LIST OF EFFECTIVE PAGES

The effective pages to this Service Bulletin following incorporation of Revision

3 are as follows:

Page Revision Number Revision Date

Bulletin

R 1 3 Dec.6/12

R 2 3 Dec.6/12

R 3 3 Dec.6/12

R 4 3 Dec.6/12

R 5 3 Dec.6/12

R 6 3 Dec.6/12

R 7 3 Dec.6/12

R 8 3 Dec.6/12

R 9 3 Dec.6/12

R 10 3 Dec.6/12

R 11 3 Dec.6/12

R 12 3 Dec.6/12

R 13 3 Dec.6/12

R 14 3 Dec.6/12

R 15 3 Dec.6/12

R 16 3 Dec.6/12

R 17 3 Dec.6/12

R 18 3 Dec.6/12

R 19 3 Dec.6/12

R 20 3 Dec.6/12

R 21 3 Dec.6/12

R 22 3 Dec.6/12

R 23 3 Dec.6/12

R 24 3 Dec.6/12

R 25 3 Dec.6/12

R 26 3 Dec.6/12

R 27 3 Dec.6/12

R 28 3 Dec.6/12

R 29 3 Dec.6/12

R 30 3 Dec.6/12

R 31 3 Dec.6/12

Appendix 1

R 1 3 Dec.6/12

R 2 3 Dec.6/12

Appendix 2

R 1 3 Dec.6/12

R 2 3 Dec.6/12

Printed in Great Britain

RB.211−72−AG046

Transmittal - Page 2
1. Planning Information

A. Effectivity

(1) Boeing 757

All RB211-535C Engines

All RB211-535E4 Engines except: 535E4-37/25, 535E4-37/39, 535E4-37/43,

535E4-37/44.

All RB211-535E4-B Engines except: 535E4-B-37/25, 535E4-B-37/35,

535E4-B-37/39, 535E4-B-37/41.

(2) Tupolev 204

All RB211-535E4-B-75 Engines.

NOTE: This Non-Modification Service Bulletin (NMSB) inspection is applicable

only to RB211-535C/E4/E4-B engines with Phase 2 Front Combustion Liners

(FCL) that are pre Service Bulletin (SB) 72-C230. SB72-C230 introduced a

new standard of FCL (Phase 5 Combustor) that is not affected by this

issue. Therefore this NMSB is not applicable to engines post SB72-C230,

and is not applicable to RB211-535E4-C engines that had a Phase 5

combustor fitted at entry into service. It is also not applicable to any

engine that has had NMSB 72-AF572 applied at engine shop visit.

B. Reason

During troubleshooting of a starting problem with a RB211-535E4-B engine, the

Fuel Spray Nozzles (FSNs) appeared misaligned and the engine was removed. Strip

investigation found that the FSNs were correctly positioned but that the Front

Combustion Liner (FCL) metering panel (EIPC 72-41-13, Fig/Item 02-324) was

cracked and distorted. Laboratory investigation revealed that the FCL metering

panel was to an incorrect material specification (N75 material, rather than

C263 material), which was determined to be the root cause of the FCL Metering

Panel cracking and distortion.

SB 72-7221 was issued, in 1984, to address the issue of Phase 2 FCL N75

metering panel cracking in the early marks of the RB211-524 engine; it replaced

the N75 metering panel with an improved standard made from C263. C263 metering

panels were fitted to all RB211-524G/H and RB211-535C/E4/E4-B engines at

initial delivery.

The use of N75 metering panels, where C263 was the intended material, has the

proven potential to lead to metering panel cracking. Significant metering panel

cracking could result in hot gas breakout from the engine casing.

ENGINE - COMBUSTION LINER - CHECK OF PHASE 2 FRONT COMBUSTION LINER METERING PANEL

MATERIAL - NON MODIFICATION SERVICE BULLETIN - NON - MOD.72-AG046

Printed in Great Britain

RB.211−72−AG046

Page 1 of 31

R Dec 17/09

Dec. 6/12
Revision 1 of this NMSB introduces an alternative alloy sorter. It also allows

accomplishment of this NMSB during engine shop visit.

Revision 2 of this NMSB extends the timeframe for compliance by one year,

following an updated assessment of service findings.

Revision 3 of this NMSB instructs taking a swab from the front combustion liner

metering panel using emery paper, and sending it to Rolls-Royce for

spectroscopic analysis. This should only be done if the inspection shows that

the panel is made from N75 material.

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C. Description

This Non-Modification Service Bulletin (NMSB) instructs an on-wing or in-shop

check for correct metering panel material, and the withdrawal from service of

any parts that have been incorrectly manufactured from N75 material.

Advise your Rolls-Royce Service representative of NMSB accomplishment and

inspection results, regardless of findings (refer to Appendix 1 and Appendix

2).

D. Compliance

ALERT

(1) Inspect all engines listed in section 1.A. Effectivity at the next

convenient maintenance opportunity or next shop visit, and no later than

31 July 2013.

(2) Inspect ANY Front Combustion Liner stock that can be fitted to those

engines listed in Section 1.A. Effectivity within 6 months of Revision 1

of this NMSB.

NOTE: This is a ONCE-ONLY inspection. No form of Non-Destructive

Examination certification is required for carrying out the

procedures detailed in this NMSB.

