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Copyright (2016) General Electric Company, U.S.A.
TRANSMITTAL INFORMATION
REVISION 2 TO SERVICE BULLETIN 79-0028
Revision 2 is issued to update paragraphs 1., PLANNING INFORMATION, 2., MATERIAL INFORMATION, and 3., ACCOMPLISHMENT INSTRUCTIONS.
Revision 1 was issued February 11, 2016. The original was issued January 06, 2016. 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
This Service Bulletin is applicable to the GEnx-1B engines that have complied with GEnx-1B S/B 79-0018.
The fuel/oil heat exchangers VIN 8103-017 (P/N 2550M15P01) and VIN 8103-022 (P/N 2550M15P02) are affected by this Service Bulletin.
B.Description
This Service Bulletin provides procedures to replace the fuel valve guide of the affected fuel/oil heat exchangers and defines all of hardware required.
C.Compliance
Category 2
GE recommends that you do this Service Bulletin at next maintenance opportunity without affecting revenue service.
 •
For the post-GEnx-1B S/B 79-0018 fuel/oil heat exchangers (with indicating capability) VIN 8103-017 (P/N 2550M15P01) and VIN 8103-022 (P/N 2550M15P02), do this Service Bulletin before 3,500 hours time since new (TSN) of the fuel/oil heat exchanger and repeat every 3,500 hours.
 •
If the fuel/oil heat exchanger VIN 8103-017 (P/N 2550M15P01) or VIN 8103-022 (P/N 2550M15P02) has already exceeded the recommended threshold on issue date of this Service Bulletin, GE recommends to accomplish the replacement procedure within 30 days after the Revision 2 issuance date of this Service Bulletin.
NOTE:
This Service Bulletin can be accomplished on wing or in shop.
D.Concurrent Requirements
None.
E.Reason
(1)Objective:
 To improve reliability of the component.
(2)Condition:
 The fuel/oil heat exchanger fuel valve guide may experience internal cavitation damage, which might eventually lead to fuel leakage within the cowling.
(3)Cause:
Cavitation phenomena presented on the bottom of the fuel valve guide.
(4)Improvement:
This Service Bulletin provides instructions for the replacement of the fuel/oil heat exchanger fuel valve guide.
(5)Substantiation:
None.
F.Approval
This Service Bulletin contains no modification information that revises the approved configuration and therefore does not require FAA approval.
G.Manpower
 After you get access to the fuel/oil heat exchanger, you will need approximately 1.5 man-hour to do the replacement portion of 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)
 Deleted
GEK 112851, GEnx-1B Engine Manual (EM)
GEK 112864, GEnx-1B Engine Illustrated Parts Catalog (EIPC)
 Deleted
GEnx-1B S/B 79-0018, OIL - Fuel/Oil Heat Exchanger (79-21-00) - Improved Main Fuel/Oil Heat Exchanger with Indicating Capability
NOTE:
The reference document listed below is for the engine manufacturer's internal use only:
BPP: 16-79-00-53631
J.Publications Affected
None.
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:
 
Part Number
Qty/ Eng
Part Name
Unit ($) Price
Pkg Qty
Lead Time Days
 
Deleted
 
Post-GEnx-1B S/B 79-0018
 
VIN 5352-1053*
(1)
Guide, Fuel Valve
NP
(-)
--
 
VIN 1355-1715*
(1)
O-Ring, Fuel Valve
NP
(-)
--
 
VIN 1355-1349*
(1)
Packing, Preformed
NP
(-)
--
NP = Not Provisioned
 
*Part not supplied by GE Engine Services Distribution L.L.C. To procure parts, contact the following:
 
Woodward Governor Co.
5001 North Second Street
P.O. Box 7001
Rockford, IL 61125-7001
U.S.A.
NOTE:
Refer to paragraph 4., APPENDIX - A to see the equivalent Meggitt part numbers.
NOTE:
All parts will be supplied by Woodward for the accomplishment of this Service Bulletin.
NOTE:
Prices are provided for planning purposes and are subject to change.
(2)Other Spare Parts:
 
