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 21. 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 Dec 17/09 R Dec. 6/12Revision 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. R R R R 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 Dec 17/09 R Dec. 6/12E. 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, Jan.13/11, May 29/12 R and was re-approved on Dec. 4/12. 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 Dec 17/09 R Dec. 6/12Part 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.**Printed in Great Britain**



# RB.211−72−AG046 Page 4 Dec 17/09 R Dec. 6/12(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**



# RB.211−72−AG046 Page 5 Dec 17/09 R Dec. 6/122. 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 Dec 17/09 R Dec. 6/12Part 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 Page 7 Dec 17/09 R Dec. 6/123. 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.**Printed in Great Britain**



# RB.211−72−AG046 Page 8 Dec 17/09 R Dec. 6/12(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).**Printed in Great Britain**



# RB.211−72−AG046 Page 9 Dec 17/09 R Dec. 6/12(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**



# RB.211−72−AG046 Page 10 Dec 17/09 R Dec. 6/12CAUTION : 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 and proceed to step (5)(p)(i). R The range indicating that FCL metering 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. R R R (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. R R R NOTE : The emery paper will be used for spectroscopic analysis if the inspection shows that the panel is made from N75 material. R R R (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.**Printed in Great Britain**



# RB.211−72−AG046 Page 11 Dec 17/09 R Dec. 6/12(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). R R (i) If Rolls-Royce confirms that the material is C263 (False Positive), then the Engine should be accepted and no further action is required. R R R (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: R R R R FCL meter panel total cycles since new (TCSN) R R Fly-on limit
< 3,000 cycles R 400 cycles 3,000 - 7,000 cycles R 100 cycles > 7,000 cycles R 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.**Printed in Great Britain**



# RB.211−72−AG046 Page 12 Dec 17/09 R Dec. 6/12(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.).**Printed in Great Britain**



# RB.211−72−AG046 Page 13 Dec 17/09 R Dec. 6/12(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).**Printed in Great Britain**



# RB.211−72−AG046 Page 14 Dec 17/09 R Dec. 6/12(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**Printed in Great Britain**



# RB.211−72−AG046 Page 15 Dec 17/09 R Dec. 6/12alloy 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.**Printed in Great Britain**



# RB.211−72−AG046 Page 16 Dec 17/09 R Dec. 6/12(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.**Printed in Great Britain**



# RB.211−72−AG046 Page 17 Dec 17/09 R Dec. 6/12(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.**Printed in Great Britain**



# RB.211−72−AG046 Page 18 Dec 17/09 R Dec. 6/12(p) If the reading indicates that the metering panel is N75, contact Rolls-Royce Technical Services through your local Field Service Office and proceed to step (5)(p)(i). R The range indicating that FCL metering 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. R R R (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. R R R NOTE : The emery paper will be used for spectroscopic analysis if the inspection shows that the panel is made from N75 material. R R R (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 R R the emery paper sample. Do not exceed the fly-on limits in 3.C (6)(c)(ii) R R

(i) If Rolls-Royce confirms that the material is C263 (False Positive), then the Engine should be accepted and no further action is required. R R R (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: R R R R**Printed in Great Britain**



# RB.211−72−AG046 Page 19 Dec 17/09 R Dec. 6/12FCL meter panel total cycles since new (TCSN) R R Fly-on limit
< 3,000 cycles R 400 cycles 3,000 - 7,000 cycles R 100 cycles > 7,000 cycles R 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.**Printed in Great Britain**



# RB.211−72−AG046 Page 20 Dec 17/09 R Dec. 6/12(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.**Printed in Great Britain**



# RB.211−72−AG046 Page 21 Dec 17/09 R Dec. 6/12G 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.**Printed in Great Britain**



# RB.211−72−AG046 Page 22 Dec 17/09 R Dec. 6/12(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.**Printed in Great Britain**



# RB.211−72−AG046 Page 23 Dec 17/09 R Dec. 6/12View from the rear of the Engine showing Inspection access at FSN position 7. Fig.1**Printed in Great Britain**



# RB.211−72−AG046 Page 24 Dec 17/09 R Dec. 6/12Polished Metering Panel Fig.2**Printed in Great Britain**



# RB.211−72−AG046 Page 25 Dec 17/09 R Dec. 6/12View of Inserted Alloy Sorter Probe at Fuel Spray Nozzle position 7 - Walkers Scientific Inc. ATS-6044T - Alloy Sorter Fig.3**Printed in Great Britain**



# RB.211−72−AG046 Page 26 Dec 17/09 R Dec. 6/12View of Inserted Probe at Fuel Spray Nozzle Position 7 - Koslow Scientific Company TE-3000 Thermoelectric Alloy Sorter Fig.4**Printed in Great Britain**



# RB.211−72−AG046 Page 27 Dec 17/09 R Dec. 6/12Close up View of Probes Positioned on Polished Portion of Metering Panel Fig.5**Printed in Great Britain**



# RB.211−72−AG046 Page 28 Dec 17/09 R Dec. 6/12Fuel Manifold Tube Assembly Fig.6A**Printed in Great Britain**



# RB.211−72−AG046 Page 29 Dec 17/09 R Dec. 6/12Clip Stack Assemblies - 1914 and 668 Fig.6B**Printed in Great Britain**



# RB.211−72−AG046 Page 30 Dec 17/09 R Dec. 6/12Pressure Test Rig Connected to a Blanked Manifold Assembly Fig.7**Printed in Great Britain**



# RB.211−72−AG046 Page 31 Dec 17/09 R Dec. 6/12Record 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**Printed in Great Britain**



# RB.211−72−AG046 Appendix 1 - Page 1 of 2 Dec 17/09 R Dec. 6/12Record of achievement - Walker Scientific Inc. ATS-6044T - Alloy Sorter**Printed in Great Britain**



# RB.211−72−AG046 Appendix 1 - Page 2 Dec 17/09 R Dec. 6/12Record 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**Printed in Great Britain**



# RB.211−72−AG046 Appendix 2 - Page 1 of 2 Dec 17/09 R Dec. 6/12Record of achievement - Koslow Scientific Company TE-3000 Thermoelectric Alloy Sorter**Printed in Great Britain**



# RB.211−72−AG046 Appendix 2 - Page 2 Dec 17/09 R Dec. 6/12