GEnx-1B Service Bulletins (SBs)

SB 72-0309 R00 ENGINE - General (72-00-00) - Fan Stator Module Assembly Rework for

GEnx-1B PIP2 Engines

Date Printed:

2016/03/14

GE PROPRIETARY INFORMATION - Not to be used, disclosed to

others or reproduced without the express written consent of

GE. Technical data is considered ITAR and/or EAR controlled;

transfer of this data to a Non-US Person, without USG

authorization, is strictly prohibited.

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GEnx-1B SERVICE BULLETIN - 72-0309 R00 Revised:

03/11/2016

SB 72-0309 R00 ENGINE - GENERAL (72-00-00) - FAN STATOR

MODULE ASSEMBLY REWORK FOR GENX-1B PIP2 ENGINES

Issued:

03/11/2016

GE PROPRIETARY INFORMATION

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 in part.

This technical data is considered EAR controlled pursuant to 15 CFR

Parts 730-774 respectively. Transfer of this data by any means to a

Non-US Person, whether in the United States or abroad, without the

proper U.S. Government authorization (e.g., License, exemption, NLR,

etc.), is strictly prohibited.

GE Aviation authorizes the Federal Aviation Administration to

incorporate this document by reference in an Airworthiness Directive.

Copyright (2016) General Electric Company, U.S.A.

1. PLANNING INFORMATION

A. Effectivity

* * * GEnx-1B64/P2, -1B67/P2, -1B70/P2, -1B70/75/P2, -1B74/75/P2

This Service Bulletin is applicable to these GEnx-1B engines:

* GEnx-1B engines, serial numbers 956162, 956195, 956198, 956201, 956232,

956233, 956275, 956277, 956279, 956280, 956281, 956285, 956288, 956289,

956291, 956329, 956408, 956411, 956413, 956415, 956416, 956418, 956419,

956421, 956423, 956424, 956426, 956427, 956428, 956479, 956481, 956492,

956493, 956494, 956495, 956496, 956497, 956498, 956499, 956500, 956503,

956514, 956516, 956543, 956618, 956622, 956628, 956636, 956646, 956647,

956651, 956665, 956672, and 956677.

No combination of the affected engines can operate on the same

aircraft after March 25, 2016.

B. Description

This Service Bulletin provides a procedure to increase the flow

path clearance between the fan stator module assembly abradable

shroud and the fan blade of the fan module assembly by Repair

Document (RD) 835-394.
GEnx-1B Service Bulletins (SBs)

SB 72-0309 R00 ENGINE - General (72-00-00) - Fan Stator Module Assembly Rework for

GEnx-1B PIP2 Engines

Date Printed:

2016/03/14

GE PROPRIETARY INFORMATION - Not to be used, disclosed to

others or reproduced without the express written consent of

GE. Technical data is considered ITAR and/or EAR controlled;

transfer of this data to a Non-US Person, without USG

authorization, is strictly prohibited.

Page

2 of 7

C. Compliance

Category 1

GE recommends that you do this Service Bulletin before March 25,

2016.

The engine combination restriction is removed by the

accomplishment of either step 3.A.(1)(a) or 3.A.(1)(b) of 

ACCOMPLISHMENT INSTRUCTIONS which will fulfill compliance with

this Service Bulletin.

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 not operate any combination of the affected engine serial numbers (ESNs)

listed in this Service Bulletin on the same aircraft, unless the rework

procedures specified in step 3.A.(1)(a) or 3.A.(1)(b) of ACCOMPLISHMENT

INSTRUCTIONS are complied with.

(2) Condition:

An engineering assessment has determined that the fan module assembly

clearances are not optimized and there is a potential for fan rubs that can

result in unserviceable distress.

(3) Cause:

The fan module assembly clearances are not optimized for a population of

GEnx-1B PIP2 engines.

(4) Improvement:

This rework will increase the clearance between the fan stator module

assembly abradable shroud and the fan blade that reduces the potential for

fan rubs.

(5) Substantiation:

Substantiation is by comparative analysis.

F. Approval

The data contained in this Service Bulletin has been reviewed by

the appropriate governmental authority 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 fan module assembly, you will need

approximately 16 hours to complete the fan grind rework procedure

per RD 835-394, for each engine.

H. Weight and Balance

The complete compliance with this Service Bulletin decreases

weight by 2.5 lb (1.1 kg). Balance is unchanged.