(3) This NMSB can be incorporated without carrying out the Accomplishment

Instructions in Section 3, if either:

(a) TV75295 has been incorporated, or

(b) The metering panel (EIPC 72-41-13, Fig/Item 02-324) was delivered from

Rolls-Royce after 23rd April 2007, or

(c) NMSB 72-AF572 has been carried out at engine shop visit.

Printed in Great Britain

RB.211−72−AG046

Page 2

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Dec. 6/12
E. Approval

The technical content of this Non-Modification Service Bulletin was approved

under the privilege of Design Organisation Approval EASA.21J.035 on Dec.17/09,

R and was re-approved on Dec. 4/12. Jan.13/11, May 29/12

F. Manpower

(1) On-wing

To gain access - 15 minutes (1 person).

To remove the FSN - 2 hours (1 person).

To clean and inspect - 0.5 hours (1 person).

To inspect the FCL if incorrect material found - 2 hours (1 person).

To replace the FSN - 2 hours (1 person).

To ground run and leak check - 4 hours (2 person).

To return the engine to a serviceable condition - 15 minutes (1 person).

The Rolls-Royce On-Wing Care Team are available to carry out this

procedure. If required, it can be arranged through your local Field

Service Office or Customer Service Officer/Manager.

NOTE: This task requires that TEST 4 - Running in (Engine Manual,

72-00-00-700-008) be carried out after completion.

(2) In shop

To gain access - 15 minutes (1 person).

To remove the FSN - 2 hours (1 person).

To clean and inspect - 0.5 hours (1 person).

To replace the FSN - 2 hours (1 person).

To return the engine to a serviceable condition - 15 minutes (1 person).

NOTE: This task requires that Test No.2 - Gas Generator Fuel and Oil Leak

Test (EM 72-00-00-700-006) and Test 05 - Running-in (EM

72-00-00-700-009) be carried out after completion.

G. Tooling.

The following tooling kit is required to accomplish Part 3 of this NMSB

Printed in Great Britain

RB.211−72−AG046

Page 3

R Dec 17/09

Dec. 6/12
Part No. Description Function

HU82287 Test equipment Determine FCL meter panel

material

SPL-10235 Pressure test adaptors Connect pressurised air

source for fuel supply

system

STD-6638 Air source - compressed.

filtered and dry

Pressurise fuel system for

test

HU27554 Pressure test plug (18

off)

Blank off fuel manifold

connections

HU27553 Blank (18 off) Blank off fuel manifold

connections

HU41769 Pressure gauge Measure pressure

H. References

(1) Rolls Royce RB211 reference Service Bulletins:

(a) 72-AF572

Engine - Combustion liner - Check of phase 2 front combustion liner

metering panel material

(b) 72-C230

Engine - Module 4 - Introduction of revised HP system incorporating an

improved combustor

(c) 72-8678

Engine - Miscellaneous Minor Alterations

(2) Engine Illustrated Parts Catalogue, 72-41-13, Engine - Combustion Liners.

(3) Engine Manual TASK, 72-00-00-700-006, Test No.2 - Fuel and Oil Leak Test.

(4) Engine Manual TASK, 72-00-41-020-018, Remove Fuel Spray Nozzles.

(5) Engine Manual TASK, 72-00-41-420-004, Install Fuel Spray Nozzles.

(6) Engine Manual TASK, 72-41-13-200-000, Pre SB 72-C230: Inspect Combustion

Front Liner Assembly - Inspection/Check-00.

(7) Aircraft Maintenance Manual TASK, 71-00-00/501, Test No.2 - Fuel and Oil

Leak Test.

(8) Aircraft Maintenance Manual TASK, 71-00-00/501, Test No.13 - Take-Off

Power.

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(9) Aircraft Maintenance Manual TASK, 72-00-00/601, Inspection of the

Combustion Liners and High Pressure Nozzle Guide Vanes (HPNGV).

(10) Aircraft Maintenance Manual TASK, 73-11-05/401, Remove/Install the Fuel

Spray Nozzle.

(11) Aircraft Maintenance Manual TASK, 73-11-11/501, Isolated Components of the

Manifold Drains System - System Test.

(12) NTO 529, Check of Phase 2 Front Combustion Liner Metering Panel for

Distortion and Cracking during routine Combustor Borescope.

Printed in Great Britain

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Page 5

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2. Material Information

A. Part required to accomplish this Service Bulletin

Part No. Part Title When Required

KB27112 Fuel Spray Nozzle Seal Ring Replace every time

BLT5265 Bolts On condition

KB27114 Seal Ring Replace every time

UP10274 Washer - Sealing Burner Ferrule Replace every time

UP10275 Seal Washer Replace every time

KB27113 Seal Ring Replace every time

UL11018 Carrier Assembly - Seal Ring

(Pre SB 72-8678)

Replace every time

UL21733 Carrier Assembly - Seal Ring

(SB 72-8678, Pre SB 72-C230)

Replace every time

UP10200 Ring - Metal Seal

(Pre SB 72-C230)

On condition

3506755 Ring - Metal Seal

(535 E4)

Replace every time

UL14915 Fuel drain manifold shroud to

disconnect panel assembly

(Pre SB 71-8135)

On condition

UL16654 Fuel drain manifold shroud to

disconnect panel assembly

(SB 71-8135)

On condition

AS21009 Bolt 0.250 in. dia x 0.562 in. On condition

LK70941 Washer On condition

CU37148 Washer On condition

400WSS6 Clip

CP668

On condition

AS20624 Nut

CP668

On condition

Printed in Great Britain

RB.211−72−AG046

Page 6

R Dec 17/09

Dec. 6/12
Part No. Part Title When Required

K8831 Washer, 0.190 in. dia

x 0,51 mm thk

CP668

On condition

UP10480 Spacer 15 mm

CP668 (Pre SB 71-9857)

On condition

UP10480 Spacer 10 mm

CP668 (SB 71-9857 )

On condition

UP10478 Spacer 5 mm

CP668 (SB 71-9857)

On condition

AS21421 Bolt 0.190 in. dia x 1.312 in.

