EXPORT CONTROLLED SERVICE BULLETIN Rolls-Royce ENGINE — REINFORCING PLATES (23075877) FOR PLUG REPAIRED FRONT FRAME FORWARD FLANGE 1. PLANNING INFORMATION A. Effectivity (1). Engines All AE3007A Series and A3007C Series engines with a front frame that has been plug repaired to remove corrosion around bolt holes on the fan case flange. See Table 1 below: FRONT | ENGINE [¥APAD] FRONT | ENGINE [#APRD| FRONT | ENGINE |#RPRD FRAMESIN| SIN | HOLES |FRAMESIN| SIN__| HOLES |FRAMESIN| SIN | HOLES XXTTS960W 44 __[xxtaasow | sti082 | 14 [xxtesos | s1ia08 | 21 x22 6 [extsoatw | si10as | 19 |xxies0s | siisos | 24 XX13468 16 |xxisovew | siios2 | 16 |xxieaeaw | atisis | 74 TH0193 RAPP | 13 _|Ti2788 aii0o_| 11 _|xxissiew | sitaze | 6 yoxise4ew | RAPP | UNK |xxtaso7w | Sitio1 | 14 |xxteses | a1icd5 | UNK XXT685 RAPP 5 |xteesew | atiti0_| te |xxtesss | sitess | 7 yorests | si000s | 17 |xxissiew | sitite | 11 [xxiesee | a1ia45 e ~ TH2740 310008 | 9 [1312603 ginies_| 17 |xxtesse__| siteso | 4 xxTsoTow | s10011 | UNK |179 aii2s | 18 _|xxtsoeaw | site73_| 7 Tots Broo1s | 6 [xxissi7w | atts | 11 [xxtesis | stiaoa_| UNK Tat6077 ‘Br0020 | 21 __|xxisszaw | sitisi | 21 |xxiesio | sti400 | 16 Tai01s Boos | 16 |xxiasa7w | siiiss | 23 |xxiess7 | si1405 | 16 Ts48137 soos | 7 |xxteses__| aiiisa | 20 |xxteoze | sitaet | 17 rT aT0204 i080 | 4 |xxtsasow | stitar | 12 |xxieeaa | siiasa | 14 rraredee ‘si00s7_| 17 __ | xxtss20w | _si1138 @ | Ts16005 sass [8 xxisasaw | 310040 | 43 [xxtseaaw | ati14a_| 12 _|xxtesso | stiase | 7 TH102T0 siooat_| 14 [oxtsevaw | 31148 @__|xxiesso__|_siiaao_[ 5 yossaas | 310049 | UNK |xxis905W | aTIT62 1__pextesss_[aivass_ [17 xxisarew | 310050 | 4 |[xxisevaw | stitss | 10 [Ts10793 Birasa [10 xxizesaw | 310083 | 5 _|xxisscow | sili7S 2 _[xxteses__| sitar [12 yorizeTow | aio0ed | 20 [xxtsosaw | sitive | 14 |xxie7s9 | siieae | 9 yoizessw | 310085 | 4 _|xxisoaaw | siiiei | UNK |xxte7eo | stteoo | 3 THarts gi0087_| 5 |xxiseaew | sitiaT 18 __| Ts16068 3its67_| 10 xxizesew | si00s7 | 8 | Ti0155 Bias | 21 |xxteres__| sit600 | 2 xxtaasaw | sioios | 26 |[xxtessaw | 3tiTea 7__ [6173 Sit6Te 5 yxizesaw | sio10s [14 [xxtssiow | stirs | 14 | Tuie08e ies | 2 Table 1 — Front Frames with repaired bolt holes : April 2, 2002 ‘AE S007A-72-247 ‘AE 3007C-72-203 Page 1 of 15Rolls-Royce EXPORT CONTROLLED SERVICE BULLETIN LEFT SIDE VIEW OFFSET HOLE ENFORCING PLATE secnonM-M. AFT SURFACE OF FRONT FRAME FORWARD FLANGE WL Be - 0050 W. 127 mn) [:S0SED DURING INSTALLATION rena ROM BUSTA BOLT MOLE 00 ‘OF REINFORCING PLATES AAEPAR INT FOR CORROSION 0210 1, (5:33 men) IN BOLT HOLE REPRESENTS & FROM ExSTING BOLT CYUNOER OFFSET FROM THE HOLE 00 ‘CURRENT BOLT HOLE CL) sce540n Front Frame Forward Flange Corrosion Limits Fig. 3 ‘Apfil2, 2002 ‘AE S007A-72-247 ‘AE 3007C-72-203, Page 10 of 15EXPORT CONTROLLED Rolls-Royce SERVICE BULLETIN (3) Hcorrosion exceeds the above repairable limits: (2) Take digital photos of area (or provide