ENGINE - Compressor Rotor Assembly (72-31-00) - Rotating CDP Seal Serrations Coating Replacement

GE PROPRIETARY INFORMATION
The information contained in this document is GE proprietary information and is disclosed in con- ¿ dence. It is the property of GE and shall not be used, disclosed to others or reproduced withoutthe express written consent of GE, including, but without limitation, it is not to be used in the creation, manufacture, development, or derivation of any repairs, modi ¿ cations, spare parts, designs, or con ¿ guration changes or to obtain FAA or any other government or regulatory approval to do so. If consent is given for reproduction in whole or in part, this notice and the notice set forth on each page of this document shall appear in any such reproduction in whole or in part. This technical data is considered EAR controlled pursuant to 15 CFR Parts 730-774 respectively. Transfer of this data by any means to a Non-US Person, whether in the United States or abroad, without the proper U.S. Government authorization (e.g., License, exemption, NLR, etc.), is strictly prohibited. GE Aviation authorizes the Federal Aviation Administration to incorporate this document by reference in an Airworthiness Directive. Copyright (2015) General Electric Company, U.S.A.

July 14, 2015 CF6-80E1 S/B 72-0529 Rev ision 01, August 21, 2015 PAGE 1 of 18ENGINE - Compressor Rotor Assembly (72-31-00) - Rotating CDP Seal Serrations Coating Replacement

TRANSMITTAL INFORMATION REVISION 1 TO SERVICE BULLETIN 72-0529 Revision 1 is issued to update paragraph 3., A C C O M P L I S H M E N T I N S T R U CT I O N S

. The original was issued July 14, 2015. Revision bars in the left margin identify changes. 1. P LA N N I N G I N F O R M A T I O N A. E f fe ct i v i ty CF6-80E1A2, A3, A4, A4/B This Service Bulletin has been introduced in production to these CF6-80E1 engines:



# . CF6-80E1 engines, serial numbers 811-761 and up. The rotating compressor discharge pressure (CDP) seals with seal serrations coated with Borazon-Nickel are affected by this Service Bulletin. B. D e s c ri pt i o n This Service Bulletin provides instruction to strip, inspect, and to replace the Borazon-Nickel coating with Aluminum-Oxide coating on the rotating CDP seal serrations. C. C o m p l i a n ce Category 3 GE recommends that you do this Service Bulletin at the next shop visit of the engine. Group A of rotating CDP seals comply before installation. Group B of rotating CDP seals comply at ¿ rst exposure of the CDP seal area. Group C of rotating CDP seals comply at next engine shop visit. N O T E 1 : This Service Bulletin can be accomplished in shop. N O T E 2 : Refer to Figure 5 for group of de¿ nitions. N O T E 3 : For the purpose of this Service Bulletin exposure of the CDP seal area is de¿ ned as removal of the CRF assembly from the HPC module. This Service Bulletin is offered to improve the reliability or performance of your GE product, or to help prevent the occurrence of the event or condition described in this Service Bulletin. If the operator elects not to participate in the bulletin, that decision will be taken into consideration by GE in evaluating future product performance issues that may arise in the operator’s À eet.

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D. C o n c u rre n t Re q u i re m e n ts None. E. Re a s o n (1) Objective: To improve reliability. (2) Condition: During a shop visit, two rotating CDP seals P/N 1669M73P02 were found with radial cracks on its seal serrations. These radial cracks have propagated from low cycle fatigue and initial rub induced quench cracks. (3) Cause: The current type of seal serration coating (Borazon-Nickel) oxidizes during engine operation, losing cutting ability during hard seal rubs, and causing excessive friction leading to serration overheating and subsequent quench cracking. (4) Improvement: The Borazon-Nickel coating is replaced with thermal spraying of new Aluminum-Oxide coating on the seal serrations of the rotating CDP seal. Fluorescent penetrant inspection (FPI) performed during the CF6-80E1 EM, 72-31-10, REPAIR 002 will detect potential seal serrations cracks. (5) Substantiation: Substantiation is by À eet experience. F. A p p rova l The data contained in this Service Bulletin has been reviewed by the appropriate governmental authority and the repair(s) and modi ¿ cation(s) herein comply with the applicable Aviation Regulations and are APPROVED for installation in the model(s) listed in this Service Bulletin. G. M a n p owe r For Group C engines only: You will need approximately 156 man-hours to get access to the HPC module, disassembly rotating CDP seal, and reassembly of the module with recoated CDP seal. H. We i g h t a n d B a l a n ce Weight and balance are not changed.