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)
GEnx-1B Service Bulletins (SBs)

SB 72-0309 R00 ENGINE - General (72-00-00) - Fan Stator Module Assembly Rework for

GEnx-1B PIP2 Engines

Date Printed:

2016/03/14

GE PROPRIETARY INFORMATION - Not to be used, disclosed to

others or reproduced without the express written consent of

GE. Technical data is considered ITAR and/or EAR controlled;

transfer of this data to a Non-US Person, without USG

authorization, is strictly prohibited.

Page

3 of 7

GEK 112862, GEnx-1B Cleaning, Inspection, and Repair Manual (CIR)

GEK 112864, GEnx-1B Engine Illustrated Parts Catalog (EIPC)

GEK 112866, GEnx-1B Illustrated Tool and Equipment Manual (ITEM)

Repair Document (RD) 835-394 (P2 or higher), Engine Assembly -

Fan Stator Module Assembly - Repair - Unlimited Size Abradable

Shroud Repair

J. Publications Affected

GEK 112862, GEnx-1B Cleaning, Inspection, and Repair Manual (CIR)

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:

None.

(2) Other Spare Parts:

None.

(3) Consumables:

None.

B. Industry Support Information

Contact GE Customer Service Manager (CSM).

C. Configuration Chart

None.

D. Parts Disposition

Rework.

E. Tooling - Price and Availability

Tool Number Description

11C3039G02 Bracket Set - Forward Propulsor, Ground Handling and

Shipping (bracket set)

11C3359P02 Rollover Engine Ship Stand (shipping stand)

11C3443P03 Stand, Shipping (shipping stand)

11C4487P02 Stand, Shipping Engine/Propulsor (shipping stand)

11C4576P01 Stand, Shipping - Engine/Propulsor GEnx-1B (shipping stand)

11C4568P01 Stand, Full Engine Air Ship (shipping stand)

11C4628G01 Bracket Set - Forward Propulsor, Ground Handling and

Shipping (bracket set), alternate tool to 11C3039G02

3. ACCOMPLISHMENT INSTRUCTIONS

A. General

(1) The intention of this Service Bulletin can be achieved by one of the

options that follow:

NOTICE

APPROVAL OF REWORK SOURCES

The repair referred to below contains complex processes that could affect

engine reliability and/or performance. Therefore it is necessary to

substantiate the ability and adequacy of a repair source to successfully

accomplish the repair. A Technical License Agreement is also required.

Information concerning a Technical License Agreement is available from:

ATTN.: Manager, Technical Licensing

GE Aviation

One Neumann Way, M/D RM100
GEnx-1B Service Bulletins (SBs)

SB 72-0309 R00 ENGINE - General (72-00-00) - Fan Stator Module Assembly Rework for

GEnx-1B PIP2 Engines

Date Printed:

2016/03/14

GE PROPRIETARY INFORMATION - Not to be used, disclosed to

others or reproduced without the express written consent of

GE. Technical data is considered ITAR and/or EAR controlled;

transfer of this data to a Non-US Person, without USG

authorization, is strictly prohibited.

Page

4 of 7

Cincinnati, Ohio 45215-6301

U.S.A.

After the repair source has obtained a Technical License Agreement, the

Repair Document and the Repair Source Substantiation requirements may be

obtained from:

ATTN.: Repair Substantiation

GE Aviation

One Neumann Way, M/D S171

Cincinnati, Ohio 45215-6301

U.S.A.

OR

Phone: (513) 552-9563

Fax: (513) 552-9587

(a) Rework the fan stator module assembly (Figure 1) by RD 835-394 as

follows:

1 For the on-wing rework instructions, refer to step 3.B.

2 For the in-shop rework instructions, refer to step 3.C.

(b) Replace the fan stator module assembly (Figure 1). Refer to RD

835-394 and GEnx-1B EM, 72-00-01, REMOVAL 001 and INSTALLATION 001

(CONFIGURATION 02).

1 Take the tip clearance and full indicated run out (FIR) measurements

at F1.0, F1.5, and F2.0 locations of the fan stator module being

installed and submitt to GE Aviation Fleet Support for evaluation of

acceptability. There is a possibility that the data evaluation can

be under the desired clearance.