detailed sketch) and submit them to Ralls-Royee CSM for disposition (©) Continue the installation of the reinforcing plates. (c) 100 hours fly-on authorized while waiting results of disposition. WARNING: D0 NOT GET THE ANTISEIZE COMPOUND ON YOUR SKIN OR BREATHE THE VAPORS. IT IS POISONOUS. IF YOU GET IT ON YOUR SKIN, CLEAN WITH SOAP AND WATER. IF YOU GET IT IN YOUR EYES, FLUSH WITH WATER, GET MEDICAL AID, (4) Apply the antiseize compound (NSN-165) to the threads of the new bolts (10, Fig. 4 or 8). (6) Install the new bolts (10), the washers (40), and the nuts (50) that attach the new reinforcing plate (30) (23075877) and the bracket (it necessary), to the fan case-to-tront ‘rame spiitine, Use the table below to determine the size of the bolt. NOTE: Position the reinforcing plate so that the offset hole on the front frame flange and the offset hole on the reinforcing plate are aligned. Balt Size ‘Bolt Hole Location ‘AE 3007A Series | MSO567—17 MS9557-16 __|2,3, 47, 48 MS9557-25 | 7,8, 23, 24, 29, 30, $3, 34, 40, 44 ‘AE 30070 Series | MS0567-17 | 1-6, 0-16, 16-22, 3 25-28, 31-32, 35-39, 42-45, 48 MS9557-18 _|Use as required WS9557-25 _|7, 8, 16, 17, 23, 24, 29, 30, 83, 34, 40, 41, 48, 47 (6) Use the torque wrench to torque the nuts (50) to 105-115 in-ib (11.9-12.9 Nm) (Ref. 70-01-04, SPM). NOTE: Make sure the nut does not touch the non-threaded shank of the bolt and a ‘minimum of three bolt threads extend past the nut when the itis fully torqued. (7) Repeat the steps 2.4.(1) thru (6) for remaining reinforcing plates, B. For engine at a Rolls-Royce authorized maintenance center. REF. FIG. 4 REF. FIG. 5 (1) Do the inspection ofthe front frame assembly (Ref. 72-25-16, EM), (2) Install the fan case to the front frame to the steps that follow: WARNING: DO NOT GET THE ANTISEIZE COMPOUND ON YOUR SKIN OR BREATHE THE VAPORS. IT IS POISONOUS. IF YOU GET IT ON YOUR, ‘SKIN, CLEAN WITH SOAP AND WATER. IF YOU GET IT IN YOUR EYES, FLUSH WITH WATER. GET MEDICAL AID. (a) Apply the antiseize compound (NSN-165) to the threads of the new bolts (10, Fig. 4 or 5). ‘April 2, 2002, ‘AE 3007A-72-247 ‘AE 3007C-72-203 Page 11 of 15Rolls-Royce SERVICE BULLETIN EXPORT CONTROLLED LEFT SIDE VIEW cea seas 10 AE 3007A Sories Fan Case-to-front Frame Spiitine Hardware ~ Installation FiG. 4 April 2, 2002 ‘AE 3007A-72-247 ‘AE 3007C~72-203 Page 12 of 18EXPORT CONTROLLED Rolls-Royce SERVICE BULLETIN LEFT SIDE VIEW eae Le whi mrese6 10 ‘AE 8007C Series Fan Case-to-tront Frame Spiitine Hardware ~ Installation FIG. 5 AE 3007A-72-247 April 2, 2002 ‘AE 3007C~72-203 Page 13 of 15EXPORT CONTROLLED Rolls-Royce SERVICE BULLETIN {b) Install the new bolts (10), the washers (40), and the nuts (50) that attach the new reinforcing plates (30) (23075877), the bracket if necessary, to the fan case-to-front frame splitine. Start at hole No. 1 bolt. Use the table below to determine the size of the NOTE: Position the reinforcing plate so that