LIST OF EFFECTIVE PAGES The effective pages to this Service Bulletin are as follows: Page Revision Number Revision Date

Bulletin 1 Dec.11/12 2 Dec.11/12 3 Dec.11/12 4 Dec.11/12 5 Dec.11/12 6 Dec.11/12 7 Dec.11/12 8 Dec.11/12 9 Dec.11/12 10 Dec.11/12 11 Dec.11/12 12 Dec.11/12 13 Dec.11/12 14 Dec.11/12 15 Dec.11/12 16 Dec.11/12 17 Dec.11/12 18 Dec.11/12 19 Dec.11/12 20 Dec.11/12 21 Dec.11/12 22 Dec.11/12 23 Dec.11/12 24 Dec.11/12 Appendix 1 1 Dec.11/12**Printed in Great Britain**



# RB.211−72−AH059 Transmittal - Page 21. Planning Information A. Effectivity Airbus A380 All RB211 TRENT 970-84, TRENT 970B-84, TRENT 972-84, TRENT 972B-84, TRENT 977-84, TRENT 977B-84, TRENT 980-84 Engines B. Reason (1) Problem Cracking of the rear balance land has previously been found in the Trent 800 and Trent 700 IP compressor shafts. The balancing feature and method is similar on Trent 900 engines although the disc geometry is different from Trent 700 and Trent 800 engines. Non-Modification Service Bulletin (NMSB) 72-G269 was issued to specify an in-shop visual inspection of the rear balance land and applies to Trent 900 engines only. NMSB 72-G448 specifies an enhanced crack detection technique, eddy current inspection for the rear balance land when the rear of the IPC module is exposed and a borescope inspection of the balance land when it is not exposed. This inspection is to be done in-shop on Trent 500 and Trent 900 engines Following inspection at shop visit, cracking was confirmed in a Trent 500 IP compressor shaft rear balance land. NMSB 72-AH059 is being issued to specify repeat on-wing borescope inspections for Trent 900 engines. (2) Substantiation This NMSB instructs an on-wing visual borescope inspection of the IP compressor rear balance land, gaining access through the intermediate case vane 8. This inspection can also be performed in-shop, in accordance with NMSB 72-G448. C. Description This NMSB instructs on-wing visual borescope inspection of the IP compressor shaft rear balance land in order to maintain serviceability and obtain data to support engineering analysis. ENGINE - IP COMPRESSOR SHAFT - VISUAL BORESCOPE INSPECTION OF BALANCE LAND - NON-MODIFICATION SERVICE BULLETIN - NON - MOD.72-AH059**Printed in Great Britain**



# RB.211−72−AH059 Page 1 of 24 Dec.11/12 Dec.11/12Send copies of the NMSB inspection results to your Rolls-Royce service representative by completion of Appendix 1 (borescope inspection) or send an equivalent form containing the same information. A record of accomplishment should be attached to the engine record. D. Compliance (1) On-wing ALERT This NMSB must be accomplished within 280 flight cycles of the publication date of this NMSB, unless NMSB 72-G448 is accomplished within this time period on this IP compressor shaft. This NMSB must then be repeated on an ongoing basis within 280 flight cycles of the last previous accomplishment of NMSB 72-AH059 or NMSB 72-G448 on the IP compressor shaft. This NMSB is anticipated to be the subject of an Airworthiness Directive. (2) At overhaul Not applicable E. Approval The technical content of this Non-Modification Service Bulletin was approved under the authority of Design Organisation Approval EASA.21J.035 on Dec.10/12. F. Manpower (1) On-wing (a) Time to gain access 1 hour (after normal engine cool down and opening of C-ducts)(one man). (b) Time to inspect 1.5 hours (two men). (c) Time to restore to serviceable condition 0.5 hours (one man). (2) At overhaul Not applicable**Printed in Great Britain**