July 14, 2015 CF6-80E1 S/B 72-0529 Revision 01, August 21, 2015 PAGE 3 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or ¿ rst page.ENGINE - Compressor Rotor Assembly (72-31-00) - Rotating CDP Seal Serrations Coating Replacement

I. Refe re n ce s GEK 99376, CF6-80E1 Engine Manual (EM). Revision 39 dated March 15, 2014 or later revision GEK 99378, CF6-80E1 Illustrated Parts Catalog (IPC). Revision 29 dated March 15, 2009 or later revision N O T E : The reference documents listed below are for the engine manufacturer's internal use only:
CID: 506380
J. P u b l i ca t i o n s Af fe cte d GEK 99376, CF6-80E1 Engine Manual (EM) K. I n te rc h a n g e a b i l i ty Not applicable. L. S of twa re Acco m p l i s h m e n t S u m m a ry Not applicable. 2. M A T E R I A L I N F O R M A T I O N A. M ate ri a l

- P ri ce a n d A va i l a b i l i ty (1) Parts necessary to do this Service Bulletin: None. (2) Other Spare Parts: None. (3) Consumables: None. B. I n d u st ry S u p p o rt I n f o rm a t i o n Industry support may be available. Contact your Customer Support Manager (CSM) for details. C. C o n ¿ g u ra t i o n C h a rt Not applicable. D. P a rts D i s p o s i t i o n

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Not applicable. E. T o o l i n g - P ri ce a n d Ava i l a b i l i ty None. 3. AC C O M P L I S H M E N T I N S T R U CT I O N S A. G e n e ra l (1) The rotating CDP seals (1, Figure 1) coated with Borazon-Nickel are affected by this Service Bulletin. Refer to Figure 2, Figure 3, and Figure 4 for differences between Borazon-Nickel and Aluminum-Oxide coating. N O T E 1 : Borazon-Nickel coating is a silver and shiny surface. Refer to Figure 2. N O T E 2 : Nickel-Aluminum bond coating with Aluminum-Oxide top coating is gray in color, gray with a blue tinted surface, or light brown after operation. (2) Find the recommended time for the rotating CDP seal (1, Figure 1) coating replacement. Refer to Figure 5 and to the groups that follows: (a) Group A (recoat rotating CDP seal (1) with the Aluminum-Oxide before the installation). 1 All rotating CDP seals (1) P/N 1669M73P02 with all of the conditions that follow:

a Rotating CDP seals (1) that have operated in an engine. b Rotating CDP seals (1) that have not had the seal tooth coating removed and replaced in accordance with the CF6-80E1 EM, 72-31-10, REPAIR 002.

c Rotating CDP seals (1) not installed in an engine. N O T E : Table 1 lists serial numbers (SNs) of the reported Group A piece part seals. Refer to paragraph 4., A P P E N D I X

- A

. (b) Group B (recoat rotating CDP seals (1) with Aluminum-Oxide at ¿ rst exposure of the rotating CDP seal area). 1 All rotating CDP seals (1) P/N 1669M73P02 with all of the conditions that follow:

a Rotating CDP seals (1) that have operated in an engine. b Rotating CDP seals (1) that have not had the seal tooth coating removed and replaced in accordance with the CF6-80E1 EM, 72-31-10, REPAIR 002.

c Rotating CDP seals (1) that are installed in an engine with a stationary CDP seal P/N 1347M28G02 that has not had the
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honeycomb replaced by the CF6-80E1 EM, 72-34-02, REPAIR 001. N O T E 1 : For the purpose of this Service Bulletin exposure of the CDP seal area is de¿ ned as removal of the CRF assembly from the HPC module. N O T E 2 : Table 2 lists engine serial numbers (ESNs) and SNs of the reported Group B seals. Refer to paragraph 4., A P P E N D I X