Part Number
Qty/ Eng
Part Name
Unit ($) Price
Pkg Qty
Lead Time Days
 
Deleted
 
Post-GEnx-1B S/B 79-0018
 
VIN 1031-2894*
(2)
Bolt, Double Hex Head
NP
(-)
--
 
VIN 1010-5768*
(2)**
Washer, Plain
NP
(-)
--
 
VIN 1520-1745*
(1)
Spring, Fuel Valve
NP
(-)
--
 
VIN 3310-1138*
(1)
Poppet, Fuel Valve
NP
(-)
--
 
8021627***
(1)
Packing, EDP Shaft
Quote
(-)
Quote
 
8024127***
(1)
Packing, EDP Housing
Quote
(-)
Quote
NP = Not Provisioned
 
*Part not supplied by GE Engine Services Distribution L.L.C. To procure parts, contact the following:
 
Woodward Governor Co.
5001 North Second Street
P.O. Box 7001
Rockford, IL 61125-7001
U.S.A.
 
Deleted.
 
**The quantity of washer VIN 1010-5768 for new configuration (with indicating capability) is two (QTY-2).
 
***These parts are required in case the engine driven pump (EDP) is removed to gain access to the fuel/oil heat exchanger. These parts must be procured according to the GEnx-1B, Boeing 787 AMM, 29-11-02, Installation, TASK PMC-B787-81205-A2301-00, Data Module DMC-B787-A-29-11-02-00B-720A-A.
NOTE:
Refer to paragraph 4., APPENDIX - A to see the equivalent Meggitt part numbers.
NOTE:
All parts will be supplied by Woodward for the accomplishment of this Service Bulletin.
NOTE:
Prices are provided for planning purposes and are subject to change.
(3)Consumables:
 
Code Number
Description
 
C02-019
Oil, Engine Lubricating (engine oil)
(Boeing Reference D00552)
B.Industry Support Information
Woodward will provide a 100 percent upfront discount against the purchase of the hardware listed in paragraph 2.A.(1), to accomplish this Service Bulletin. The discount is determined under the following conditions:
•
The Purchase Order must include the Service Bulletin targeted incorporation date and affected engine serial number (ESN) Flight Hours of each affected ESN. Parts will be shipped based on priority.
 •
Woodward will provide $150.00 back-end spare parts credits per engine affected by this Service Bulletin to compensate for direct labor hours required to perform the Service Bulletin.
•
In addition, Woodward will provide one set of spares parts [one part each from paragraph 2.A.(2)] with a 100 percent upfront discount, per each customer affected by this Service Bulletin to avoid any possible interruption on the field. This hardware will be needed only if disassembled hardware will be found non-conforming.
C.Configuration Chart
None.
D.Parts Disposition
The fuel valve guide VIN 5352-1053 removed to accomplish this Service Bulletin may be locally scrapped.
E.Tooling - Price and Availability
 
Tool Number
Description
 
J644P18
Bolt, Machine
(special tool bolt)
 