NOTE:The GE Aviation Fleet Support Contact Information is as follows:

Fleet Support:

http://www.geaviation.com/support/

OR

E-mail (USA): aviation.fleetsupport@ge.com 

E-mail (China & Asia): aviation.fleetsupport.cn@ge.com

OR

GE Aviation 

M/D Rm. 285

One Neumann Way

Cincinnati, OH 45215

U.S.A.

OR

U.S.A. Phone: 877-432-3272

International Phone: (513) 552-3272 

China & Asia Phone: +86 21 38777666

B. On-Wing Rework

NOTE: GE recommends that you do this procedure in a hangar or enclosed maintenance

facility.

(1) Remove the inlet cowl and cover the tail pipe to avoid uncontrolled engine

rotation, if outdoors. Refer to the GEnx-1B, Boeing 787 AMM, 71-11-01,

Removal, TASK DMC-B787-A-G71-11-01-00A-520A.

(2) Apply masking to cover the booster inlet, outlet guided vane (OGV).

(3) Rework the fan stator module assembly (Figure 1). Refer to RD 835-394 and

do as follows:

(a) Do a grind of sequences 1, 2, 4, 5, and 8.

(b) Post grind, measure the fan case FIR and clearances at F1.0 and F1.5

only.

(4) Mark the fan case with "Complied with rework per RD 835-394 per SB 72-0309"

in a 3x3 inch label located at 9 o'clock forward looking aft (FLA) (Figure

1). Refer to the SPM, 70-16-09, PERMANENT INK MARKING STANDARD PRACTICE -
GEnx-1B Service Bulletins (SBs)

SB 72-0309 R00 ENGINE - General (72-00-00) - Fan Stator Module Assembly Rework for

GEnx-1B PIP2 Engines

Date Printed:

2016/03/14

GE PROPRIETARY INFORMATION - Not to be used, disclosed to

others or reproduced without the express written consent of

GE. Technical data is considered ITAR and/or EAR controlled;

transfer of this data to a Non-US Person, without USG

authorization, is strictly prohibited.

Page

5 of 7

EPOXY COATED INK MARKING.

(5) Remove all masking.

(6) Install the inlet cowl. Refer to the GEnx-1B, Boeing 787 AMM, 71-11-01,

Installation, TASK DMC-B787-A-G71-11-01-00A-720A-A.

C. In-Shop Rework

(1) Install the 11C3039 or 11C4628 bracket set on either 11C3443, 11C3359,

11C4487, 11C4568, or 11C4576 shipping stand. Refer to Figure 2.

(2) Install the engine in the 11C3443, 11C3359, 11C4487, 11C4586, or 11C4576

shipping stand.

(3) Apply masking to cover the booster inlet and OGV.

(4) Rework the fan stator module assembly (Figure 1). Refer to RD 835-394 and

do as follows:

(a) Do a grind of sequences 1, 2, 4, 5, and 8.

(b) Post grind, measure the fan case FIR and clearances at F1.0 and F1.5

only.

(5) Mark the fan case with "Complied with rework per RD 835-394 per SB 72-0309"

in a 3x3 inch label located at 9 o'clock FLA (Figure 1). Refer to the

SPM, 70-16-09, PERMANENT INK MARKING STANDARD PRACTICE - EPOXY COATED INK

MARKING.

(6) Remove all masking.
GEnx-1B Service Bulletins (SBs)

SB 72-0309 R00 ENGINE - General (72-00-00) - Fan Stator Module Assembly Rework for

GEnx-1B PIP2 Engines

Date Printed:

2016/03/14

GE PROPRIETARY INFORMATION - Not to be used, disclosed to

others or reproduced without the express written consent of

GE. Technical data is considered ITAR and/or EAR controlled;

transfer of this data to a Non-US Person, without USG

authorization, is strictly prohibited.

Page

6 of 7

Fan Stator Module Assembly

Figure 1
GEnx-1B Service Bulletins (SBs)

SB 72-0309 R00 ENGINE - General (72-00-00) - Fan Stator Module Assembly Rework for

GEnx-1B PIP2 Engines

Date Printed:

2016/03/14

GE PROPRIETARY INFORMATION - Not to be used, disclosed to

others or reproduced without the express written consent of

GE. Technical data is considered ITAR and/or EAR controlled;

transfer of this data to a Non-US Person, without USG

authorization, is strictly prohibited.

Page

7 of 7

Engine Placement in Shipping Stand with Bracket Support

Figure 2

GE PROPRIETARY INFORMATION - Subject to the restrictions on the media.