 | GEnx-1B SERVICE BULLETIN - 73-0063 R04 | Revised: 10/11/2022 |
| SB 73-0063 R04 ENGINE FUEL AND CONTROL - General (73-00-00) - GEnx-1B Electrical Harnesses Bonding Rework | Issued: 12/28/2017 | |
| GEnx-1B SERVICE BULLETIN - 73-0063 R04 | Revised: 10/11/2022 |
| SB 73-0063 R04 ENGINE FUEL AND CONTROL - General (73-00-00) - GEnx-1B Electrical Harnesses Bonding Rework | Issued: 12/28/2017 | |
| 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 (2022) General Electric Company, U.S.A. |
| TRANSMITTAL INFORMATION |
| REVISION 4 TO SERVICE BULLETIN 73-0063 |
| Revision 4 is issued to update paragraphs 1., PLANNING INFORMATION, 2., MATERIAL INFORMATION, and 3., ACCOMPLISHMENT INSTRUCTIONS. |
| Revision 3 was issued August 09, 2019. Revision 2 was issued January 11, 2019. Revision 1 was issued May 18, 2018. The original was issued December 28, 2017. 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 all GEnx-1B engines. |
| The electrical harnesses listed in paragraph 4., APPENDIX A, that do not have a B marking in the data marker, are affected by this Service Bulletin, except for the W30 and W31 harness serial numbers listed in paragraph 6., APPENDIX C. |
| NOTE: |
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| B. | Description |
| This Service Bulletin provides the rework instructions to address the quality issues affecting the electrical harnesses bonding requirements. |
| C. | Compliance |
| Category 2 |
| GE recommends that you do this Service Bulletin as soon as possible without effect on revenue service but before December 31, 2024. |
| Impact A |
| This recommendation is to address a condition that may affect Flight Safety. |
| NOTE: |
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| NOTE: |
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| 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 address a quality escape. |
| (2) | Condition: |
| Non-conformities include 360-degree shield to backshell terminations and other related shield termination process issues. |
| (3) | Cause: |
| Non-conformance of harness shield termination may result in shield to connector/backshell degradation over time. |
| (4) | Improvement: |
| The rework procedure returns the electrical harnesses to the original design intent and satisfies the engine bonding requirements. The reworked electrical harnesses are reidentified with a superseding part number to facilitate the identification of the electrical harnesses that have already been reworked. |
| (5) | Substantiation: |
| Substantiation is by analysis and comparative analysis. |
| F. | Approval |
| The data contained in this Service Bulletin has been reviewed by the FAA or authorized entity representing the FAA 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 removing the affected electrical harnesses, you will need approximately 1 man-hour, at shop only, to rework each electrical harness connector. |
| For electrical harness replacement on wing, you will need approximately 10 man-hours to remove and replace the electrical harnesses. |
| For propulsor harness replacement on wing, you will need approximately 20 man-hours to remove and replace the electrical harnesses. |
| H. | Weight and Balance |
| Weight and balance are not changed. |
| I. | References (Use the latest version of these documents) |
| GEnx-1B, Boeing 787 Aircraft Maintenance Manual (AMM) |
| GEK 112851, GEnx-1B Engine Manual (EM) |
| GEK 112864, GEnx-1B Engine Illustrated Parts Catalog (EIPC) |
| GEK 114019, GEnx-1B Component Maintenance Manual (CMM), 73-21-64 |
| GEK 114025, GEnx-1B Component Maintenance Manual (CMM), 73-21-63 |
| GEK 114047, GEnx-1B Component Maintenance Manual (CMM), 73-31-01 |
| GEnx-1B S/B 72-0395, ENGINE - Fan Stator Module Assembly (72-00-01) - Release of Surface Cooler System Bracket Optimization |
| GEnx-1B S/B 73-0060, ENGINE FUEL AND CONTROL - General (73-00-00) - Introduction of Redesigned W30 Harness, W31 Harness, and Support Brackets |
| Product Support Repair Work Instruction (PSRWI).J04.0050 |
| Product Support Repair Work Instruction (PSRWI).J04.0053 |
| NOTE: |
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| J. | Publications Affected |
| GEK 112864, GEnx-1B Engine Illustrated Parts Catalog (EIPC) |
| K. | Interchangeability |
| The electrical harnesses superseding the old part numbers retain the same design definition. As such, there is no impact for intermixing the superseded and new part numbers and can be introduced either concurrently or sparsely while existing stock is depleted and field-reworked. The part number change release serves the unique purpose of providing traceability to electrical harnesses on field engines for resolving a quality escape. |