the offset hole on the front frame flange and the offset hole on the reinforcing plate are aligned. Balt Size Bolt Hole Location ‘AE SOO7A Series | MS9557-17 |, 9-6, 9-22, 25-28, 31-32, /95-39, 42-46 MS9557-18 _|2,3, 47, 48 WMS9557-25 | 7, 8,23, 24, 29, 30, 33, $4, 40, 41 AE S007G Series | MS0557-17 | 1-6, 9-15, 18-22, 25-28, 31-32, 35-39, 42-45, 48 MS9557-16 [Use as required MS9557-25 __|7, 8, 16, 17, 23, 24, 29, 30, 33, 34, 40, 41, 46, 47 (3). Use the torque wrench to torque the nuts (50) to 105~115 in-ib (11.9-12.9 Nm) (Ret. 70-01-04, SPM). NOTE: Make sure the nut does not touch the non-threaded shank of the bolt and a ‘minimum of three bolt threads extend past the nut when the its fully torqued. C. Record compliance with this service bulletin in the applicable section of the engine logbook. April, 2002 ‘AE 007A-72-247 ‘AE 3007C-72-203 Page 14 of 15Rolls-Royce EXPORT CONTROLLED SERVICE BULLETIN 3, MATERIAL INFORMATION A. Configuration Chart ROUS- ROYCE ow ary) | instructions’ | _in-House NewPn | ENG NAME OLD PIN | ENG | DISPOSITION | DISPOSITION 2078877 | 6 | Plate, Front Frame = = 7 = Reinforcing sess7-17 | AR | Bolt, Mach, 12 PT, msoss714 | AR 13 = vaseeo7-17 | ALT |0.250-28X1.188LG ‘883580419 | ALT msoss7-18 | AR |Bolt, Mach, 12 PT, mso5s7-16 | AR 1,3 - Msgeg7-18 | ALT |0.250-28 X 1.250LG A83580-4-20| ALT msess7-25 | AR | Bolt, Mach, 12 PT, msoss7-22 | AR 13 S Mso697-25 | ALT |0.250-28 X 1.688LG 883580-4-27 |_ ALT INSTRUCTIONS/DISPOSITION NOTES. 1. New item. 2, Retum removed item. 3. Discard item. 4, Rework item to new configuration. 5. Change quantity. B. Consumable Materials (1) Compound, antiseize, NSN-165. Expendable Parts ~ None April 2, 2002 ‘AE 3007A-72-247 ‘AE 30070-72203 Page 16 of 15Rolls-Royce EXPORT CONTROLLED SERVICE BULLETIN FRONT | ENGINE [#RPAD | FRONT | ENGINE |#APRD] FRONT | ENGINE ]#RPAD FRAMESIN| SIN | HOLES |FRAMESIN| S/N__| HOLES |FRAMESIN| SIN _| HOLES xxizeeaw | sio1t0 | 8 |xxtsovaw | aiites | 11 |xxeseve | siieea | 3 xxisoviw | sioit | 30 | Tietie 311198 a__pextesis_|_stiees_ | _2 xxr26saw | s10129 | 14 |xxtsozaw | sti202 | t2 | Tsiei02 ss001s_| 6 voxisasaw | stores | 5 |xxissdow | sti203 | G2 | Ts10071 wao0at_| 11 vxiseasw | sioi76 | 4 |xxtessyw | sii20s | 4 | 110067 330022 | 12 XxISeaSW | 310180 | 48 _|xxte00SW | Stizi2 | i7 | TJ1019T 330059 | 12 pxiaeerw | siioo2 | 13 |xxieasaw | siizta | 6 | Tsi02i5 330088] 14 Tsi27a8 Bi100s | 14 _|xxiso17w | siiais | is |xxizezaw | sa0071 | 10, yexteess | sit007 | te |xxieseo | siiai7 | 10 | Xxxiz601 wa0072_| 6 yoxze7aw | s11012 | 20 _|xxtesoaw | attaio | 24 | Ts12a59 330084 | 6 roiaesow | 311016 | 2 |xxieo1ow | sitaes | 68 | Tsi2aa8 330086 | 17 isaoiw | sioi7 | 13 | Tuasi9s Bitaes_| 18 | Ts10217 7330080 | 19 xextaaoaw | Sito1s | 21 |xxisesiw | sita2s | 24 | Ts12725 ‘gs0103_| 2 THa756 Biota | 3 |xxisooaw | siiase | 4 |xxiseea | sa0i0s | 12 xxissoow | Sit0a1 | i2 |xxizesaw | Sit2s8 | UNK |TJ12734 aor | 12 xxisoraw | ait023 | 11 |xxtaaaew | sitaso | 9 |xxiseiaw | 80120 | 18 yoxiscew_| sit02s | i7__|xxteooaw | siteao | 13 |xxieaa7w | so0i2a | 4 yoia6a8 | sit040 | 11 _|Xxteoi7w | Sitesi | 25 |xxissos | ss0128 | 22 yoia7oaw | s11045 | _UNK |xxtseoiw | sit2as_| 10 _|xxieao7w | 00138 | 17 yoa70s | 311046 9 __|xxieoasw | sites [ie |acsasiw | sso1aa | 18 yocissoaw | sit04s | 10 |xxigeviw | sites7 | 14 |xxisazew | sooie2 | 16 Taa772 ‘Biss | 10 |xxieasew | sizes | 18 |xcisa2aw | sa0iss | 29 yorize7ew | 311067 | 12 | 1316095 ait2e7_| 18 _|Xxis4eaw | s30i57_| UNK xextaaasw | 311068 | 8 | Tut0178 siia7e_| 18 |xxisasew | Sc0108 | UNK XXTas7IW | 11069 | 14 _|Xxxteao1W | sites | 17 __|xxibe7eW | sa0192 | 10 votaaea__ | Sit071 2__pxxteseaw | sizes [12 |xxtesai__| sa02a7 a xxTadeaw | sito7s | 8 |xxteavew | siteoi | 11 |xxiesas | ssozas | 16 TH2ast ‘Bios | 15 fxxsssae | atizes_| 14‘ [ Tu160684 ‘sa0as2 | 22 April 2, 2002 NOTE: Tho engine serial numbers above are based on maintenance center records and ‘Table 1 (Cont) ~ Front Frames with repaired bolt holes ‘should be used for planning purposes only. (2) Spares — Ail AE 3007A-72-247 ‘AE 3007C-72-203 Page 2 of 15EXPORT CONTROLLED Rolls-Royce SERVICE BULLETIN B. Reason Rolls-Royce has determined that the repair procedure released for front frame, front flange, bolt hole corrosion may not provide sufficient strength margin under axial loads generated during a fan blade-off occurrence. Versions of the plug repair procedure wore released by the documents that follow: (1) TVF641 ~ published 29 June 2000 (2) TVF824 — published 10 October 2000 (3) AE3007 SERIES ENGINE MANUAL, TASK 72-25-16-300-810 ~ Revised Jan 1, 2002 In order to provide sufficient strength margin for the front frame front flange, reinforcing (backing) plates are required on the aft side (nut side) of all front frames that have been plug repaired for bolt hole corrosion. ©. Description This service bulletin gives you the procedure to install reinforcing plates (23075877) on all front frames that have been plug repaired for bolt hole corrosion, D. Approval Technical aspects are FAA approved. E. Manpower In Service ‘Approximately 4.0 man hours are necessary to do this service bulletin. NOTE: Repair for corrosion found during incorporation of this bulletin will require additional man hours. Engine Removed Approximately 2.0 man hours are necessary to do this service bulletin. NOTE: Repair for corrosion found during incorporation of this bulletin will require additional man hours. For AE S007A Series engines: Labor required to accomplish this bulletin will be reimbursed by Rolls-Royce according to the ‘warranty/support agreements when accomplished at a Rolls-Royce authorized maintenance faclity. For AE 3007C Series engines: Labor required to accomplish this bulletin will be reimbursed by Rolls-Royce in accordance with your Power By The Hour® contract, when accomplished at a Rolls-Royce authorized ‘maintenance