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Copyright (2017) General Electric Company, U.S.A.
TRANSMITTAL INFORMATION
REVISION 1 TO SERVICE BULLETIN 79-0031
Revision 1 is issued to update paragraphs 1., PLANNING INFORMATION, 2., MATERIAL INFORMATION, and 3., ACCOMPLISHMENT INSTRUCTIONS.
The original was issued August 09, 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 all the GEnx-1B engines that have complied with GEnx-1B S/B 79-0018.
This Service Bulletin has been introduced in production to these GEnx-1B engines:
•
GEnx-1B engines, serial numbers 956-777 and up.
These serial numbers are the best available data.
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 introduces new fuel/oil heat exchangers VIN 8103-023 (P/N 2550M15P03) and VIN 8103-024 (P/N 2550M15P04) assembled with an improved fuel valve guide. It also provides instructions to rework the affected parts by the replacement of the fuel valve guide.
This Service Bulletin also serves as the terminating action of the GEnx-1B S/B 79-0028.
C.Compliance
Category 2
GE recommends that you do this Service Bulletin considering the following:
 •
If the fuel/oil heat exchanger has not complied with the GEnx-1B S/B 79-0028 previously, Table 1 below applies:
Table 1
 
Fuel/Oil Heat Exchanger Condition
Action
 
If time since new (TSN) of the fuel/oil heat exchanger is less than 2,000 hours.
Do this Service Bulletin within 2,000 hours TSN of the fuel/oil heat exchanger or within 30 days of the issue date of this Service Bulletin revision, whichever threshold occurs last.
 
If TSN of the fuel/oil heat exchanger is greater than 2,000 hours.
Do this Service Bulletin before 30 days from this Service Bulletin revision issue date.
•
If the fuel/oil heat exchanger has complied with the GEnx-1B S/B 79-0028 previously, Table 2 below applies:
Table 2
 
Fuel/Oil Heat Exchanger Condition
Action
 
If time since last accomplishment of the GEnx-1B S/B 79-0028 is less than 2,000 hours.
Do this Service Bulletin within 2,000 hours TSN of the last accomplishment of the GEnx-1B S/B 79-0028 or before 30 days of the issue date of this Service Bulletin revision, whichever threshold occurs last.
 
If time since last accomplishment of the GEnx-1B S/B 79-0028 is greater than 2,000 hours.
Do this Service Bulletin before 30 days from this Service Bulletin revision issue date.
 Impact D
 This recommendation is to address a condition that may result in a Delay or Cancellation (D&C).
NOTE:
This Service Bulletin can be accomplished 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 operators fleet.
D.Concurrent Requirements
None.
E.Reason
(1)Objective:
To introduce new parts and improve reliability.
(2)Condition:
The fuel valve guide of the fuel/oil heat exchanger may experience internal cavitation damage, which may lead to fuel leakage.
(3)Cause:
Erosion presented on the bottom of the fuel valve guide due to cavitation.
(4)Improvement:
This Service Bulletin introduces a redesigned fuel valve guide for the fuel/oil heat exchanger.
(5)Substantiation:
Substantiation is by comparative analysis and test.
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 you get access to the fuel/oil heat exchanger, you will need approximately 1.5 man-hour for each engine or component.
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 112864, GEnx-1B Engine Illustrated Parts Catalog (EIPC)
GEK 114094, GEnx-1B Component Maintenance Manual (CMM), 79-11-16
GEnx-1B S/B 79-0018, OIL - Fuel/Oil Heat Exchanger (79-21-00) - Improved Main Fuel/Oil Heat Exchanger with Indicating Capability
GEnx-1B S/B 79-0028, OIL SYSTEM - Fuel/Oil Heat Exchanger (79-21-00) - Fuel Valve Guide Replacement
NOTE:
The reference documents listed below are for the engine manufacturer's internal use only:
CID: 575727
BPP: 15-72-00-50335
J.Publications Affected
GEK 112864, GEnx-1B Engine Illustrated Parts Catalog (EIPC)
GEK 114094, GEnx-1B Component Maintenance Manual (CMM), 79-11-16
K.Interchangeability
One-way interchangeable.
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
 
VIN 5352-1055*
(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
 
VIN 1031-2894*
(2)
Bolt, Double Hexagon 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
(-)
--
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.
 