# RB.211−72−AH059 Page 2 Dec.11/12 Dec.11/12G. Material Price and Availability OMat 2/142 - Safety Cable H. Tooling Price and Availability The following equipment is required to perform the inspection (1) 4mm or 6mm flexible borescope with forward viewing and side view tips (2) IP Rotor turning tool HU43985 (Trent 900) (3) Borescope guide tube HU82346 or, as an alternative, a locally manufactured nylon guide tube (made in accordance with the approximate dimensions given in Fig.7) may be required to assist the correct positioning of the probe viewing tip during inspection. (4) LP system immobiliser HU44211 or HU44525-1 I. References (1) Rolls-Royce RB211 Non-Modification Service Bulletins: (a) 72-G269 Engine - IP Compressor Shaft - Visual Inspection of Balance Land (b) 72-G448 Engine - IP Compressor Shaft - Eddy Current Inspection of Balance Land (2) Aircraft Maintenance Manual (AMM), 72-00-00, Turn the Engine Intermediate Pressure System.**Printed in Great Britain**



# RB.211−72−AH059 Page 3 Dec.11/12 Dec.11/122. Material Information A. Parts required to accomplish this NMSB: 75-22-49 FIG ITEM NO. NEW PART NO. QTY PART TITLE MAT OLD PART NO. INSTR DISP
13100 FW24803 AR Air Tube - FW24803 - 13106 AS48528 AR Bolt - AS48528 - 13107 AS48512 AR Bolt - AS48512 - 13125, 13133, 01033, 01041, 02059, 02051, 03541 AS48409 AR Bolt - AS48409 -

13126, 13136, 01034, 01042, 02060, 02052, 03542 K8831 AR Washer - K8831 -

13132, 13140, 01048, 02066, 02058 AS41104 AR Clip Nut - AS41104 -

13128, 13136 UL12526 AR Clip - UL12526 - 01044, 01036 UL12506 AR Clip - UL12506 - 02062 UL12505 AR Clip - UL12505 - 02054 UL12510 AR Clip - UL12510 - 03544 UL12012 AR Clip - UL12012 -**Printed in Great Britain**



# RB.211−72−AH059 Page 4 Dec.11/12 Dec.11/12FIG ITEM NO. NEW PART NO. QTY PART TITLE MAT OLD PART NO. INSTR DISP
03548 AS20624 AR Nut - AS20624 - 02056 UP10479 AR Spacer - UP10479 -

NOTE : Quantity As Required (AR) up to a maximum of 7.**Printed in Great Britain**



# RB.211−72−AH059 Page 5 Dec.11/12 Dec.11/123. Accomplishment Instructions A. On-Wing Borescope Inspection of Trent 900 Engines

WARNING : YOU MUST NOT TOUCH HOT PARTS WITHOUT APPLICABLE GLOVES. HOT PARTS CAN CAUSE AN INJURY. IF YOU GET AN INJURY PUT IT IN COLD WATER FOR 10 MINUTES AND GET MEDICAL AID. WARNING : DO NOT TOUCH THE COMPONENTS OF THE OIL SYSTEM IF THE ENGINE IS HOT. THESE COMPONENTS STAY HOTTER THAN OTHER COMPONENTS. HOT COMPONENTS CAN CAUSE INJURY. CAUTION : IN ORDER TO REDUCE THE POTENTIAL FOR MULTIPLE ENGINE IN FLIGHT SHUTDOWN, POWER LOSS OR OTHER ANOMALIES DUE TO MAINTENANCE ERROR, ROLLS-ROYCE RECOMMENDS THAT OPERATORS AVOID PERFORMING MAINTENANCE ON MULTIPLE ENGINES INSTALLED ON THE SAME AIRCRAFT AT THE SAME TIME. IF IT IS NOT POSSIBLE TO AVOID MAINTENANCE ON MORE THAN ONE ENGINE AT THE SAME TIME, ROLLS-ROYCE RECOMMENDS THAT ADDITIONAL CONTROLS ARE APPLIED IN ORDER TO ENSURE THAT MAINTENANCE TASKS HAVE BEEN COMPLETED AS DEFINED. MAINTENANCE GUIDELINES SHOULD BE REVISED, WHERE POSSIBLE, TO PROMOTE THIS RECOMMENDATION. CAUTION : DO NOT START THE BORESCOPE INSPECTION UNTIL THE ENGINE HAS COOLED TO WITHIN THE BORESCOPE MANUFACTURERS RECOMMENDATIONS. THE ENGINE IS HOT IMMEDIATELY AFTER THE ENGINE IS STOPPED AND CAN CAUSE BURNS AND DAMAGE TO BORESCOPE INSPECTION EQUIPMENT. (1) Prepare the engine for Borescope Inspection of the Intermediate Pressure (IP) Compressor Stage 8 Balance Land. (a) Open the applicable circuit breakers and install safety tags in accordance with Aircraft Maintenance Manual (AMM) 72-00-00, Turn the Engine Intermediate Pressure System. (b) Safely open the left and right thrust reversers in accordance with AMM 72-00-00, Turn the Engine Intermediate Pressure System. (c) Use the LP system immobiliser (HU44211 or HU44525-1) to prevent movement of the LP compressor in accordance with AMM 72-00-00, Turn the Engine Intermediate Pressure System. (d) Attach the Rolls-Royce Trent IP Turning Tool (HU43985) to turn the IP system in accordance with AMM 72-00-00, Turn the Engine Intermediate Pressure System.**Printed in Great Britain**



