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Copyright (2024) General Electric Company, U.S.A.
TRANSMITTAL INFORMATION
REVISION 2 TO SERVICE BULLETIN 75-0029
Revision 2 is issued to update paragraphs 2., MATERIAL INFORMATION and 3., ACCOMPLISHMENT INSTRUCTIONS.
Revision 1 was issued June 14, 2019. The original was issued February 06, 2018. 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.
This Service Bulletin has been introduced in production to these GEnx-1B engines:
•
GEnx-1B engines, serial numbers 958-067 and up.
These serial numbers are the best available data.
The air duct seal P/N 1682M91P08 and seal housing P/N 2406M07P01 are affected by this Service Bulletin.
B.Description
This Service Bulletin provides improvement in the high pressure turbine (HPT) air manifold connectors by replacing the affected metallic seal housing and silicone air duct seal with fire-proof fabric reinforced silicone rubber low pressure turbine (LPT) active clearance control (ACC) air bellows (air bellows) P/N 2363M85P04 and low pressure hose clamp (hose clamp) P/N 1519M13P08.
C.Compliance
Category 3
GE recommends that you do this Service Bulletin at the next shop visit of the engine/module.
Impact E
This recommendation is to improve the cost of ownership, reduce maintenance requirements or is a product improvement.
NOTE:
This Service Bulletin can be done on wing or in shop.
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 operator’s fleet.
D.Concurrent Requirements
None.
E.Reason
(1)Objective:
To introduce new parts and improve maintainability.
(2)Condition:
The present configuration has field findings of metal-to-metal wear against the HPT air manifolds, which has been fixed by applying room temperature vulcanized (RTV) silicone at the interface between the seal housings and HPT air manifolds.
(3)Cause:
The metallic seal housing shape has led to seal housing and HPT air manifolds wear in the field.
(4)Improvement:
Introduction of proposed rubber air bellows and hose clamp configuration standardizes the hardware of the HPT ACC and LPT ACC and improves manufacturing efficiency by eliminating the assembly steps required to apply RTV silicone on the seal housing. This change also reduces the clamping load to a value that will not deform the duct but sufficient to prevent the rubber bellows from sliding.
(5)Substantiation:
Substantiation is by 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
No additional man-hours are required to comply with this Service Bulletin.
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 9250, Commercial Engine Standard Practices Manual (SPM)
GEK 112851, GEnx-1B Engine Manual (EM)
GEK 112864, GEnx-1B Engine Illustrated Parts Catalog (EIPC)
GEnx-1B S/B 75-0003, AIR SYSTEM - HPTACC Manifolds (75-24-30) - HPTACC Improvement
GEnx-1B S/B 75-0022, AIR - HPT ACC Manifolds (75-24-30) - Seal Housing RTV Application
NOTE:
The reference documents listed below are for the engine manufacturer's internal use only:
CID: 551382, 575978
BPP: 15-72-00-49177.B
J.Publications Affected
GEnx-1B, Boeing 787 Aircraft Maintenance Manual (AMM)
GEK 112851, GEnx-1B Engine Manual (EM)
GEK 112864, GEnx-1B Engine Illustrated Parts Catalog (EIPC)
K.Interchangeability
Qualified interchangeability.
The new air bellows and hose clamps must be introduced in complete engine sets in a new make production and at engine shop visit.
For on-wing conditions, it is not required to introduce the new air bellows and hose clamps in complete engine sets. It is allowable to replace one or more old metal seal housing P/N 2406M07P01 with the new silicone rubber air bellows P/N 2363M85P04. Each new air bellows P/N 2363M85P04 must be introduced with two new hose clamps P/N 1519M13P08.
NOTE:
The new air bellows part numbers supersede the requirement for RTV silicone as specified in GEnx-1B S/B 75-0022.
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
 
2363M85P04
(8)
Bellows, LPT ACC Air
Quote
(-)
--
 
1519M13P08
(16)
Clamp, Low Pressure Hose
Quote
(-)
--
 NOTE:
Prices are found in the GE Materials Catalog.
(2)Other Spare Parts:
None.
(3)Consumables:
 