| The electrical harnesses with the old part number and the B marking in the data marker are electrical harnesses that have already been reworked by Unison or built new to the latest bonding manufacturing assembly procedures prior to the introduction of the superseding part numbers. Refer to Figure 1 to identify the B marking location. Only electrical harnesses with the old part number and the B marking in the data marker are two-way interchangeable with the new part numbers during the compliance period granted per the service recommendation and also once this same period is completed. |
| 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: |
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| NP = Not Provisioned |
| *Part not supplied by GE Engine Services Distribution L.L.C. To procure parts, contact the following: |
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| (3) | Consumables: |
| None. |
| B. | Industry Support Information |
| Unison is pleased to provide industry support for compliance as outlined below. This support is valid until December 31, 2024. After that date, contact Unison for support details: |
| (1) | Rework of the electrical harnesses at engine shop visit: |
| (a) | Electrical harnesses under warranty (the warranty period is extended through 12,000 hours for this Service Bulletin): |
| For electrical harnesses requiring this GEnx-1B S/B 73-0063, on engines that are below 12,000 hours at the time of the shop visit, Unison is pleased to provide rework free of charge. This offer is valid for rework or equivalent exchange for each GEnx electrical harness listed in this Service Bulletin (does not include W30/W31), at Unisons election. |
| (b) | Electrical harnesses not under warranty (the warranty period is extended through 12,000 hours for this Service Bulletin): |
| For electrical harnesses requiring this GEnx-1B S/B 73-0063, on engines that are above 12,000 hours at the time of the shop visit, Unison is pleased to provide a discounted price of $850.00. This discounted repair price is valid for rework or equivalent exchange for each GEnx electrical harness listed in this Service Bulletin (does not include W30/W31), at Unisons election. If additional repairs are required outside this GEnx-1B S/B 73-0063, standard repair pricing would apply. |
| (2) | Replacement of the electrical harnesses on wing: |
| (a) | The majority of GEnx-1B engines are returned for shop visit without the fan module installed. The following support is established for customers that have sent engines to the maintenance repair and overhaul (MRO) shop without the fan module. The customer must remove the electrical harnesses from the fan module at their maintenance location and return the removed electrical harnesses for rework at Unison. |
| Deleted. |
| Deleted. |
| Deleted. |
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| (b) | Electrical harnesses under warranty (the warranty period is extended through 12,000 hours for this Service Bulletin): |
| For electrical harnesses requiring this GEnx-1B S/B 73-0063, on fan modules that are below 12,000 hours at the time of the shop visit, Unison is pleased to provide rework free of charge, for each of the electrical harnesses listed above. The returned electrical harnesses can be new or reworked, at Unisons election. |
| Place a no charge purchase or repair order referencing the engine serial number (ESN) and time since new (TSN) to the address below. |
| (c) | Electrical harnesses not under warranty (the warranty period is extended through 12,000 hours for this Service Bulletin). |
| For electrical harnesses requiring this GEnx-1B S/B 73-0063, on fan modules that are above 12,000 hours at the time of removal, Unison is pleased to provide rework for electrical harnesses at a price of $850.00 for each of the electrical harnesses listed above. If additional repairs are required outside this GEnx-1B S/B 73-0063, standard repair pricing would apply. |
| Place a chargeable purchase or repair order referencing the ESN and TSN to the address below. |
| Return the removed electrical harnesses to Unison or AAR (non-direct customers) at the following address for rework. |
| Customers (direct) are invited to contact their Unison representative for order inquiries. |
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| OR |
| Customers (non-direct) are invited to contact the AAR CORP. representative at unisondistribution@aarcorp.com or phone: +1 800-422-2213. |
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| (d) | Deleted. |
| (e) | For operators with low utilization aircraft/engines that will not need a shop visit in the 7-year compliance period, contact your Unison or AAR representative. |
| (3) | Labor: |