**The quantity of washer VIN 1010-5768 for new configuration (with indicating capability) is two (QTY-2).
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, affected engine serial number (ESN), engine TSN, and fuel/oil heat exchanger TSN.
 •
Hardware will be allocated on priority on the fuel/oil heat exchangers with the TSN at approximately 2,000 flight hours or above.
In addition, Woodward will provide $150 back-end spare parts credits per engine affected by this Service Bulletin to compensate for direct labor hours required to perform the Service Bulletin.
C.Configuration Chart
 
New Part Number
Qty/ Eng
Part Name
Old Part Number/ IPC Location
Qty/ Eng
Op Code
Chg/ Sprt Code
 
(PRODUCTION ONLY)
 
2305M70G08
(X)
Accessory Gearbox Module Assembly
2305M70G08
(X)
RM
-/-
 
.VIN 8103-024 (2550M15P04)
01-014, 79-21-00
(1)
Heat Exchanger, Main Fuel/Oil
(SIN 40700)
.VIN 8103-022 (2550M15P02)
01-012, 79-21-00
(1)
RW
1/A
 
(FIELD ONLY)
 
2305M70G04/ G05/G06/G07/ G08
(X)
Accessory Gearbox Module Assembly
2305M70G04/ G05/G06/G07/ G08
(X)
RM
-/-
 
.VIN 8103-023 (2550M15P03)
01-013, 79-21-00
(1)
Heat Exchanger, Main Fuel/Oil
(SIN 40700)
.VIN 8103-017 (2550M15P01)
01-011, 79-21-00
(1)
RW
1/A
 
.VIN 8103-024 (2550M15P04)
01-014, 79-21-00
(1)
Heat Exchanger, Main Fuel/Oil
(SIN 40700)
.VIN 8103-022 (2550M15P02)
01-012, 79-21-00
(1)
RW
1/A
 
Operation Codes
RM=Remains
RW=Rework
Change Codes
1=One-way interchangeable.
Support Codes
A=Old parts will no longer be supplied.
D.Parts Disposition
Discard old parts and remark the fuel/oil heat exchanger assembly as specified in step 3.C.(1)(i)6a
of paragraph 3., ACCOMPLISHMENT INSTRUCTIONS.
E.Tooling - Price and Availability
 
Tool Number
Description
 
AS3237-20*
Bolt, Double Hexagon Machine
(special tool bolt)
 
OR
 
--
Equivalent Bolt (0.250-28, 1.312 to 1.375 inch length)
(special tool bolt)
*Part not supplied by GE Engine Services Distribution L.L.C. Procure through local purchase.
3.ACCOMPLISHMENT INSTRUCTIONS
A.General
(1)Before you start to work on the fuel/oil heat exchanger (1, Figure 1), 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 (MFP) 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).
C.Replacement of Fuel Valve Guide [Post-GEnx-1B S/B 79-0018 (with Indicating Capability)]
(1)Replace the fuel valve guide (2, Figure 1) 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, 73-11-43, Figure 2) as specified in the instructions in the table below:
NOTE:
It is recommended to follow steps in the table below in order to avoid the removal of the engine driven pump (EDP).
 
Step No.
Action
Part
From Component
Comments
 
1
Disconnect
B-nuts of drain tube (25-041)
Strut drain hose tube (drain hose) (25-010)
Do these steps to remove drain tube (25-041, 73-11-43).
 
Upper drain manifold (01-380, 72-00-05)
 
2
Remove
Bolt (25-050, 73-11-43)
Cushioned loop clamp (cushioned clamp) (25-061)
 
Drain support bracket (bracket) (01-450, 72-00-05)
 
3
Remove
Bolt (25-056, 73-11-43)
Cushioned clamp (25-061)
 
Support bracket (01-171, 72-00-05)
 
4
Remove
Bolt (25-056, 73-11-43)
Cushioned clamp (25-061)
 
Bracket (10-430, 79-22-10)
 
5
Remove
Bolt (25-050, 73-11-43)
Cushioned clamp (25-061)
 
Support bracket (01-120, 75-42-10)
(b)Remove the bolts (3, Figure 1) 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)Do a visual inspection of the poppet (6).
NOTE:
It is expected that the poppet stem is polished due to normal operation.
(g)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 3 and 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. Refer to Figure 3 and Figure 4 for the poppet inspection details.
•
Damage to the non-sealing surfaces more than 0.005 inch (0.13 mm) in depth.
(h)Do a visual inspection of the spring (5, Figure 1). Replace with a new spring (5) if you find one or more of the conditions that follow:
•
Corrosion.
•
Cracks, wear, or other damage.
(i)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 spring (5) in the end cover subassembly (8).
  CAUTION:
MAKE SURE THAT THE SPRING (5) IS CORRECTLY SEATED IN THE POPPET (6) HEAD END AND THE FUEL VALVE GUIDE (2) END, OTHERWISE IT COULD CAUSE DAMAGE TO THE FUEL VALVE GUIDE (2). REFER TO FIGURE 5.
5Install the new fuel valve guide (2) on the end cover subassembly (8) as follows:
aOnce the spring (5) 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, 73-11-43, Figure 2) as specified in the instructions in the table below:
 
Step No.
Action
Part
To Component
Comments
 
1
Connect
B-nuts of drain tube (25-041)
Drain hose (25-010)
Tighten the B-nuts with your hand to install the drain tube (25-041, 73-11-43).
 