# RB.211−72−AH059 Page 6 Dec.11/12 Dec.11/12(e) Gain access to the intermediate case Vane 8, by removing the IP8 air tube (P/N FW24803). Refer to Fig.1. CAUTION : YOU MUST HOLD THE TUBE(S) WHEN YOU LOOSEN OR TIGHTEN THE CONNECTIONS. MAKE SURE THE TUBE(S) CANNOT TWIST. DAMAGE CAN OCCUR IF THE TUBE(S) DO TWIST. (i) Disassemble and retain the seven clip positions 210106, 210107, 210101, 210100, 210104, 210103 and 210105. (ii) Disconnect air tube (P/N FW24803) from the two IP8 air tubes (P/N FW48296 and P/N FW30489). (iii) Remove and retain the two bolts (P/N AS48528) and the one bolt (P/N AS48512) that attach the tube to the compressor intermediate case. (iv) Remove the IP8 air tube (P/N FW24803). (2) Perform the initial borescope inspection of the IP compressor stage 8 disc balance land using the forward viewing tip. Refer to Fig.2. CAUTION : YOU MUST MAKE SURE THAT THE BORESCOPE IS NOT IN THE PATH OF ANY ROTATING COMPONENT WHEN YOU TURN THE ENGINE. IF THE BORESCOPE AND THE ROTATING COMPONENT TOUCH, DAMAGE TO EITHER THE ROTATING COMPONENT OR THE BORESCOPE WILL OCCUR. (a) Insert the borescope with a forward viewing tip fitted into the intermediate case IP8 offtake hole. The vane will guide the borescope towards the rear of the IP compressor stage 8 disc. Articulate the borescope to view the balance land with a forward viewing tip as shown in Fig.2. (b) Use the HU43985 turning tool to slowly rotate the IP compressor and inspect the balance land from over the entire circumference of the balance land. Note that together with the final inspection, zone A of the balance land should be inspected over the entire circumference. Refer Fig.3. (c) Look for cracks, dents or nicks and loose balance weights (see Fig.4 and Fig.5). For acceptance criteria refer to step 3.A.(5). NOTE : Carefully inspect the area around the balance weights. Carefully inspect all around the edge of the clamp plate to make sure there is no cracking that has started underneath the clamp plate. (d) Record the results in Appendix 1. (e) Withdraw the borescope from the intermediate case.**Printed in Great Britain**