| (a) | Unison is pleased to offer up to 1 man-hour of labor for each electrical harness per engine for the removal and installation of the electrical harnesses. The available labor rate is the GE General Terms Agreement (GTA) agreed labor rate or the GE Standard Labor rate if a GTA labor rate has not been established. |
| (b) | Contact your Unison or AAR Customer Account Representative for any warranty claim support. |
| C. | Configuration Chart |
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| Operation Codes RE=Replace RI=Reidentify RM=Remains RW=Rework |
| Change Codes 1=One-way interchangeable. |
| NOTE: |
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| Support Codes B=Old parts will be supplied until all old parts are sold. |
| D. | Parts Disposition |
| Rework the affected electrical harnesses. |
| E. | Tooling - Price and Availability |
| None. |
| 3. | ACCOMPLISHMENT INSTRUCTIONS |
| A. | Identification of Electrical Harness Status |
| (1) | Find out if it is necessary to rework an electrical harness, or if no action is necessary, as specified in this Service Bulletin as follows: |
| (a) | Find out if the part number of the electrical harness is affected by this Service Bulletin. Refer to paragraph 4., APPENDIX A and do as follows: |
| 1 | If the part number is not listed in paragraph 4., APPENDIX A, no action is necessary on that specific part number. |
| 2 | If the part number is listed in paragraph 4., APPENDIX A, continue with step 3.A.(1)(b). |
| (b) | Do a visual inspection of the electrical harness to find out if it has a B marking. Refer to Figure 1 and do as follows: |
| NOTE: |
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| 1 | If you find the B marking, it is not necessary to rework the electrical harness and therefore no action is necessary in that specific part number. |
| 2 | If you do not find the B marking in the indicated location, then you must rework the electrical harness in shop or replace it in shop or on wing with its superseding part number. Refer to paragraph 5., APPENDIX B for superseding part numbers and then continue with paragraphs 3.B., Removal through 3.E., Installation. |
| B. | Removal |
| (1) | Remove the electrical harnesses (Figure 2 and Figure 3) that you must rework or replace as follows: |
| NOTE: |
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| (a) | For in-shop removal instructions, refer to the GEnx-1B EM, 72-00-00, DISASSEMBLY 001, 72-00-01, DISASSEMBLY 001, and 72-00-02, DISASSEMBLY 001 and DISASSEMBLY 002. |
| (b) | For on-wing removal instructions, refer to the GEnx-1B Boeing 787-8 AMM, G73-22-01, Removal, DMC-B787-A-G73-22-01-00A-520A-A, 26-11-03, Removal, DMC-B787-A-26-11-03-00A-520A-A, G77-21-04, Removal, DMC-B787-A-G77-21-04-00A-520A-A, and G77-21-05, Removal, DMC-B787-A-G77-21-05-00A-520A-A. |
| C. | Rework |
| (1) | Obey the detailed instructions to rework the electrical harnesses which are contained within the controlled PSRWI.J04.0050 (latest version) and PSRWI.J04.0053 (latest version) documents. |
| NOTE: |
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| (2) | For other shops, on-wing support, and customers that must rework an electrical harness, route the electrical harnesses to the OEM Unison Industries facility in 7575 Baymeadows Way, Jacksonville, Florida. 32256. U.S.A. or through the AAR Corporation in 8001 Westside Industrial Dr, Suite 5, Jacksonville, FL 32219, U.S.A. |
| D. | Reidentification |
| (1) | The electrical harnesses reworked at Celma, Caledonian, EGAT, and the Unison Industries facility in Jacksonville, Florida must obey the reidentification instructions included in the PSRWI.J04.0050 (latest version) and PSRWI.J04.0053 (latest version) documents. |
| E. | Installation |
| (1) | Install all the removed and reworked or replaced electrical harnesses (Figure 2 and Figure 3) as follows: |
| NOTE: |
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| (a) | For in-shop installation instructions, refer to the GEnx-1B EM, 72-00-00, ASSEMBLY 001, 72-00-01, ASSEMBLY 001, and 72-00-02, ASSEMBLY 005 and ASSEMBLY 006. |
| (b) | For on-wing installation instructions, refer to the GEnx-1B Boeing 787-8 AMM, G73-22-01, Installation, DMC-B787-A-G73-22-01-00A-720A-A, 26-11-03, Installation, DMC-B787-A-26-11-03-00A-720A-A, G77-21-04, Installation, DMC-B787-A-G77-21-04-00A-720A-A, and G77-21-05, Installation, DMC-B787-A-G77-21-05-00A-720A-A. |
| 4. | APPENDIX A - AFFECTED ELECTRICAL HARNESSES PART NUMBERS |
| 5. | APPENDIX B - SUPERSEDING ELECTRICAL HARNESSES PART NUMBERS |
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| 6. | APPENDIX C - W30 HARNESS P/N 2613M71P01 and W31 HARNESS P/N 2613M72P01 SERIAL NUMBERS WITHOUT THE B MARKING |
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