facility. April2, 2002 ‘AE S007A-72-247 ‘AE 3007C-72-203 Page 3 of 15Rolls-Royce EXPORT CONTROLLED SERVICE BULLETIN F. Compliance Recommended. This bulletin should be done on all engines with a front frame that has ‘compliad with a bolt hole plug repair listed in step 1.B, for any number of holes. Compliance period noted below. In Shop: Before engine shipped for retum to service. Spare engine: Before engine installed In Service: Within 12 months of the publication date of this bulletin. ‘Suggested priority: Any aircraft where both engines require this bulletin (Ref. Table 1). Highest number of plug repaired bolt holes (Ref. Table 1). Interchangeability ~ Not affected Material Availability NEW PIN NAME GTVIENG | UNIT PRICE DOLLARS 23075821 | Kit, Front Frame Reinforcing Plates T $7,300.00, (AE 3007A Series) 23075955 | Kit, Front Frame Reinforcing Plates 1 1,900.00 (AE 3007C Series) Unit prices listed in this service bulletin are valid when the service bulletin is published, Unit prices are subject to change. Contact your Account Representative at Rolls-Royce Supply Services for current unit prices. ‘The parts listed above will be provided free of charge. Contact your Account Representative at Rolls-Royce Supply Services for parts availabilty as follows: Mailing Address: Rolls-Royce Corporation P.O. Box 420 Indianapolis, Indiana 46206-0420 usa Altention: AE Order Administration ‘Speed Code R39 Telephone: 317-290-2016 FAX: 317-230-8899 |. Tooling ~ Not applicable J. Weight and Balance Engine weight will increase by 2.4 Ib (1.1 kg) when you incorporate this bulletin. K. Electrical Load Data Not affected ‘AE 3007A-72-247 April 2, 2002 ‘AE 3007C-72-203 Page 4 of 15EXPORT CONTROLLED: Rolls-Royce SERVICE BULLETIN L. References (1) Advance Engineering Memorandum (AEM), CN111245 and CN111277. NOTE: The documents above are referenced for the internal use of Rolls-Royce only. (2) AE 3007A Series iustrated Parts Catalog (IPC), CSP33002. (3) AE 3007C Series iltustrated Parts Catalog (IPC), CSP93001. (4) AE 3007 Series Engine Manual (EM), CSP31010. (6) A-Series Standard Practices Manual (SPM), CSP40000. (6) TVF1528 Rev 2~ Release reinforcing plates to maintenance centers in advance of this service bull (7) TVF1559 — Release reinforcing plates to maintenance centers in advance of this service bulletin. M. Other Publications Affected (1) AE 3007A Sories illustrated Parts Catalog (IPC), CSP33002. (2) AE 3007A Series Maintenance Manual (MM), CSP34022. (3) AE 3007C Series tlustrated Parts Catalog (IPC), CSP33001. (4) AE 3007C Series Maintenance Manual (MM), CSP34012. (5) AE 3007 Series Engine Manual (EM), CSP31010. N. Prerequisites ~ None 2, ACCOMPLISHMENT INSTRUCTIONS NOTE: If the front frame forward flange has been repaired for bolt hole corrosion per TVF841, ‘TVF824, or AE3OO7 Series EM, TASK 72-25-16-300-810, Revised Jan 1, 2002, then install the reinforcing plates (23075877). ‘A. For engine