Code Number
Description
 
C01-007
RTV, Silicone Elastomer
 
C04-002
Solvent, General (solvent)
 
C04-035
Solvent, General (isopropyl alcohol)
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/
G06/G07/G08/
G09
(X)
Propulsor Module Assembly
2376M20G05/
G06/G07/G08/
G09
(X)
RM
-/-
 
2447M20G01/
G02/G03/G04/
G05
(X)
Propulsor Module Assembly
2447M20G01/
G02/G03/G04/
G05
(X)
RM
-/-
 
.2363M85P04
15-090C, 75-24-30
(8)
Housing, Seal
(Old Name)
Bellows, LPT ACC Air
(New Name)
(SIN 62109)
.2406M07P01
15-090A, 75-24-30
(7)
RE/
QTC
5/A
 
--
(-)
Housing, Seal
(SIN 6210J)
.2406M07P01
15-140, 75-24-30
(1)
DE
5/A
 
--
(-)
Seal, Air Duct
(SIN 62151)
.1682M91P08
15-100, 75-24-30
(16)
DE
5/A
 
.1519M13P08
15-160, 75-24-30
(16)
Clamp, Low Pressure Hose
(SIN 62188)
--
(-)
AD
5/-
Operation Codes
AD=Add
DE=Delete
QTC=Quantity Change RE=Replace
RM=Remains
Change Codes
5=Qualified interchangeability. Refer to paragraph 1.K.,Interchangeability.
Support Codes
A=Old parts will no longer be supplied.
D.Parts Disposition
Discard old parts.
E.Tooling - Price and Availability
None.
3.ACCOMPLISHMENT INSTRUCTIONS
A.In-Shop Removal
(1)Remove the HPT air manifolds. Removal instructions of the HPT air manifolds have not changed. Refer to the GEnx-1B EM, 72-00-02, DISASSEMBLY 003, Subtask 72-00-02-030-441.
B.On-Wing Removal
(1)Remove the HPT air manifolds. Removal instructions of the HPT air manifolds have not changed. Refer to the GEnx-1B, Boeing 787 AMM, G75-24-05, Removal, DMC-B787-A-G75-24-05-00A-520A-A.
C.Installation
(1)Install the HPT air manifolds. Refer to Figure 1 of this Service Bulletin and to the GEnx-1B EM, 72-00-02, ASSEMBLY 004, CONFIG 01 or CONFIG 02 or GEnx-1B, Boeing 787 AMM, G75-24-05, Installation, DMC-B787-A-G75-24-05-00A-720A-A, to help with the installation and do as follows:
NOTE:
Old and new configurations of the HPT air manifold connectors are shown in Figure 1.
(a)For pre-GEnx-1B S/B 75-0003 engines, do as follows:
1Install the HPT air manifolds (15-030, 15-040, 15-050, 15-060, 15-070, 15-080, 15-010, and 15-020, 75-24-30, Figure 1, Sheet 1) as follows:
aInstall one of the new air bellows (4, Sheet 5) at the 12:00 o'clock position aft looking forward (ALF) on the HPT air manifold (15-030, Sheet 1). Push the air bellows (4, Sheet 5) fully onto the HPT air manifold (15-030, Sheet 1) tube and attach it firmly with a new hose clamp (3, Sheet 5).
bInstall the HPT air manifold (15-030, Sheet 1) at the 1:00 o'clock position ALF on the HPT stator case (01-490, 72-52-00, Sheet 2).
cAttach the forward end of the HPT air manifold (15-030, Sheet 1) with one machine bolt (bolt) (15-120, 75-24-30, Sheet 2) and one retaining washer (washer) (15-130) at the center bolt hole. Hand-tighten the bolt (15-120).
dAttach the aft end of the HPT air manifold (15-030, Sheet 1) with one bolt (15-110, Sheet 2) and one washer (15-130) at the center bolt hole. Hand-tighten the bolt (15-110).
eInstall the remaining HPT air manifolds on the HPT stator case (01-490, 72-52-00). Make sure that the HPT air manifold (15-010, 75-24-30) is installed at the 10:00 o'clock position ALF.
fWhen all the HPT air manifolds are installed, carefully move the air bellows (4, Sheet 5) in a clockwise (CW) direction to connect the adjacent HPT air manifold.
