected engines can operate on the same aircraft after March 25, 2016.
B.Description
This Service Bulletin provides a procedure to increase the flow path clearance between the fan stator module assembly abradable shroud and the fan blade of the fan module assembly by Repair Document (RD) 835-394.
C.Compliance
Category 1
GE recommends that you do this Service Bulletin before March 25, 2016.
The engine combination restriction is removed by the accomplishment of either step 3.A.(1)(a) or 3.A.(1)(b) of ACCOMPLISHMENT INSTRUCTIONS which will fulfill compliance with this Service Bulletin.
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 operators fleet.
D.Concurrent Requirements
None.
E.Reason
(1)Objective:
To not operate any combination of the affected engine serial numbers (ESNs) listed in this Service Bulletin on the same aircraft, unless the rework procedures specified in step 3.A.(1)(a) or 3.A.(1)(b) of ACCOMPLISHMENT INSTRUCTIONS are complied with.
(2)Condition:
An engineering assessment has determined that the fan module assembly clearances are not optimized and there is a potential for fan rubs that can result in unserviceable distress.
(3)Cause:
The fan module assembly clearances are not optimized for a population of GEnx-1B PIP2 engines.
(4)Improvement:
This rework will increase the clearance between the fan stator module assembly abradable shroud and the fan blade that reduces the potential for fan rubs.
(5)Substantiation:
Substantiation is by comparative analysis.
F.Approval
The data contained in this Service Bulletin has been reviewed by the appropriate governmental authority and the repair(s) and modification(s) herein comply with the applicable Aviation Regulations and are APPROVED for installation in the model(s) listed in this Service Bulletin.
G.Manpower
After you get access to the fan module assembly, you will need approximately 16 hours to complete the fan grind rework procedure per RD 835-394, for each engine.
H.Weight and Balance
The complete compliance with this Service Bulletin decreases weight by 2.5 lb (1.1 kg). Balance is unchanged.
I.References (Use the latest version of these documents)
GEnx-1B, Boeing 787 Aircraft Maintenance Manual (AMM)
GEK 9250, Commercial Engine Standard Practices Manual (SPM)
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)
GEK 112866, GEnx-1B Illustrated Tool and Equipment Manual (ITEM)
Repair Document (RD) 835-394 (P2 or higher), Engine Assembly - Fan Stator Module Assembly - Repair - Unlimited Size Abradable Shroud Repair
J.Publications Affected
GEK 112862, GEnx-1B Cleaning, Inspection, and Repair Manual (CIR)
K.Interchangeability
Not applicable.
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:
None.
(3)Consumables:
None.
B.Industry Support Information
Contact GE Customer Service Manager (CSM).
C.Configuration Chart
None.
D.Parts Disposition
Rework.
E.Tooling - Price and Availability
 
Tool Number
Description
 
11C3039G02
Bracket Set - Forward Propulsor, Ground Handling and Shipping (bracket set)
 
11C3359P02
Rollover Engine Ship Stand (shipping stand)
 
11C3443P03
Stand, Shipping (shipping stand)
 
11C4487P02
Stand, Shipping Engine/Propulsor (shipping stand)
 
11C4576P01
Stand, Shipping - Engine/Propulsor GEnx-1B (shipping stand)
 
11C4568P01
Stand, Full Engine Air Ship (shipping stand)
 
11C4628G01
Bracket Set - Forward Propulsor, Ground Handling and Shipping (bracket set), alternate tool to 11C3039G02
3.ACCOMPLISHMENT INSTRUCTIONS
A.General
(1)The intention of this Service Bulletin can be achieved by one of the options that follow:
 
NOTICE
 
APPROVAL OF REWORK SOURCES
 
The repair referred to below contains complex processes that could affect engine reliability and/or performance. Therefore it is necessary to substantiate the ability and adequacy of a repair source to successfully accomplish the repair. A Technical License Agreement is also required. Information concerning a Technical License Agreement is available from:
 
ATTN.: Manager, Technical Licensing
GE Aviation
One Neumann Way, M/D RM100
Cincinnati, Ohio 45215-6301
U.S.A.
 