Upper drain manifold (01-380, 72-00-05)
 
2
Install
Bolt (25-050)
Cushioned clamp (25-061)
Tighten the bolt (25-050, 73-11-43) with your hand.
 
Drain tube (25-041)
 
Bracket (01-120 or 01-120A, 75-42-10)
 
3
Install
Bolt (25-056)
Cushioned clamp (25-061)
Tighten the bolt (25-056, 73-11-43) with your hand.
 
Drain tube (25-041)
 
Bracket (10-430, 79-22-10)
 
4
Install
Bolt (25-056)
Cushioned clamp (25-061)
Tighten the bolt (25-056, 73-11-43) with your hand.
 
Drain tube (25-041)
 
Support bracket (01-171, 72-00-05)
 
5
Install
Bolt (25-050)
Cushioned clamp (25-061)
Tighten the bolt (25-050, 73-11-43) with your hand.
 
Drain tube (25-041)
 
Bracket (01-450, 72-00-05)
 
6
Torque
B-nut of the drain tube (25-041)
Drain hose (25-010)
Torque value: 78 to 92 lb ft (105.7 to 124.7 Nm).
 
 
7
Torque
B-nut of the drain tube (25-041)
Upper drain manifold (01-380, 72-00-05)
Torque value: 460 to 540 lb in. (51.9 to 61.0 Nm).
 
8
Torque
Bolts (25-050 and 25-056)
--
Torque value: 32 to 38 lb in. (3.6 to 4.2 Nm).
6Remark the nameplate of the fuel/oil heat exchanger as follows:
NOTE:
The fuel/oil heat exchanger will be provided with a nameplate that shows the corresponding new part number when the unit is removed for the next shop visit.
 aReidentify the nameplate with the new part number and put a mark on the nameplate with S/B 79-0031 and accomplishment date (in format mm/dd/yyyy) with indelible ink or dot peening. Refer to the SPM, 70-16-09, PERMANENT INK MARKING STANDARD PRACTICE - EPOXY COATED INK MARKING or 70-16-08, DOT PEEN MARKING FOR OPTICAL CHARACTER RECOGNITION.
D.Test and Close-Up Procedures
(1)Do the Test No. 1 - Dry-Motor Leak Test. Refer to the GEnx-1B, Boeing 787 AMM, 71-00-00, STANDARD PRACTICES, TASK DMC-B787-A-G71-00-00-09A-950A-A.
(2)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.
E.Model Update at Repair Station
(1)If the fuel/oil heat exchanger is not installed on the engine, the update of model numbers to the new fuel/oil heat exchangers VIN 8103-023 (P/N 2550M15P03) or VIN 8103-024 (P/N 2550M15P04) can be accomplished when you send the unit to an authorized repair facility and request the upgrade of the unit.
Please contact the vendor for details:
 
Woodward Governor Co.
5001 North Second Street
P.O. Box 7001
Rockford, IL 61125-7001
U.S.A.
Fuel Valve Guide (Post-GEnx-1B S/B 79-0018) Location
Figure 1  
Drain Tube Removal/Installation
Figure 2  
Poppet Serviceable Conditions
Figure 3   (Sheet 1)
Poppet Serviceable Conditions
Figure 3   (Sheet 2)
Poppet Non-Serviceable Conditions
Figure 4  
Installation of the Fuel Valve Guide
Figure 5  
4.APPENDIX - A
 
Woodward Part Number
Meggitt Part Number
Part Name
 
VIN 1010-5768
VIN 22182-0330
Washer, Plain
 
VIN 1031-2894
VIN 22876-2239
Bolt, Double Hex Head
 
VIN 1355-1715
VIN 26121-8647
O-Ring, Fuel Valve
 
VIN 5352-1055
VIN 32321-1075
Guide, Fuel Valve
 
VIN 3310-1138
VIN 37714-6031
Poppet, Fuel Valve