- A

. (c) Group C (recoat rotating CDP seals (1) with Aluminum-Oxide at next engine shop visit). 1 All rotating CDP seals (1) P/N 1669M73P02 with all of the conditions that follow:

a Rotating CDP seals (1) that have operated in an engine. b Rotating CDP seals (1) that have not had the seal tooth coating removed and replaced in accordance with the CF6-80E1 EM, 72-31-10, REPAIR 002.

c Rotating CDP seals (1) that are installed in an engine with a new stationary CDP seal P/N 1347M28G02 or a stationary CDP seal P/N 1347M28G02 that has had the honeycomb replaced by the CF6-80E1 EM, 72- 34-02, REPAIR 001. N O T E : Table 3 lists ESNs and SNs of the reported Group C seals. Refer to paragraph 4., A P P E N D I X

- A

. B. E n g i n e a s s e m b l y l eve l (1) Disassemble the engine assembly. Refer to the CF6-80E1 EM, 72-00-00, DISASSEMBLY 001. (2) Disassemble the core module. Refer to the CF6-80E1 EM, 72-00-02, DISASSEMBLY 001. (3) Remove the rotating CDP seal (1, Figure 1). Refer to the CF6-80E1 EM, 72-00-31, SPECIAL PROCEDURES 008. (4) Strip, do an inspection, and recoat the rotating CDP seal (1, Figure 1). Refer to the CF6-80E1 EM, 72-31-10, REPAIR 002. (5) Reinstall the rotating CDP Seal (1, Figure 1). Refer to the CF6-80E1 EM, 72-00-31, SPECIAL PROCEDURES 008. C. H P C Roto r a s s e m b l y l eve l (1) Remove the rotating CDP seal (1, Figure 1). Refer to the CF6-80E1 EM, 72-00-31, SPECIAL PROCEDURES 008.

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(2) Strip, do an inspection, and recoat the rotating CDP seal (1, Figure 1). Refer to the CF6-80E1 EM, 72-31-10, REPAIR 002. (3) Reinstall the rotating CDP Seal (1, Figure 1). Refer to the CF6-80E1 EM, 72-00-31, SPECIAL PROCEDURES 008.

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Rotating CDP Seal Location Figure 1

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Borazon-Nickel Coating Figure 2

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Aluminum-Oxide Coating Figure 3

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Aluminum-Oxide Coating After Operation Figure 4

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Engine Group De¿ nition Figure 5

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4. A P P E N D I X

- A The information in the Tables 1, 2, and 3 is the best data available reported to GE Aviation. It may not be fully complete and accurate. The group classi ¿ cation of the installed rotating CDP seal should be veri ¿ ed at engine shop visit. Table 1 - SNs of Reported Group A Rotating CDP Seals
FCU00062 LKMM5880 NCE0700F NCE0702F NCE0703F NCE0713F NCE1000F NCE634BF NCE656HD NCE7028J NCE935BR Table 2 - ESNs and SNs of Reported Group B Rotating CDP Seals

E S N Rotat i n g C D P S e a l P/ N 1 6 6 9 M 7 3 P 0 2 S e ri a l N u m b e r E S N Rotat i n g C D P S e a l P/ N 1 6 6 9 M 7 3 P 0 2 S e ri a l N u m b e r E S N Rota t i n g C D P S e a l P/ N 1 6 6 9 M 7 3 P 0 2 S e ri a l N u m b e r 810105 LKMK8086 810106 -- 811129 -- 811142 NCE9420F 811171 NCE7030J 811184 NCE6365N 811185 NCE6266M 811186 NCE1570P 811260 NCE1789R 811261 NCE1788R 811269 NCE1008R 811294 NCE4859Y 811296 NCE4899Y 811297 FCU00032 811313 NCE4891Y 811321 FCU00049 811335 FCU00054 811358 NCE062AK 811365 FCU00075 811368 FCU00083 811369 NCE051AK 811370 NCE491AB 811386 NCE067AK 811397 FCU00099 811399 FCU00100 811417 FCU00077 811420 FCU00124 811425 FCU00114 811432 NCE936BR 811437 NCE545BU 811438 NCE932BR 811451 FCU00113 811461 NCE644BF