CP668

On condition

400WSS4 Clip

CP668 and CP1914

On condition

Printed in Great Britain

RB.211−72−AG046

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3. Accomplishment Instructions

A. The accomplishment procedure will depend on the type of alloy sorter kit used:

Alloy Sorter Type Paragraph

Walker Scientific Inc. ATS-6044T -

Alloy Sorter

3.B.

Koslow Scientific Company TE-3000

Thermoelectric Alloy Sorter

3.C.

Consumable Materials

OMat 238 Lockwire 0.028 to 0.031 in. dia

Staybrite DTD189A (G02354)

B. Inspect the Phase 2 Front Combustion Liners (FCL), use Walker Scientific Inc.

ATS-6044T - Alloy sorter.

CAUTION: IN ORDER TO REDUCE THE POTENTIAL FOR MULTIPLE ENGINE IN-FLIGHT SHUTDOWN,

POWER LOSS OR OTHER ANOMOLIES 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.

(1) Prepare the aircraft for work in accordance with AMM 72-00-00/601 (Prepare

the Airplane for the Inspection).

(2) Remove the Fuel Spray Nozzle (FSN) at position 7 to allow access to the

FCL metering panel, in accordance with AMM 73-11-05/401 or EM TASK

72-00-41-020-018, Remove Fuel Spray Nozzles. Refer to Fig.1.

CAUTION: YOU MUST ONLY REMOVE THE MINIMUM AMOUNT OF MATERIAL THAT IS

NECESSARY TO EXPOSE A BRIGHT AND SHINY SURFACE. REMOVAL OF

EXCESSIVE MATERIAL CAN WEAKEN THE FCL METERING PANEL. MAKE SURE

THAT A NEW FLAP WHEEL IS USED EACH TIME TO AVOID CONTAMINATION

OF THE FCL.

NOTE: This operation is critical to make sure that an accurate reading is

obtained.

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(3) Clean a small area of the FCL metering panel using the supplied 120 grit

flap wheel in the rotary power tool. Carefully polish the surface of the

metering panel to remove any oxidation until the surface is bright and

shiny. This should take approximately 3 minutes. Refer to Fig.2.

(4) Make sure that the ATS-6044T - Alloy sorter is fully operational and, make

sure the battery is sufficiently charged if the mains electricity supply

is not being used. Also make sure that the probes are not misaligned and

that the alloy sorter is fully intact and there are no loose parts that

could become detached when the apparatus is used.

WARNING: THE HOT TIP OF THE ALLOY SORTER PROBE IS FACTORY PRESET TO

OPERATE AT A HIGH TEMPERATURE. AVOID DIRECT CONTACT WITH THE HOT

SIDE OF THE PROBE AS INJURY MAY OCCUR

CAUTION: MAKE SURE THAT THE PROBE DOES NOT COME INTO CONTACT WITH THE

SURFACES AFFECTED BY HEAT. WHEN THE PROBE IS NOT IN USE, MAKE

SURE THAT THE HOT SIDE IS ABOVE THE COLD SIDE

NOTE: Use emery paper only on the side of the test piece that is not

marked with the material type.

(5) Testing of the Test Pieces using the ATS-6044T - Alloy sorter.

CAUTION: DO NOT USE THE SAME PIECE OF EMERY PAPER FOR BOTH TEST PIECES.

IF YOU USE THE SAME PIECE OF EMERY PAPER IT CAN CAUSE THE

READINGS TO BE CONTAMINATED.

(a) Remove any dirt, contamination or oxidation from the surface of the

test pieces, use fine grade emery paper. Use the side of the test

piece not marked with the material type so that this does not get

removed.

(b) The alloy sorter has 2 probes, one hot and the other cold (these are

marked on the apparatus). Clean both of the probes before use, use an

acetone wipe.

(c) Set the temperature on the alloy sorter to LO.

NOTE: The alloy sorter has HI and LO positions. Make sure that it is

set to LO as this will affect the readout.

(d) The alloy sorter must be switched on and allowed to warm up until the

temperature readout stabilises at between 250 and 280 (this is a read

out only - there are no applicable temperature units).

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(e) Align the probes with the non-marked surface of the supplied N75 test

piece and touch the probe marked cold onto the surface first

immediately followed by the probe marked hot. Keep both probes in

contact with the test piece until the alloy sorter reading stabilises.

Record the reading. Repeat this process until 3 consistent readings

are obtained. Wait a minimum of 10 seconds before the next reading is

done. Calculate the average of the 3 consistent readings.

(f) Wipe the surface of the test piece with an acetone wipe to remove any

potential material contamination from the alloy sorter probes.

WARNING: TAKE CARE NOT TO HANDLE THE HOT PROBE. THIS WILL BURN THE SKIN.

(g) Record the 3 readings in Appendix 1 or equivalent.