installed in aircraft or spare: REF. FIG.1 REF FIG.2 REF. FIG. 3 REF. FIG. 4 REF FIG. 5 NOTE: Only remove enough hardware for the installation of one reinforcing plate at any one time. (1) Remove the nuts (50, Fig. 1 or 2), the washers (40), the bolts (10), and the bracket (it necessary) from hole No. 1 thru 8. April 2, 2002 ‘AE S0O7A~72-247 ‘AE 3007C~72-203 Page 5 of 15EXPORT CONTROLLED Rolls-Royce SERVICE BULLETIN LEFT SIDE VIEW A) [- AES 2 su nscasoa 0 AE 3007A Series Fan Case-to-front Frame Spiitine Hardware - Removal FIG. 1 ‘AE 3007A-72-247 ‘AE 30070-72-203 April 2, 2002, Page 6 of 15EXPORT CONTROLLED: Rolls-Royce SERVICE BULLETIN LEFT SIDE VIEW i 7 ( nresa5e8 0 ‘AE 3007C Series Fan Case-to-front Frame Spiiiine Hardware — Removal FIG. 2 ‘AE 3007A-72-247 April 2, 2002 ‘AE 3007C~72-203 Page 7 of 15EXPORT CONTROLLED Rolls-Royce SERVICE BULLETIN (2) Examine the surface of the exposed bolt holes and flange of the front frame for corrosion. ‘See table below for serviceable limits, repair limits and action necessary (Ret. Fig. 3) TEM ‘SERVICEABLE LIMITS REPAIR LIMITS "ACTION NECESSARY Bolt hole bore — without plug repair = Corrosion (in bore) None permitted. 0.84 cylinder bounded —_a) Clean bolt hole only by: to extent that visible, a) Maximum of 0.050 in. loose corrosion is (1.27 mm) from bolt removed. hole towards flange _—_b) Touch-up affected oo. area with dichromate b) Maximum of 0.210 in. (Ret. 70-32-03, SPM). (6.33 mm) from bolt __c) Touch-up affected hole towards flange |.D. area with resin coating (Ref. 70-32-04, SPM). Resin will air cure. Continue assembly with uncured resin. Bolt hole bore — with plug repair = Corrosion (in bore) None permitted. Plug 0.0. a) Clean bolt hole only to extent that visible, Toose corrosion is removed. b) Touch-up affected area with dichromate (Ret. 70-32-03, SPM). ©) Touch-up affected area with resin coating (Ret. 70-32-04, SPM), Resin will air cure. Continue assembly with uncured resin. April 2, 2002 ‘AE 3007A-72-247 ‘AE 3007C-72-203 Page 8 of 15EXPORT CONTROLLED Rolls-Royce SERVICE BULLETIN Trem ‘SERVICEABLE LIMITS REPAIR LIMITS “AGTION NECESSARY Forward flange, aft surface - with or without plug repair = Corrosion, pitting None permitted. Forward flange outer rim - in area not covered by fan case flange = Corrosion, pitting __ None permitted. Maximum of 0.080 in. (1.27 mm) in depth, Maximum of 0.050 in. (1.27 mm) in depth, a) Remove loose corrosion with ‘Scotch-Brite. b) Touch-up affected area with dichromate (Ref, 70-32-03, SPM). ) Touch-up affected area with resin coating (Ret. 70-32-04, SPM). Resin will air cure. Continue assembly with uncured resin. 1a) Remove loose corrosion with ‘Scotch-Brite. ) Touch-up affected area with dichromate (Ret. 70-32-03, SPM). ©) Touch-up affected area with resin coating (Ret, 70-32-04, SPM). Resin will air cure. Continue assembly with uncured resin. April 2, 2002 ‘AE 3007A-72-247 ‘AE 3007C-72-203 Page 9 of 15