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E S N Rotat i n g C D P S e a l P/ N 1 6 6 9 M 7 3 P 0 2 S e ri a l N u m b e r E S N Rotat i n g C D P S e a l P/ N 1 6 6 9 M 7 3 P 0 2 S e ri a l N u m b e r E S N Rota t i n g C D P S e a l P/ N 1 6 6 9 M 7 3 P 0 2 S e ri a l N u m b e r 811465 NCE482AB 811466 NCE481AB 811470 NCE800BY 811478 NCE941BR 811479 NCE937BR 811480 NCE799BY 811481 NCE059AK 811482 NCE994BR 811495 NCE759CE 811497 NCE374DD 811498 NCE332DH 811499 FCU00128 811500 NCE331DH 811501 NCE327DH 811508 NCE455DU 811509 NCE329HD 811512 NCE755CE 811513 NCE054EA 811514 NCE056EA 811518 NCE515EH 811519 NCE512EH 811520 NCE052EA 811523 NCE442EN 811524 NCE443EN 811525 NCE444EN 811526 NCE275ER 811527 NCE276ER 811530 NCE090EP 811531 NCE084FB 811532 NCE079FB 811533 NCE078FB 811534 NCE081FB 811535 NCE083FB 811536 NCE080FB 811537 NCE082FB 811538 NCE395FB 811539 FCU00106 811540 NCE391FB 811541 NCE393FB 811542 NCE394FB 811545 NCE392FB 811547 NCE662FK 811548 NCE658FK 811549 NCE659FK 811550 NCE661FK 811552 NCE663FK 811553 NCE664FK 811554 NCE083FR 811555 NCE660FK 811556 NCE085FR 811557 NCE090FT 811560 NCE087FT 811561 NCE084FR 811563 NCE285FY 811564 NCE284FY 811566 NCE282FY 811567 NCE286FY 811568 NCE088FT 811569 NCE655HD 811570 NCE658HD 811571 NCE659HD 811572 NCE874HE 811573 NCE775HE 811574 NCE243HJ 811575 NCE875HE 811576 NCE776HE 811577 NCE238HM 811578 NCE237H 811579 NCE241HJ 811580 NCE242HJ 811583 NCE774HE 811584 NCE319HU 811591 NCE290HY 811592 NCE478HY 811595 NCE730HY 811596 NCE844HN 811597 NCE824HN 811599 NCE475HY 811600 NCE289HY 811601 NCE953JB 811602 NCE956JB 811603 NCE477HY 811604 NCE955JB 811605 NCE949JB 811606 NCE501JD 811607 NCE951JB 811608 NCE498JD

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E S N Rotat i n g C D P S e a l P/ N 1 6 6 9 M 7 3 P 0 2 S e ri a l N u m b e r E S N Rotat i n g C D P S e a l P/ N 1 6 6 9 M 7 3 P 0 2 S e ri a l N u m b e r E S N Rota t i n g C D P S e a l P/ N 1 6 6 9 M 7 3 P 0 2 S e ri a l N u m b e r 811610 NCE500JD 811611 NCE502JD 811612 NCE952JB 811613 NCE661JH 811614 NCE667JH 811615 NCE170JH 811616 NCE666JH 811617 NCE663JH 811618 NCE174JH 811619 NCE662JH 811620 NCE499JD 811621 NCE664JH 811622 NCE172JH 811623 NCE173JH 811624 NCE476HY 811625 NCE763JK 811626 NCE175JH 811628 NCE765JK 811629 NCE291HY 811630 NCE764JK 811631 NCE767JK 811632 NCE761JK 811633 NCE660JH 811634 NCE739JR 811635 NCE740JR 811636 NCE171JH 811637 NCE766JK 811638 NCE738JR 811639 NCE177JH 811640 NCE130J 811642 NCE737JR 811643 NCE131J 811644 NCE132J 811645 NCE129J 811646 NCE127J 811647 NCE128J 811648 NCE133J 811649 NCE769JK 811650 NCE176JH 811651 NCE769KA 811652 NCE766KA 811653 NCE770KA 811654 NCE768KA 811655 NCE772KA 811656 NCE370KD 811657 NCE371KD 811658 NCE947KE 811659 NCE949KE 811660 NCE771KA 811661 NCE946KE 811662 NCE376KD 811663 NCE945KE 811664 NCE375KD 811665 NCE372KD 811666 NCE948KE 811667 NCE019KJ 811668 NCE373KD 811669 NCE023KJ 811670 NCE024KJ 811671 NCE021KJ 811672 NCE058KM 811673 NCE057K 811674 NCE018KJ 811675 NCE063KM 811676 NCE059K 811677 NCE062K 811678 NCE061KM 811679 NCE020KJ 811680 NCE060K 811681 NCE195KN 811682 NCE197KN 811683 NCE191KN 811684 NCE193KN 811685 NCE125KP 811686 NCE192KN 811687 NCE123KP 811688 NCE122KP 811689 NCE128KP 811690 NCE127KP 811691 NCE124KP 811692 NCE167KT 811693 NCE196KN 811694 NCE165KT 811695 NCE164KT 811696 NCE169KT 811697 NCE168KT 811698 NCE194KN