OR
 
Deleted
 
--
Equivalent Bolt (0.250-28, 1.312 inch length)
(special tool bolt)
3.ACCOMPLISHMENT INSTRUCTIONS
A.General
(1)Before you start to work on the fuel/oil heat exchanger (1, Figure 1 or Figure 2) prepare the engine and aircraft for maintenance. Refer to the GEnx-1B, Boeing 787 AMM, 79-21-01, REMOVAL, TASK DMC-B787-A-G79-21-01-00A-520A-A, paragraphs 1.A. and 1.B.
B.Draining of Fuel System
(1)Drain the main fuel pump strainer. This task includes the reinstallation of the drain plug with a new preformed packing. Refer to the GEnx-1B, Boeing 787 AMM, 73-11-04, REMOVAL, TASK DMC-B787-A-G73-11-04-00B-520A-A, paragraphs 1.A., 1.B., and 1.C.(1).
NOTE:
This drain procedure will be effective to drain the low pressure side of the fuel system that includes the fuel/oil heat exchanger (1, Figure 1 or Figure 2).
C.Deleted.
D.Replacement of Fuel Valve Guide [Post-GEnx-1B S/B 79-0018 (with Indicating Capability)]
(1)Replace the fuel valve guide (2, Figure 2) on the post-GEnx-1B S/B 79-0018 fuel/oil heat exchanger (1) as follows:
CAUTION:
BE CAREFUL TO AVOID THE INTRODUCTION OF ANY KIND CONTAMINATION INTO THE FUEL/OIL HEAT EXCHANGER (1) DURING THIS PROCEDURE. THE FUEL SYSTEM IS VERY SENSITIVE TO CONTAMINATION. IF THE FUEL/OIL HEAT EXCHANGER (1) IS INADVERTENTLY CONTAMINATED DURING THIS PROCEDURE THE FUEL/OIL HEAT EXCHANGER (1) MUST BE REMOVED AND REPLACED.
CAUTION:
BE CAREFUL WHEN YOU REMOVE THE DOUBLE HEXAGONAL HEAD BOLTS (BOLTS) (3) THAT ATTACH THE FUEL VALVE GUIDE (2) TO THE END COVER SUBASSEMBLY (8). THE FUEL VALVE GUIDE (2) IS UNDER SPRING PRESSURE AND CAN BE PUSHED OUT AT HIGH SPEED WHEN YOU REMOVE THE BOLTS (3).
 (a)Remove the drain tube (25-041, Figure 3) as follows:
  NOTE:
It is recommended to follow steps 3.D.(1)(a)1
to 3.D.(1)(a)5
in order to avoid the removal of the EDP.
 1Disconnect the B-nuts of the drain tube (25-041) from the strut drain hose tube (drain hose) (25-010) and the upper drain manifold (01-380, 72-00-05) to remove the drain tube (25-041).
 2Remove the bolt (25-050) from the cushioned clamp (25-061) and bracket (01-450, 72-00-05).
 3Remove the bolt (25-056) from the cushioned clamp (25-061) and support bracket (01-171, 72-00-05).
 4Remove the bolt (25-056) from the cushioned clamp (25-061) and bracket (10-430, 79-22-10).
 5Remove the bolt (25-050) from the cushioned clamp (25-061) and bracket (01-120, 75-42-10).
 (b)Remove the bolts (3, Figure 2) and washers (4) that attach the fuel valve guide (2) to the end cover subassembly (8).
(c)Carefully remove the fuel valve guide (2), fuel valve spring (spring) (5), and fuel valve poppet (poppet) (6).
(d)Remove and discard the fuel valve O-ring (O-ring) (7) from the fuel valve guide (2).
(e)Replace the old fuel valve guide (2) and O-ring (7) with the new fuel valve guide (2) and O-ring (7).
(f)Deleted.
(g)Do a visual inspection of the poppet (6).
  NOTE:
It is expected that the poppet stem is polished due to normal operation.
 (h)Replace with a new poppet (6) if you find one or more of the conditions that follow:
 •
Erosion or cavitation on the poppet stem located more than 1.00 inch (25.4 mm) from the end (outboard) of the stem towards the poppet head. Refer to Figure 4 for the poppet inspection details.
•
Corrosion.
•
Contact mark or fretting wear on the sealing surface of the poppet (6) more than 0.005 inch (0.13 mm) in depth.
•
Damage to the non-sealing surfaces more than 0.005 inch (0.13 mm) in depth.
 (i)Do a visual inspection of the spring (5, Figure 2). Replace with a new spring (5) if you find one or more of the conditions that follows:
•
Corrosion.
•
Cracks, wear, or other damage.
(j)Install the new fuel valve guide (2) as follows:
1Make sure that the poppet (6) moves freely in/out of the new fuel valve guide (2).
WARNING:
REFER TO THE PRODUCT LABEL AND THE MANUFACTURERS (MATERIAL) SAFETY DATA SHEET (SDS) FOR INSTRUCTIONS ON THE HAZARDS, STORAGE, SAFE HANDLING AND PROPER USE OF THIS PRODUCT.
2Apply a thin layer of C02-019 engine oil to the new O-ring (7).
3Install the new O-ring (7) in the location groove on the fuel valve guide (2).
4Install the poppet (6) and the spring (5) in the end cover subassembly (8).
CAUTION:
THERE MUST BE A CLEARANCE BETWEEN THE FUEL VALVE GUIDE (2) AND OIL VALVE GUIDE WHEN YOU INSTALL IN THE END COVER SUBASSEMBLY (8).
5Install the new fuel valve guide (2) on the end cover subassembly (8) as follows:
NOTE:
The thinner section of the fuel valve guide (2) must point to the oil valve guide. When you installed, the fuel valve guide (2) will follow the casting with a small clearance all the way around.
aOnce the spring (5, Figure 2) and poppet (6) are installed in the end cover subassembly (8), use one or two special tool bolts to engage the threaded inserts.
bThread temporarily the special tool bolts in order to help to compress the spring (5).
cOnce the special tool bolts reach the bottom of the threaded hole disengage one of the two special tool bolts.
dKeep the fuel valve guide (2) compressed with the hand and install a bolt (3).
eDo the step above again to replace the special tool bolt with a bolt (3) if two special tool bolts were used.
fAttach the new fuel valve guide (2) with bolts (3) and washers (4) on the end cover subassembly (8).
gTorque the bolts (3) between 55 to 70 lb in. (6.2 to 7.9 Nm).
 hInstall the drain tube (25-041, Figure 3) as follows:
 (1)Connect the B-nuts of the drain tube (25-041) to the drain hose (25-010) and the upper drain manifold (01-380, 72-00-05). Tighten the B-nuts with your hand to install the drain tube (25-041).
 (2)Install the bolt (25-050) to attach the cushioned clamp (25-061) and drain tube (25-041) to the bracket (01-120, 75-42-10). Tighten the bolt (25-050) with your hand.
 (3)Install the bolt (25-056) to attach the cushioned clamp (25-061) and drain tube (25-041) to the bracket (10-430, 79-22-10). Tighten the bolt (25-056) with your hand.
 (4)Install the bolt (25-056) to attach the cushioned clamp (25-061) and drain tube (25-041) to the support bracket (01-171, 72-00-05). Tighten the bolt (25-056) with your hand.
 (5)Install the bolt (25-050) to attach the cushioned clamp (25-061) and drain tube (25-041) to the bracket (01-450, 72-00-05). Tighten the bolt (25-050) with your hand.
 (6)Torque the B-nut of the drain tube (25-041) to the drain hose (25-010) to 78 to 92 lb ft (105.7 to 124.7 Nm).
 (7)Torque the remaining B-nut of the drain tube (25-041) to the upper drain manifold (01-380, 72-00-05) to 460 to 540 lb in. (51.9 to 61.0 Nm).
 (8)Torque the bolts (25-050 and 25-056) to 32 to 38 lb in. (3.6 to 4.2 Nm).
E.Marking, Test, and Close-Up Procedures
(1)Put a mark on the exterior of new fuel valve guide (2, Figure 2) with "S/B 79-0028" and accomplishment date (in format mm/dd/yyyy) with indelible ink.
(2)Do the Test No. 1 - Dry-Motor Leak Test. Refer to the GEnx-1B, Boeing 787 AMM, 71-00-00, POWER PLANT REFERENCE TABLE, TASK DMC-B787-A-G71-00-00-09A-950A-A.
(3)Put the airplane back to its usual condition. Refer to the GEnx-1B, Boeing 787 AMM, 73-11-04, INSTALLATION, TASK DMC-B787-A-G73-11-04-00B-720A-A.
Deleted
Figure 1  
Fuel Valve Guide (Post-GEnx-1B S/B 79-0018) Location
Figure 2  
Drain Tube Removal/Installation
Figure 3  
Poppet Stem Visual Inspection
Figure 4  
4.APPENDIX - A
 
Woodward Part Number
Meggitt Part Number
Part Name
 
VIN 1010-5768
VIN 22182-0330
Washer, Plain
 
Deleted
 
VIN 1031-2894
VIN 22876-2239
Bolt, Double Hex Head
 
VIN 1355-1715
VIN 26121-8647
O-Ring, Fuel Valve
 
Deleted
 
VIN 5352-1053
VIN 32321-1059
Guide, Fuel Valve