(i) Record the average (mean) of the 3 readings as X in Appendix 1

or equivalent.

(h) Repeat steps (5)(a) to (5)(f) for the second test piece marked C263.

(i) Record the readings in Appendix 1 or equivalent.

(i) Record the average (mean) of the 3 readings as Y in Appendix 1

or equivalent.

NOTE: If at this stage it is not possible to get 3 consistent

readings for one of the test pieces, re-clean the surface

of the test piece with emery paper and repeat. If this does

not correct the problem stop the process and contact your

local Rolls-Royce representative. Test piece C263 is the

same material as the correct standard of Metering Panel.

(j) Insert the alloy sorter into the combustion case orifice at the

removed FSN at position 7 (refer to Fig.3). Use the alloy sorter as

per instruction in step (5)(e), test the cleaned surface of the FCL

metering panel (refer to Fig.5). Repeat this process until 3

consistent readings within the applicable value range for either N75

or C263 are obtained, (see Appendix 1 for values X and Y). Wait a

minimum of 10 seconds before the next reading is carried out.

Calculate the average of the 3 readings.

(k) Record the readings in Appendix 1 or equivalent.

(i) Record the average (mean) of the 3 readings as Z in Appendix 1

or equivalent.

(l) Check that the alloy sorter is fully intact and that no parts have

become detached and dropped into the engine.

Printed in Great Britain

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CAUTION: YOU MUST ONLY REMOVE THE MINIMUM AMOUNT OF MATERIAL THAT IS

NECESSARY TO EXPOSE A BRIGHT AND SHINY SURFACE. REMOVAL OF

EXCESSIVE MATERIAL CAN WEAKEN THE FCL METERING PANEL

(m) Locally clean the surface of the FCL metering panel where the alloy

sorter has been applied using the supplied 120 grit flap wheel in

rotary power tool to remove any potential material contamination from

the alloy sorter probes.

(n) Repeat steps (5)(d), (e) and (f) on the N75 and C263 sample test

pieces to confirm that the alloy sorter still correctly identifies the

materials. If the readings differ significantly from those originally

recorded in Appendix 1, contact Rolls-Royce Technical Services through

your local Field Service Office.

(o) If the readings taken on the engine FCL metering panel indicate that

it is C263 proceed to step (6)(e). The range indicating that FCL

metering panel is made from C263 is Z=Y +/- 3 units.

(p) If the reading indicates that the metering panel is N75, contact

Rolls-Royce Technical Services through your local Field Service Office

R The range indicating that FCL metering and proceed to step (5)(p)(i).

panel is made from N75 is Z=X +/- 3 units.

CAUTION: YOU MUST ONLY REMOVE THE MINIMUM AMOUNT OF MATERIAL THAT IS

NECESSARY FOR A SWAB TO BE TAKEN. REMOVAL OF EXCESSIVE MATERIAL

CAN WEAKEN THE FCL METERING PANEL.

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(i) Take a swab from the surface of the polished area using a fine

grade emery paper. Preserve this paper, and send to your

Rolls-Royce representative. Avoid contamination of this paper.

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NOTE: The emery paper will be used for spectroscopic analysis if

the inspection shows that the panel is made from N75

material.

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(q) If the reading is ambiguous (i.e. it cannot be determined whether the

metering panel is made from N75 or C263) check that the alloy sorter

is set to the LO setting. If it is not set to LO, then set the alloy

sorter to LO and repeat steps (5)(a) to (5)(p).

(r) If the alloy sorter is in the LO setting and the reading is still

ambiguous, stop the process and contact your local Rolls-Royce

representative.

(6) If the alloy sorter reading indicates that FCL metering panel is N75 do

these steps:

(a) If this NMSB is accomplished at shop visit, the FCL assembly must be

replaced with a FCL that conforms to this NMSB or NMSB 72-AF572 before

the engine is returned to service.

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(b) If this NMSB is accomplished on-wing, inspect the FCL metering panel

for signs of cracking in accordance with AMM 72-00-00/601 - Inspection

of the Combustion Liners and HPNGV. NTO529 gives advice with respect

to signs of FCL metering panel cracking and distortion. Reject if

damage is outside of acceptable limits given in the AMM - the FCL

assembly must be replaced with a FCL that conforms to this NMSB or

NMSB 72-AF572 before the engine is returned to service.

(c) If this NMSB is being accomplished on-wing and the FCL metering panel

conforms to AMM damage acceptance limits, then await Rolls-Royce

findings from

R

R the emery paper sample. Do not exceed the fly-on limits

in 3.C (6)(c)(ii).

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(i) If Rolls-Royce confirms that the material is C263 (False

Positive), then the Engine should be accepted and no further

action is required.

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(ii) If Rolls-Royce confirms that the material is N75, then the

complete FCL assembly must be removed and replaced with a FCL

that conforms to this NMSB or NMSB72-AF572 within the number of

flights specified below:

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R

FCL meter panel total cycles

since new (TCSN)

R

R

Fly-on limit

R < 3,000 cycles 400 cycles

R 3,000 - 7,000 cycles 100 cycles

R > 7,000 cycles 50 cycles

NOTE: Section 1.D. Compliance gives details on how you can determine

that the replacement FCL uses a metering panel in C263

material.

(d) If the TCSN of the FCL metering panel cannot be determined, use the

engine TCSN.