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E S N Rotat i n g C D P S e a l P/ N 1 6 6 9 M 7 3 P 0 2 S e ri a l N u m b e r E S N Rotat i n g C D P S e a l P/ N 1 6 6 9 M 7 3 P 0 2 S e ri a l N u m b e r E S N Rota t i n g C D P S e a l P/ N 1 6 6 9 M 7 3 P 0 2 S e ri a l N u m b e r 811699 NCE950KU 811700 NCE948KU 811701 NCE945KU 811702 NCE946KU 811703 NCE944KU 811704 NCE947KU 811705 NCE456KY 811706 NCE459KY 811707 NCE458KY 811708 NCE455KY 811709 NCE457KY 811710 NCE461KY 811712 NCE068LB 811713 NCE069LB -- -- Table 3 - ESNs and SNs of Reported Group C Rotating CDP Seals

E S N Rotat i n g C D P S e a l P/ N 1 6 6 9 M 7 3 P 0 2 S e ri a l N u m b e r E S N Rotat i n g C D P S e a l P/ N 1 6 6 9 M 7 3 P 0 2 S e ri a l N u m b e r E S N Rotat i n g C D P S e a l P/ N 1 6 6 9 M 7 3 P 0 2 S e ri a l N u m b e r 810102 NCE0699F 810107 LKMM6162 811102 NCE7035J 811104 NCE0395G 811106 NCE7036J 811109 LKMM5875 811110 NCE6509M 811111 NCEO701F 811112 LKMM5989 811114 lkmm5879 811120 NCE0707F 811121 NCE0122J 811124 LKMP7542 811125 NCE017KJ 811127 NCE0694F 811132 NCE0398G 811133 NCE0119J 811137 NCE7032J 811141 NCE7460Y 811154 NCE7034J 811156 NCE7037J 811157 NCE2188K 811159 NCE2187K 811160 NCE2191K 811161 NCE1453M 811163 -- 811164 NCE2181K 811167 NCE6508M 811173 NCE7033J 811174 NCE7357L 811175 -- 811176 NCE2189K 811177 NCE7354L 811178 NCE2186K 811179 NCE6358N 811180 NCE6351N 811181 NCE6361N 811183 NCE6363N 811187 NCE7796N 811189 NCE7798N 811190 NCE7355L 811192 NCE6354N 811194 NCE6356N 811196 NCE7792N 811198 NCE1566P 811199 NCE7795N 811201 NCE6265M 811204 NCE170KT 811206 NCE6362N 811207 NCE6357N 811210 NCE7793N 811213 NCE1572P 811214 NCE7358L 811216 NCE6272M 811217 NCE768JK 811222 NCE1852P 811225 NCE1577P