After the repair source has obtained a Technical License Agreement, the Repair Document and the Repair Source Substantiation requirements may be obtained from:
 
ATTN.: Repair Substantiation
GE Aviation
One Neumann Way, M/D S171
Cincinnati, Ohio 45215-6301
U.S.A.
OR
Phone: (513) 552-9563
Fax: (513) 552-9587
(a)Rework the fan stator module assembly (Figure 1) by RD 835-394 as follows:
1For the on-wing rework instructions, refer to step 3.B.
2For the in-shop rework instructions, refer to step 3.C.
(b)Replace the fan stator module assembly (Figure 1). Refer to RD 835-394 and GEnx-1B EM, 72-00-01, REMOVAL 001 and INSTALLATION 001 (CONFIGURATION 02).
1Take the tip clearance and full indicated run out (FIR) measurements at F1.0, F1.5, and F2.0 locations of the fan stator module being installed and submitt to GE Aviation Fleet Support for evaluation of acceptability. There is a possibility that the data evaluation can be under the desired clearance.
NOTE:
The GE Aviation Fleet Support Contact Information is as follows:
 
Fleet Support:
http://www.geaviation.com/support/
 
OR
 
E-mail (USA): aviation.fleetsupport@ge.com
E-mail (China & Asia): aviation.fleetsupport.cn@ge.com
 
OR
 
GE Aviation
M/D Rm. 285
One Neumann Way
Cincinnati, OH 45215
U.S.A.
 
OR
 
U.S.A. Phone: 877-432-3272
International Phone: (513) 552-3272
China & Asia Phone: +86 21 38777666
B.On-Wing Rework
NOTE:
GE recommends that you do this procedure in a hangar or enclosed maintenance facility.
(1)Remove the inlet cowl and cover the tail pipe to avoid uncontrolled engine rotation, if outdoors. Refer to the GEnx-1B, Boeing 787 AMM, 71-11-01, Removal, TASK DMC-B787-A-G71-11-01-00A-520A.
(2)Apply masking to cover the booster inlet, outlet guided vane (OGV).
(3)Rework the fan stator module assembly (Figure 1). Refer to RD 835-394 and do as follows:
(a)Do a grind of sequences 1, 2, 4, 5, and 8.
(b)Post grind, measure the fan case FIR and clearances at F1.0 and F1.5 only.
(4)Mark the fan case with Complied with rework per RD 835-394 per SB 72-0309 in a 3x3 inch label located at 9 oclock forward looking aft (FLA) (Figure 1). Refer to the SPM, 70-16-09, PERMANENT INK MARKING STANDARD PRACTICE - EPOXY COATED INK MARKING.
(5)Remove all masking.
(6)Install the inlet cowl. Refer to the GEnx-1B, Boeing 787 AMM, 71-11-01, Installation, TASK DMC-B787-A-G71-11-01-00A-720A-A.
C.In-Shop Rework
(1)Install the 11C3039 or 11C4628 bracket set on either 11C3443, 11C3359, 11C4487, 11C4568, or 11C4576 shipping stand. Refer to Figure 2.
(2)Install the engine in the 11C3443, 11C3359, 11C4487, 11C4586, or 11C4576 shipping stand.
(3)Apply masking to cover the booster inlet and OGV.
(4)Rework the fan stator module assembly (Figure 1). Refer to RD 835-394 and do as follows:
(a)Do a grind of sequences 1, 2, 4, 5, and 8.
(b)Post grind, measure the fan case FIR and clearances at F1.0 and F1.5 only.
(5)Mark the fan case with Complied with rework per RD 835-394 per SB 72-0309 in a 3x3 inch label located at 9 oclock FLA (Figure 1). Refer to the SPM, 70-16-09, PERMANENT INK MARKING STANDARD PRACTICE - EPOXY COATED INK MARKING.
(6)Remove all masking.
Fan Stator Module Assembly
Figure 1  
Engine Placement in Shipping Stand with Bracket Support
Figure 2