(e) Once the inspection is complete, refit the removed FSN in position 7

in accordance with AMM 73-11-05/401, Install the Fuel Spray Nozzle

(FSN) or EM TASK 72-00-41-420-004, Install Fuel Spray Nozzle.

(f) Use the internal inspection equipment to make sure that the FSN is

correctly installed AMM 72-00-00/601, Inspection of the Combustion

Liners and HPNGV or EM TASK 72-41-13-200-000, Inspection of front

combustion liner.

(g) If the NMSB is accomplished on-wing, do a pressure test of the

right-hand manifold.

(i) Disconnect the fuel drain - manifold shroud to disconnect panel

tube from the 4-way adaptor, and release, as necessary, the

clips to allow the tube to move. Refer to Fig.6A.

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(ii) Remove and retain clipstacks CP668 and CP1914. Refer to Fig.6B.

(iii) Attach the engine fuel feed pressure test adaptor, SPL10235 to

the left disconnect point on the 4-way adaptor.

(iv) Make sure the isolation valve is closed and attach a

satisfactory supply pressure.

(v) Do these steps to pressurise the system.

(1) Open the isolation valve and pressurise the system to 80

lbf/in.sq. (550kPa).

(2) Close the isolation valve.

(3) Do not change the system for a minimum time of 2 minutes.

(vi) Examine the system for a decrease in pressure.

If a pressure loss occurs, do these steps:

(1) Disconnect the pressure supply.

(2) Attach a label to each fuel manifold to burner tube.

(3) Disconnect and remove all fuel manifold to burner tubes from

the right hand fuel manifold half, Ref. AMM 73-11-11.

(4) Examine the condition of the plug seals.

(5) Lubricate and install a blank plug, HU27554 into the manifold

connection and attach it with a blanking plug, HU27553 at

each manifold connection.

(6) Do the pressure leak test operation in step (v) above again.

(7) If there is a decrease in pressure, disconnect the pressure

supply and replace the right fuel manifold half and do the

pressure leak test operation in step (v) above again (Ref.

AMM 73-11-11).

NOTE: A pressure leak test must be done as each manifold to

burner tube is installed to make sure there is not

more than one failure.

(8) Disconnect the pressure supply.

(9) Remove the blank plug HU27554 and blank plug HU27553,

farthest from the 4-way connector (see Fig.6.A.).

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(10) Install the correct fuel manifold to burner tube to the right

fuel manifold half and the fuel spray nozzle.

(11) Do the pressure leak test operation again:

A If there is a decrease in pressure, disconnect the

pressure supply.

B Replace the fuel manifold to burner tube.

C Do the pressure leak test operation in step (v) above.

D If there is no decrease in pressure, continue to remove

the blanks and plugs.

E Install the fuel manifold to burner tubes.

F Do the pressure leak test operation in step (v) above.

G Replace the defective fuel manifold to burner tubes as

necessary (Ref. AMM 73-11-11).

(vii) Disconnect the pressure supply and remove the pressure test

equipment.

(viii) Install the fuel drain manifold shroud to disconnect panel tube

to the 4-way adaptor.

(ix) Torque the connectors on the fuel drain manifold shroud to

disconnect panel tube in accordance with Standard Practices

Manual, 70-51-00, Torque tightening techniques.

(x) Wire lock the connectors. Use OMat 238, lockwire.

(xi) Install the clipstacks CP668 and CP1914. Refer to Fig.6A and

Fig.6B.

(1) Lubricate the bolts and nuts that attach the clips at the

clip positions CSA668 and CSA1914.

(2) Loosely assemble the items at the clip positions CSA668 and

CSA1914.

(xii) Torque the nuts of the clipstacks CSA668 and CSA1914 in

accordance with Standard Practices Manual, 70-51-00, Torque

tightening techniques.

(h) If the NMSB is accomplished on-wing, return the aircraft to its usual

condition in accordance with AMM 72-00-00/601 (Put the Airplane Back

in its Usual Condition).

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(i) If the NMSB is accomplished at overhaul and the 04 module is not

disassembled, do step (k).

(j) If the NMSB is accomplished at overhaul and the 04 module is

disassembled, do a leak test of the right-hand manifold. Refer to Fig.

7.

(i) Blank off all manifold connections using HU27554 (pressure

blanking plug) 18 off and HU41769 (pressure gauge) 1 off.

(ii) Make sure the sealing rubbers are in good condition.

(iii) Fit a nitrogen or air supply to drain point C on the four way

adaptor.

(iv) Pressurise to 550 kPa (80 psi). Use the HU41769, pressure

gauge.

(v) Close the ON/OFF valve and check there is no pressure decay for

a minimum of 2 minutes.

(vi) Open the ON/OFF valve and release the pressure.

(vii) If a leak is found:

(1) Check that the leak is not external through the rubber seal

joints on the connectors.

(2) Check the torque loading.

(3) If there is no leak through the rubber seals on the

connectors and the torque loading is correct, replace the

damaged part.

(k) Do Test No. 2 - Fuel and Oil Leak (AMM Task 71-00-00/501 or EM TASK

72-00-00-700-006).

(l) If NMSB is accomplished on-wing, Do test No. 13 - Take-off Power (AMM

Task 71-00-00/501).

C. Inspect the Phase 2 FCLs, use Koslow Scientific Company TE-3000 thermoelectric

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alloy sorter.