gInstall the remaining bolts (15-120, Sheet 2) and washers (15-130) in the forward end of the HPT air manifolds.
hInstall the remaining bolts (15-110) and washers (15-130) in the aft end of the HPT air manifolds.
iTorque the bolts (15-120 and 15-110) to 106 to 124 lb in. (11.9 to 14.0 Nm).
2Torque the hose clamps (3, Figure 1, Sheet 5 and Sheet 6) as follows:
 aTorque the hose clamps (3) to 18 to 22 lb in. (2.0 to 2.4 Nm) and do as follows:
  CAUTION:
MAKE SURE TO REMOVE ALL BURRS TO PREVENT DAMAGE TO THE HARDWARE.
 (1)Remove the excessive length of the hose clamp (3) tab to expose a maximum material length of 1.00 inch (25.4 mm) beyond the screw housing. No burrs are permitted. Refer to the SPM, 70-42-00, BLENDING AND REMOVAL OF HIGH METAL PROCEDURES.
  WARNING:
REFER TO THE PRODUCT LABEL AND THE MANUFACTURER’S (MATERIAL) SAFETY DATA SHEET (SDS) FOR INSTRUCTIONS ON THE HAZARDS, STORAGE, SAFE HANDLING AND PROPER USE OF CONSUMABLE PRODUCTS.
 bApply C01-007 silicone elastomer RTV on the screw and cylinder of the hose clamp (3) as follows:
(1)Clean the surface with C04-002 solvent or C04-035 isopropyl alcohol.
(2)Apply C01-007 silicone elastomer RTV on the screw of the hose clamp (3) to prevent further movement of the hose clamp (3) and air bellows (4). Make sure to only apply on the area of interest and not on the surrounding hardware.
(b)For post-GEnx-1B S/B 75-0003 and all PIP 2 engines, do as follows:
1Install one of the new air bellows (4, Figure 1, Sheet 5) on the CW end of the HPT air manifold (15-040A, Sheet 1). Push the air bellows (4, Sheet 5) fully onto the HPT air manifold (15-040A, Sheet 1) tube and attach it firmly with a new hose clamp (3, Sheet 5).
2Install the HPT air manifold (15-040A, Sheet 1) on the HPT stator case (01-490, 72-52-00, Sheet 2) at the 2:00 o'clock position aft looking forward (ALF).
3Install one machine bolt (bolt) (15-120 or 15-125A, 75-24-30) and one flat washer (washer) (15-130 or 15-130A) at the forward center bolt hole and attach the HPT air manifold (15-040A, Sheet 1) to the HPT manifold bracket (bracket) (34-370, 72-00-02, Sheet 4).
4Install the flat wire spring (spring) (15-145, 75-24-30, Sheet 4) between the retainers (15-150 and 15-155).
5Install one bolt (15-125), retainers (15-150 and 15-155), and spring (15-145) at each forward corner bolt hole and attach the HPT air manifold (15-040A, Sheet 4) to the HPT manifold brackets (34-360, 72-00-02).
6Install the remaining HPT air manifolds (15-030A, 15-050A, 15-060A, 15-070A, 15-080A, 15-010A, and 15-020A, 75-24-30, Sheet 1) as follows:
aInstall one of the new air bellows (4, Sheet 5) on the CW end of the HPT air manifold (15-050A, Sheet 1). Push the air bellows (4, Sheet 5) fully onto the HPT air manifold (15-050A, Sheet 1) tube and attach it firmly with a new hose clamp (3, Sheet 5).
bInstall the HPT air manifold (15-050A, Sheet 1) on the HPT stator case (01-490, 72-52-00, Sheet 2) at the 4:00 o'clock position ALF.
cInstall one bolt (15-125, 75-24-30) and one washer (15-130A) at the forward center bolt hole and attach the HPT air manifold (15-050A, Sheet 1) to the bracket (34-091, 72-00-02, Sheet 2).
dInstall the spring (15-145, 75-24-30) between the retainers (15-150 and 15-155).