# RB.211−72−AH059 Page 7 Dec.11/12 Dec.11/12(3) Perform the final borescope inspection of the IP compressor stage 8 disc balance land using the side viewing tip. Refer to Fig.2. CAUTION : YOU MUST MAKE SURE THAT THE BORESCOPE IS NOT IN THE PATH OF ANY ROTATING COMPONENT WHEN YOU TURN THE ENGINE. IF THE BORESCOPE AND THE ROTATING COMPONENT TOUCH, DAMAGE TO EITHER THE ROTATING COMPONENT OR THE BORESCOPE WILL OCCUR. (a) Insert the borescope with a side viewing tip fitted into the guide tube so that the tip of the borescope is just short of the guide tube end. Face the curved end of the guide tube towards the front of the engine and insert it into the intermediate case IP8 offtake hole. The guide tube will need to be straightened by hand to go into the vane. Push the guide tube into the engine until its end is in the cavity behind the stage 8 disc when it will then spring back to its original shape. (b) Push the borescope through the guide tube until the viewing tip emerges from the guide tube. Rotate and articulate the borescope until it views the balance land recess outer diameter and chamfer as shown in Fig.2. (c) Use the HU43985 turning tool to slowly rotate the IP compressor and inspect the balance land over the entire circumference of the balance land. Note that together with the initial inspection, zone A of the balance land should be inspected over the entire circumference. Refer to Fig.3. (d) Look for cracks, dents or nicks and loose balance weights (Refer to Fig.5 and Fig.6). For acceptance criteria refer to step 3.A.(5). NOTE : Carefully inspect the area around the balance weights. Carefully inspect all around the edge of the clamp plate to make sure there is no cracking that has started underneath the clamp plate. (e) Record the results in Appendix 1. (f) Withdraw the borescope until the viewing tip is inside the guide tube and then withdraw the borescope and guide tube through the intermediate case.**Printed in Great Britain**



# RB.211−72−AH059 Page 8 Dec.11/12 Dec.11/12(4) Restore the engine to serviceable condition. CAUTION : YOU MUST HOLD THE TUBE(S) WHEN YOU LOOSEN OR TIGHTEN THE CONNECTIONS. MAKE SURE THE TUBE(S) CANNOT TWIST. DAMAGE CAN OCCUR IF THE TUBE(S) DO TWIST. (a) Install the IP8 air tube (P/N FW24803). Refer to Fig.1. (i) Attach the IP8 air tube (P/N FW24803) to the two tubes (P/N FW30489 and P/N FW48296). (ii) Attach the tube to the compressor intermediate case with the two bolts (P/N AS48528) and the bolt (P/N AS48512). (iii) Torque the two bolts (P/N AS48528) to 11,5 Nm (100 lbfin.) and the bolt (P/N AS48512) to 11,5 Nm (100 lbfin). (iv) Assemble the clip positions 210106, 210107, 210101, 210100, 210104, 210103 and 210105. (v) Torque the tube nut on the tube (P/N FW30489) that connects to the tube (P/N FW24803) to 84,0 Nm (61.9 lbfft). (vi) Torque the tube nut on the tube (P/N FW48296) that connects to the tube (P/N FW24803) to 61,0 Nm (540 lbfin). (vii) Secure the tube connection with OMat 2/142 safety cable. (b) Make the engine ready for operation. (i) Remove the Rolls-Royce Trent IP turning tool (HU43985) and LP system immobiliser (HU44211) or (HU44525-1) in accordance with AMM 72-00-00, Turn the Engine Intermediate Pressure System. (ii) Return the engine to operating condition in accordance with the AMM, 72-00-00, Turn the Engine Intermediate Pressure System. (5) Acceptance Criteria (a) Cracked - Reject, inform Rolls-Royce as soon as practically possible. (b) Dented or Nicked: (i) Reject within 20 cycles. Supply pictures of dent or nick to Rolls-Royce Technical Help Desk.**Printed in Great Britain**



# RB.211−72−AH059 Page 9 Dec.11/12 Dec.11/12(c) Loose balance weights: (i) Reject within 20 cycles. Supply pictures of balance weights to Rolls-Royce Technical Help Desk. NOTE : If any of the acceptance criteria in step 3.A.(5) are not met; retain and quarantine the balance weights, clamp plates, bolts and washers and IP compressor shaft when removed within 20 cycles. Refer to Rolls-Royce via your local representative within 2 weeks of the inspection. (6) Record the inspection results on the inspection sheet provided in Appendix 1 or similar form containing the same information. (7) Accomplishment of this Non-Modification Service Bulletin should be recorded in the engine logbook.**Printed in Great Britain**