CAUTION: IN ORDER TO REDUCE THE POTENTIAL FOR MULTIPLE ENGINE IN-FLIGHT SHUTDOWN,

POWER LOSS OR OTHER ANOMOLIES 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.

(1) Prepare the aircraft for work in accordance with AMM 72-00-00/601 (Prepare

the Airplane for the inspection).

(2) Remove the Fuel Spray Nozzle (FSN) at position 7 to allow access to the

FCL metering panel, in accordance with AMM 73-11-05/401 or EM TASK

72-00-41-020-018, Remove Fuel Spray Nozzles. Refer to Fig.1.

(3) Clean a small area of the FCL metering panel using the supplied 120 grit

flap wheel in the rotary power tool. Carefully polish the surface of the

metering panel to remove any oxidation until the surface is bright and

shiny. This should take approximately 3 minutes. Refer to Fig.2.

CAUTION: YOU MUST ONLY REMOVE THE MINIMUM AMOUNT OF MATERIAL THAT IS

NECESSARY TO EXPOSE A BRIGHT AND SHINY SURFACE. REMOVAL OF

EXCESSIVE MATERIAL CAN WEAKEN THE FCL METERING PANEL MAKE SURE

THAT A NEW FLAP WHEEL IS USED EACH TIME TO AVOID CONTAMINATION

OF THE FCL.

NOTE: This operation is critical to make sure that an accurate reading is

obtained.

(4) Make sure that the TE-3000 - Alloy sorter is fully operational. Also make

sure that the probes are not misaligned and that the alloy sorter is fully

intact and there are no loose parts that could become detached whilst

using the apparatus.

WARNING: THE HOT TIP OF THE ALLOY SORTER PROBE IS FACTORY PRESET TO

OPERATE AT A HIGH TEMPERATURE. AVOID DIRECT CONTACT WITH THE HOT

SIDE OF THE PROBE AS INJURY MAY OCCUR.

CAUTION: MAKE SURE THAT THE PROBE DOES NOT COME INTO CONTACT WITH THE

SURFACES AFFECTED BY HEAT. WHEN THE PROBE IS NOT IN USE, MAKE

SURE THAT THE HOT SIDE IS ABOVE THE COLD SIDE.

NOTE: Use emery paper only on the side of the test piece that is not

marked with the material type.

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(5) Testing of the Test Pieces using the TE-3000 - Alloy sorter.

CAUTION: DO NOT USE THE SAME PIECE OF EMERY PAPER FOR BOTH TEST PIECES.

IF YOU USE THE SAME PIECE OF EMERY PAPER IT CAN CAUSE THE

READINGS TO BE CONTAMINATED.

(a) Remove any dirt, contamination or oxidation from the surface of the

test pieces, use fine grade emery paper. Use the side of the test

piece not marked with the material type so that this does not get

removed. Never use the same piece of emery paper for both test pieces

as this may contaminate the readings.

(b) The alloy sorter has 2 probes. Clean both of the probes before use,

using an fine grade emery paper where necessary or an acetone wipe.

The hot probe is identified.

(c) Plug the TE-3000 alloy sorter into a suitable power supply.

(d) Switch the power supply to ON. The amber light will remain constant

for about one minute.

WARNING: DO NOT TOUCH THE METAL SHAFT OR TIP OF THE PROBE. THIS WILL BURN

THE SKIN.

(e) Wait approximately 10 minutes for the probe temperature to stabilise.

The amber light will blink regularly to indicate the probe is at the

correct temperature. The display LCD must read 0000 +/- 2.

(f) Align the probes with the non-marked surface of the supplied N75 test

piece and touch the probe marked cold on the surface first,

immediately followed by the probe marked hot. Press lightly. Read the

number on the alloy sorter display. If required, press down lightly on

the alloy sorter one or two times to achieve a clear reading. Record

the reading. Repeat the process until 3 consistent readings are

obtained. Wait a minimum of 10 seconds between readings. Calculate the

average of the 3 consistent readings.

NOTE: Do not keep probes in contact with the material for more than 2

seconds as the values can drift because of heat dissipation.

(g) Record the 3 readings in Appendix 2 or equivalent.

(i) Record the average (mean) of the 3 readings as X in Appendix 2

or equivalent.

(h) Repeat steps (5)(a) thru (5)(f) for the second test piece marked C263.

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(i) Record the 3 readings in Appendix 2 or equivalent.

(i) Record the average (mean) of the 3 readings as Y in Appendix 2

or equivalent.

NOTE: If at this stage the test piece readings for X and Y do not

differ by a minimum of 25 units, re-clean the surface of

the test piece with emery paper and repeat. If this does

not correct the problem stop the process and contact your

local Rolls-Royce representative. Test piece C263 is the

same material as the correct standard of metering panel.

(j) Insert the alloy sorter into the combustion case orifice at the

removed FSN at position 7 (refer to Fig.4). Use the alloy sorter as

per instruction (5)(f), test the cleaned surface of the FCL metering

panel (refer to Fig.5). Repeat this process until 3 consistent

readings within the applicable value range for either N75 or C263 are

obtained, (see Appendix 2 for values X and Y). Wait a minimum of 10

seconds before the next reading is carried out. Calculate the average

of the 3 readings.

(k) Record the readings in Appendix 2 or equivalent.

(i) Record the average (mean) of the 3 readings as Z in Appendix 2

or equivalent.

(l) Check that the alloy sorter is fully intact and that no parts have

become detached and dropped into the engine.