eInstall one bolt (15-125), retainers (15-150 and 15-155), and spring (15-145) at each forward corner bolt hole and attach the HPT air manifold (15-050A, Sheet 1) to the brackets (34-111, 72-00-02, Sheet 2 and 34-360, 72-00-02, Sheet 4).
fInstall the remaining HPT air manifolds at their correct positions. Do again steps 3.C.(1)(b)6
a
through 3.C.(1)(b)6
d
.
gFor the HPT air manifolds (15-060A, 15-070A, 15-080A, and 15-010A, 75-24-30, Sheet 1) installation, do as follows:
(1)Install one bolt (15-125, Sheet 2), retainers (15-150 and 15-155), and spring (15-145) at each forward corner bolt hole and attach the HPT air manifolds (15-060A, 15-070A, 15-080A, and 15-010A, Sheet 1) to the brackets (34-111, 72-00-02, Sheet 2).
hFor the HPT air manifold (15-020A, 75-24-30, Sheet 1) installation, do as follows:
(1)Install one bolt (15-125, Sheet 2), retainers (15-150 and 15-155), and spring (15-145) at each forward corner bolt hole and attach the HPT air manifold (15-020A, Sheet 1) to the brackets (34-111 and 34-071, 72-00-02, Sheet 2 and Sheet 3).
iFor the HPT air manifold (15-030A, 75-24-30, Sheet 1) installation do as follows:
(1)Install one bolt (15-125, Sheet 2), retainers (15-150 and 15-155), and spring (15-145) at each forward corner bolt hole and attach the HPT air manifold (15-030A, Sheet 1) to the brackets (34-360 and 34-071, 72-00-02, Sheet 3 and Sheet 4).
7When all the HPT air manifolds are installed, carefully move the air bellows (4, Sheet 5) in a CW direction to connect the adjacent HPT air manifold.
8Install the remaining spring (15-145, 75-24-30, Sheet 2) between the retainers (15-150 and 15-155).
9Install one bolt (15-125), retainers (15-150 and 15-155), and spring (15-145) at the aft corner bolt holes on the HPT air manifolds and attach the HPT air manifolds to the support bracket (34-241, 72-00-02, Sheet 2 and Sheet 3).
10Torque the bolts (15-125, 75-24-30) to 51 to 59 lb in. (5.7 to 6.6 Nm).
11Torque the hose clamps (3, Figure 1, Sheet 5 and Sheet 6) as follows:
 aTorque the hose clamps (3) to 18 to 22 lb in. (2.0 to 2.4 Nm) and do as follows:
  CAUTION:
MAKE SURE TO REMOVE ALL BURRS TO PREVENT DAMAGE TO THE HARDWARE.
 (1)Remove the excessive length of the hose clamp (3) tab to expose a maximum material length of 1.00 inch (25.4 mm) beyond the screw housing. No burrs are permitted. Refer to the SPM, 70-42-00, BLENDING AND REMOVAL OF HIGH METAL PROCEDURES.
  WARNING:
REFER TO THE PRODUCT LABEL AND THE MANUFACTURER’S (MATERIAL) SAFETY DATA SHEET (SDS) FOR INSTRUCTIONS ON THE HAZARDS, STORAGE, SAFE HANDLING AND PROPER USE OF CONSUMABLE PRODUCTS.
 bApply C01-007 silicone elastomer RTV on the screw and cylinder of the hose clamp (3) as follows:
 (1) Clean the surface with C04-002 solvent or C04-035 isopropyl alcohol.
 (2)Apply C01-007 silicone elastomer RTV on the screw of the hose clamp (3) to prevent further movement of the hose clamp (3) and air bellows (4). Make sure to only apply on the area of interest and not on the surrounding hardware.
Installation of HPT Air Manifolds
Figure 1   (Sheet 1)
Installation of HPT Air Manifolds
Figure 1   (Sheet 2)
Installation of HPT Air Manifolds
Figure 1   (Sheet 3)
Installation of HPT Air Manifolds
Figure 1   (Sheet 4)
Installation of HPT Air Manifolds
Figure 1   (Sheet 5)
Installation of HPT Air Manifolds
Figure 1   (Sheet 6)