# RB.211−72−AH059 Page 10 Dec.11/12 Dec.11/12deh0013240 210106

210107

210101 210100 210104 210103

210105 TUBE FW24803



## B **C C**  **B**

TUBE FW48296

TUBE FW30489 BOLT AS48528

(2 off) BOLT AS48512

TUBE FW24803 COMPRESSOR INTERMEDIATE CASE FW61486 72−33−10

02−500

**NOTE:** All IPC Fig/Item numbers are 75−22−49 unless identified differently 

## A



## A 13−100

13−500

13−700 13−106 13−107

13−100

Trent 900 - Location of IP8 air tube Fig.1 (sheet 1 of 8)**Printed in Great Britain**



# RB.211−72−AH059 Page 11 Dec.11/12 Dec.11/12FW31940 02−240

CLIP POSITION 210100

deh0013230 AS48409 75−22−49

13−125 K8831 75−22−49

13−126
UL12526 75−22−49

13−128

AS41104 75−22−49

13−132 72−00−41 FW24803 75−22−49

13−100

BRACKET BOLT

WASHER

CLIP

CLIP NUT TUBE

Clip Position 210100 Fig.1 (sheet 2 of 8)**Printed in Great Britain**



# RB.211−72−AH059 Page 12 Dec.11/12 Dec.11/12AS48409 75−22−49

13−133 K8831 75−22−49

13−134

UL12526 75−22−49

13−136

AS41104 75−22−49

13−140 CLIP POSITION 210106

deh001323 1 FW26575 72−41−11

01−342 FW24803 75−22−49

13−100 BOLT
WASHER

CLIP

CLIP NUT BRACKET TUBE

Clip Position 210106 Fig.1 (sheet 3 of 8)**Printed in Great Britain**



# RB.211−72−AH059 Page 13 Dec.11/12 Dec.11/12deh0013245 AS48408 71−52−23

01−033 K8831 71−52−23

01−034
UL12506 71−52−23

01−036

AS41104 71−52−23

01−040

CLIP POSITION 210103 ELECTRICAL

HARNESS 71−52−23

01−015

FW24803 75−22−49

13−100 BOLT
WASHER

CLIP

CLIP NUT FW30246

TUBE

Clip Position 210103 Fig.1 (sheet 4 of 8)**Printed in Great Britain**



# RB.211−72−AH059 Page 14 Dec.11/12 Dec.11/12deh0013243 AS48408 71−52−23

01−041 K8831 71−52−23

01−042 UL12506 71−52−23

01−044

AS41104 71−52−23

01−048

CLIP POSITION 210104 ELECTRICAL

HARNESS 71−52−23

01−015

FW24803 75−22−49

13−100 BOLT
WASHER

CLIP

CLIP NUT FW30246

TUBE

Clip Position 210104 Fig.1 (sheet 5 of 8)**Printed in Great Britain**



# RB.211−72−AH059 Page 15 Dec.11/12 Dec.11/12deh0013244 BOLT 77−32−15

02−059 WASHER 77−32−15

02−060

CLIP 77−32−16

02−062 CLIP 77−32−15

02−062

CLIP NUT 77−32−15

02−066
CLIP POSITION 210105 TUBE 75−22−49

13−100 VIBRATION

LEAD 1 77−32−14

01−200 VIBRATION

LEAD 2 77−32−14

01−200 AS48409
K8831

UL12505 UL12505

AS41104 FW24803

922−347−000−111 922−347−000−111

Clip Position 210105 Fig.1 (sheet 6 of 8)**Printed in Great Britain**



# RB.211−72−AH059 Page 16 Dec.11/12 Dec.11/12BOLT 71−51−42

02−051

WASHER 71−51−42

02−052 CLIP 71−51−42

02−054

TUBE 75−22−49

13−100 CLIP NUT 71−51−42

02−058

CLIP POSITION 210107

deh0013241 SPACER 71−51−42

02−056 ELECTRICAL

HARNESS 71−51−42

01−015 AS48415

K8831 UL12510

FW24803

AS41104 UP10479 FW34195

Clip Position 210107 Fig.1 (sheet 7 of 8)**Printed in Great Britain**



# RB.211−72−AH059 Page 17 Dec.11/12 Dec.11/12AS48408 79−22−49

03−541

K8831 79−22−49

03−542 FW24803 75−22−49

13−100

AS20624 79−22−49

03−548

CLIP POSITION 210101