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E S N Rotat i n g C D P S e a l P/ N 1 6 6 9 M 7 3 P 0 2 S e ri a l N u m b e r E S N Rotat i n g C D P S e a l P/ N 1 6 6 9 M 7 3 P 0 2 S e ri a l N u m b e r E S N Rotat i n g C D P S e a l P/ N 1 6 6 9 M 7 3 P 0 2 S e ri a l N u m b e r 811227 NCE1444M 811228 NCE1443M 811229 NCE7786N 811234 NCE7360L 811237 NCE7352L 811243 NCE7356L 811248 NCE7361L 811249 NCE1450M 811252 NCE1783R 811255 NCE513EH 811257 NCE1790R 811259 NCE6271M 811267 NCE1779R 811270 NCE1009R 811272 NCE1010R 811273 NCE1791R 811276 FCU00001 811277 FCU00003 811279 FCU00009 811284 FCU00016 811289 FCU00026 811291 NCE665JH 811292 NCE4894Y 811293 NCE4896Y 811295 NCE4898Y 811298 FCU00024 811299 FCU00022 811300 FCU00021 811301 FCU00028 811302 FCU00025 811303 FCU00034 811307 NCE4897Y 811308 FCU00029 811310 NCE7469Y 811315 FCU00035 811318 FCU00036 811319 NCE092EP 811320 NCE330DH 811323 FCU00040 811324 FCU00061 811325 FCU00041 811326 FCU00046 811327 FCU00038 811328 NCE7465Y 811329 NCE4892Y 811331 FCU00066 811333 NCE091EP 811334 NCE7466Y 811339 FCU00058 811340 NCE053AK 811342 NCE240HJ 811344 FCU00065 811346 FCU00052 811347 FCU00063 811348 FCU00044 811349 FCU00037 811350 FCU00060 811351 FCU00053 811352 NCE7461Y 811353 FCU00074 811355 FCU00082 811357 NCE054AK 811366 FCU00073 811367 FCU00081 811371 NCE063AK 811375 FCU00084 811377 NCE049AK 811384 FCU00125 811385 FCU00068 811387 FCU00093 811390 FCU00130 811391 FCU00120 811392 FCU00126 811393 FCU00090 811394 FCU00086 811396 FCU00094 811402 FCU00092 811403 FCU00088 811404 NCE647BF 811406 NCE637BF 811408 FCU00127 811409 FCU00115 811410 NCE643BF 811411 FCU00104 811412 FCU00103 811415 NCE588AD 811416 NCE483AB

July 14, 2015 CF6-80E1 S/B 72-0529 Revision 01, August 21, 2015 PAGE 17 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or ¿ rst page.ENGINE - Compressor Rotor Assembly (72-31-00) - Rotating CDP Seal Serrations Coating Replacement

E S N Rotat i n g C D P S e a l P/ N 1 6 6 9 M 7 3 P 0 2 S e ri a l N u m b e r E S N Rotat i n g C D P S e a l P/ N 1 6 6 9 M 7 3 P 0 2 S e ri a l N u m b e r E S N Rotat i n g C D P S e a l P/ N 1 6 6 9 M 7 3 P 0 2 S e ri a l N u m b e r 811418 NCE474AB 811419 NCE488AB 811423 NCE648BF 811424 NCE843HN 811428 FCU00091 811431 FCU00097 811434 NCE939BR 811435 NCE930BR 811439 NCE235BN 811442 NCE945BR 811443 NCE933BR 811444 NCE639BF 811445 FCU00122 811446 FCU00117 811447 NCE942BR 811448 NCE543BU 811449 FCU00096 811452 FCU00102 811453 FCU00101 811454 FCU00112 811455 FCU00105 811456 FCU00118 811457 FCU00085 811459 NCE938BR 811460 NCE946BR 811462 NCE934BR 811463 NCE477AB 811464 NCE064AK 811467 -- 811469 NCE479AB 811483 NCE472AB 811486 FCU00079 811488 NCE542BU 811489 NCE490AB 811492 NCE929BR 811493 NCE375D 811503 NCE757CE 811504 NCE756CE 811510 NCE451DU 811515 NCE053EA 811516 NCE517EH 811521 NCE051EA 811528 NCE447EN 811546 NCE665FK 811551 NCE943BR 811558 NCE082FR 811559 NCE089FT 811565 NCE283FY 811581 NCE236HM 811582 NCE235H 811585 NCE136HU 811586 NCE317HU 811587 NCE316HU 811588 NCE318HU 811589 NCE138HU 811590 NCE137HU 811593 NCE479HY 811594 NCE841HN 811598 NCE954JB 811609 NCE497JD 811641 NCE766JK -- -- -- --

July 14, 2015 CF6-80E1 S/B 72-0529 Revision 01, August 21, 2015 PAGE 18 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or ¿ rst page.