CAUTION: YOU MUST ONLY REMOVE THE MINIMUM AMOUNT OF MATERIAL THAT IS

NECESSARY TO EXPOSE A BRIGHT AND SHINY SURFACE. REMOVAL OF

EXCESSIVE MATERIAL CAN WEAKEN THE FCL METERING PANEL

(m) Locally clean the surface of the FCL metering panel where the alloy

sorter has been applied using the supplied 120 grit flap wheel in

rotary power tool to remove any potential material contamination from

the alloy sorter probes.

(n) Repeat steps (5)(d) thru (5)(f) on the N75 and C263 sample test pieces

to confirm that the alloy sorter still correctly identifies the

materials. If the readings are outside the permitted range for either

material, contact Rolls-Royce Technical Services through your local

Field Service Office.

(o) If the readings taken on the engine FCL metering panel indicate that

it is C263 proceed to step (6)(e). The range indicating that FCL

metering panel is made from C263 is Z=Y +/- 10 units.

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(p) If the reading indicates that the metering panel is N75, contact

Rolls-Royce Technical Services through your local Field Service Office

R The range indicating that FCL metering and proceed to step (5)(p)(i).

panel is made from N75 is Z=X +/- 10 units.

CAUTION: YOU MUST ONLY REMOVE THE MINIMUM AMOUNT OF MATERIAL THAT IS

NECESSARY FOR A SWAB TO BE TAKEN. REMOVAL OF EXCESSIVE MATERIAL

CAN WEAKEN THE FCL METERING PANEL.

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(i) Take a swab from the surface of the polished area using a fine

grade emery paper. Preserve this paper, and send to your

Rolls-Royce representative. Avoid contamination of this paper.

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NOTE: The emery paper will be used for spectroscopic analysis if

the inspection shows that the panel is made from N75

material.

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(q) If the readings are ambiguous (i.e. it cannot be determined whether

the metering panel is made from N75 or C263), contact your local

Rolls-Royce office.

(6) If the alloy sorter reading shows that FCL metering panel is N75 do these

steps:

(a) If this NMSB is accomplished at shop visit, the FCL assembly must be

replaced with a FCL that conforms with this NMSB or NMSB 72-AF572

before the engine is returned to service.

(b) If this NMSB is accomplished on-wing, inspect the FCL metering panel

for signs of cracking in accordance with AMM 72-00-00/601 - Inspection

of the Combustion Liners and HPNGV. NTO529 gives advice with respect

to signs of FCL metering panel cracking and distortion. Reject if the

damage is outside of acceptable limits given in the AMM - the FCL

assembly must be replaced with a FCL that conforms to this NMSB or

NMSB 72-AF572 before the engine is returned to service.

(c) If this NMSB is accomplished on-wing and the FCL metering panel

conforms to AMM acceptance limits, then await Rolls-Royce findings

from

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R the emery paper sample. Do not exceed the fly-on limits in 3.C

(6)(c)(ii)

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(i) If Rolls-Royce confirms that the material is C263 (False

Positive), then the Engine should be accepted and no further

action is required.

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(ii) If Rolls-Royce confirms that the material is N75, then the

complete FCL assembly must be removed and replaced with a FCL

that conforms to this NMSB or NMSB72-AF572 within the number of

flights specified below:

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FCL meter panel total cycles

since new (TCSN)

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Fly-on limit

R < 3,000 cycles 400 cycles

R 3,000 - 7,000 cycles 100 cycles

R > 7,000 cycles 50 cycles

NOTE: Section 1.D. Compliance gives details on how you can determine

that the replacement FCL uses a metering panel in C263

material.

(d) If the TCSN of the FCL metering panel cannot be determined, use the

engine TCSN.

(e) Once the inspection is complete, refit the removed FSN in position 7

in accordance with AMM 73-11-05/401, Install the Fuel Spray Nozzle

(FSN) or EM TASK 72-00-41-420-004, Install Fuel Spray Nozzle.

(f) Use the internal inspection equipment to make sure that the FSN is

correctly installed AMM 72-00-00/601, Inspection of the Combustion

Liners and HPNGV or EM TASK 72-41-13-200-000, Inspection of Front

Combustion Liner.

(g) If the NMSB is accomplished on-wing, do a pressure test of the

right-hand manifold.

(i) Disconnect the fuel drain - manifold shroud to disconnect panel

tube from the 4-way adaptor, and release, as necessary, the

clips to allow the tube to move. Refer to Fig.6A.

(ii) Remove and retain clipstacks CP668 and CP1914. Refer to Fig.6B.

(iii) Attach the engine fuel feed pressure test adaptor, SPL10235 to

the left disconnect point on the 4-way adaptor.

(iv) Make sure the isolation valve is closed and attach a

satisfactory supply pressure.

(v) Do these steps to pressurize the system.

(1) Open the isolation valve and pressurise the system to 80

lbf/in.sq. (550kPa).

(2) Close the isolation valve.

(3) Do not change the system for a minimum time of 2 minutes.

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(vi) Examine the system for a decrease in pressure.

If a pressure loss occurs, do these steps:

(1) Disconnect the pressure supply.

(2) Attach a label to each fuel manifold to burner tube.

(3) Disconnect and remove all fuel manifold to burner tubes from

the right hand fuel manifold half, Ref. AMM 73-11-11.

(4) Examine the condition of the plug seals.