deh0013242 FW44988 79−22−49

03−500 UP12012 79−22−49

03−544 BOLT

WASHER TUBE

NUT TUBE CLIP

Clip Position 210101 Fig.1 (sheet 8 of 8)**Printed in Great Britain**



# RB.211−72−AH059 Page 18 Dec.11/12 Dec.11/12deh0013225 GUIDE TUBE BORESCOPE



## A **A**

SIDE VIEWING TIP FINAL INSPECTION

FORWARD VIEWING TIP

INITIAL INSPECTION

Trent 900 Engines - Borescope View Directions Fig.2**Printed in Great Britain**



# RB.211−72−AH059 Page 19 Dec.11/12 Dec.11/12deh0013229 

## A **A**

ZONE A

Trent 900 Engines - Identification of Zone A - The Zone to be Inspected Fig.3**Printed in Great Britain**



# RB.211−72−AH059 Page 20 Dec.11/12 Dec.11/12CAREFULLY INSPECT AROUND THE EDGE OF THE CLAMP PLATE

TO ENSURE THAT THERE IS NO CRACK THAT HAS STARTED UNDERNEATH THE CLAMP PLATE

deh0013226 

### CRACK (Example)

Previously seen Crack Position on Trent 700 Engine Fig.4**Printed in Great Britain**



# RB.211−72−AH059 Page 21 Dec.11/12 Dec.11/12deh0013228 CIRCUMFERENTIAL FWD
INNER DISC WASHER TIGHT AND CORRECTLY FITTED, WITH LOCKING FEATURES BENT UPWARDS, MAKING CONTACT WITH BOLT HEAD

BOLT HEAD CLOSELY ATTACHED TO CLAMP PLATE

NO VISIBLE GAPS BETWEEN CLAMP PLATE AND WEIGHT OR

WEIGHT AND BALANCE LAND

BALANCE LAND

Properly fitted Balance Weight Fig.5**Printed in Great Britain**



# RB.211−72−AH059 Page 22 Dec.11/12 Dec.11/12deh0013227 CRACK CAREFULLY INSPECT AROUND THE EDGE OF THE CLAMP PLATE

TO ENSURE THAT THERE IS NO CRACK THAT HAS STARTED UNDERNEATH THE CLAMP PLATE



### (Example)

Previously seen Crack Position on Trent 800 Engine Fig.6**Printed in Great Britain**



# RB.211−72−AH059 Page 23 Dec.11/12 Dec.11/12deh0013727 288 mm

290 mm 326 mm 38 mm

52°

Ø 7.5 mm

Ø 10 mm 97 mm
R 35.5 mm

Nylon Guide Tube Fig.7**Printed in Great Britain**



# RB.211−72−AH059 Page 24 Dec.11/12 Dec.11/121. This form is to be completed for every shaft inspected in accordance with Accomplishment Instructions (3.A.). 2. Record Accomplishment of this Non-Modification Service Bulletin in accordance with local Service Bulletin tracking procedures 3. Advise your local Rolls-Royce service representative of NMSB accomplishment and inspection results regardless of findings. Trent 900 Visual Borescope Inspection Results Form to be completed for every engine inspected, results to be sent to Rolls-Royce, via your local representative. Feedback Sheet NMSB 72-AH059 Visual Borescope Inspection of IPC 8 Balance Land Operator Date of Inspection Engine Serial Number Engine Mark Engine CSN Engine TSN IPC Shaft Part No. IPC Shaft Ser No. IPC Shaft CSN IPC Shaft TSN Borescope Inspection Result (if none, record N/A, if finding record dimensions and position) Initial Inspection Final Inspection Cracking
Dents or Nicks on the Balance Land Loose Balance Weights Inspected by: Stamp: APPENDIX 1**Printed in Great Britain**



# RB.211−72−AH059 Appendix 1 - Page 1 of 1 Dec.11/12 Dec.11/12