(5) Lubricate and install a blank plug, HU27554 into the manifold

connection and attach it with a blanking plug, HU27553 at

each manifold connection.

(6) Do the pressure leak test operation in step (v) above again.

(7) If there is a decrease in pressure, disconnect the pressure

supply and replace the right fuel manifold half and do the

pressure leak test operation in step (v) above again (Ref.

AMM 73-11-11).

NOTE: A pressure leak test must be done as each manifold to

burner tube is installed to make sure there is not

more than one failure.

(8) Disconnect the pressure supply.

(9) Remove the blank plug HU27554 and blank plug HU27553,

farthest from the 4-way connector (see Fig.6.A.).

(10) Install the correct fuel manifold to burner tube to the right

fuel manifold half and the fuel spray nozzle.

(11) Do the pressure leak test operation again:

A If there is a decrease in pressure, disconnect the

pressure supply.

B Replace the fuel manifold to burner tube.

C Do the pressure leak test operation in step (v) above.

D If there is no decrease in pressure, continue to remove

the blanks and plugs.

E Install the fuel manifold to burner tubes.

F Do the pressure leak test operation in step (v) above.

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G Replace the defective fuel manifold to burner tubes as

necessary (Ref. AMM 73-11-11).

(vii) Disconnect the pressure supply and remove the pressure test

equipment.

(viii) Install the fuel drain manifold shroud to disconnect panel tube

to the 4-way adaptor. Refer to Fig.6A.

(ix) Torque the connectors on the fuel drain manifold shroud to

disconnect panel tube in accordance with Standard Practices

Manual, 70-51-00, Torque tightening techniques.

(x) Wire lock the connectors. Use OMat 238, lockwire.

(xi) Install the clipstacks CP668 and CP1914. Refer to Fig.6A and

Fig.6B.

(1) Lubricate the bolts and nuts that attach the clips at the

clip positions CSA668 and CSA1914.

(2) Loosely assemble the items at the clip positions CSA668 and

CSA1914.

(xii) Torque the nuts of the clipstacks CSA668 and CSA1914 in

accordance with Standard Practices Manual, 70-51-00, Torque

tightening techniques.

(h) If the NMSB is accomplished on-wing, return the aircraft to its usual

condition in accordance with AMM 72-00-00/601 (Put the Airplane Back

in its Usual Condition).

(i) If the NMSB is accomplished at overhaul and the 04 module is not

disassembled, do step (k).

(j) If the NMSB is accomplished at overhaul and the 04 module is

disassembled, do a leak test of the right-hand manifold. Refer to Fig.

7.

(i) Blank off all manifold connections using HU27554 (pressure

blanking plug) 18 off and HU41769 (pressure gauge) 1 off.

(ii) Make sure the sealing rubbers are in good condition.

(iii) Fit a nitrogen or air supply to drain point C on the four way

adaptor.

(iv) Pressurise to 550 kPa (80 psi). Use the HU41769, pressure

gauge.

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(v) Close the ON/OFF valve and check there is no pressure decay for

a minimum of 2 minutes.

(vi) Open the ON/OFF valve and release the pressure.

(vii) If a leak is found:

(1) Check that the leak is not external through the rubber seal

joints on the connectors.

(2) Check the torque loading.

(3) If there is no leak through the rubber seals on the

connectors and the torque loading is correct, replace the

damaged part.

(k) Do Test No. 2 - Fuel and Oil Leak (AMM Task 71-00-00/501 or EM task

72-00-00-700-006).

(l) If NMSB is accomplished on-wing, Do test No. 13 - Take-off Power (AMM

Task 71-00-00/501).

D. Accomplishment of this Non-Modification Service Bulletin is to be recorded in

the engine logbook.

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View from the rear of the Engine showing Inspection access at FSN position 7.

Fig.1

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Polished Metering Panel

Fig.2

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View of Inserted Alloy Sorter Probe at Fuel Spray Nozzle position 7 - Walkers

Scientific Inc. ATS-6044T - Alloy Sorter

Fig.3

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View of Inserted Probe at Fuel Spray Nozzle Position 7 - Koslow Scientific Company

TE-3000 Thermoelectric Alloy Sorter

Fig.4

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Close up View of Probes Positioned on Polished Portion of Metering Panel

Fig.5

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Fuel Manifold Tube Assembly

Fig.6A

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Clip Stack Assemblies - 1914 and 668

Fig.6B

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Pressure Test Rig Connected to a Blanked Manifold Assembly

Fig.7

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Record of achievement - Walkers Scientific Inc. ATS-6044T - Alloy sorter

1. This Form is to be completed in accordance with Accomplishment Instructions

(3.B.).

2. Results to be sent to Rolls-Royce via your local representative.

APPENDIX 1

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Appendix 1 - Page 1 of 2

R Dec 17/09

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Record of achievement - Walker Scientific Inc. ATS-6044T - Alloy Sorter

Printed in Great Britain

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Appendix 1 - Page 2

R Dec 17/09

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Record of achievement - Koslow Scientific Company TE-3000 thermoelectric alloy

sorter

1. This Form is to be completed in accordance with Accomplishment Instructions

(3.C.).

2. Results to be sent to Rolls-Royce via your local representative.

APPENDIX 2

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Appendix 2 - Page 1 of 2

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Record of achievement - Koslow Scientific Company TE-3000 Thermoelectric Alloy

Sorter

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Appendix 2 - Page 2

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