ENGINE FUEL AND CONTROL - Fuel System (73-00-00) - Inspection of the Block Clamps and Epoxy Wear Sleeve/PTFE Coated Para-Aramid Tape Areas in the Fuel Manifolds

GE PROPRIETARY INFORMATION
The information contained in this document is GE proprietary information and is disclosed in confi 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 fi cations, spare parts, designs, or con fi 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. Copyright (2014) General Electric Company, U.S.A.

July 02, 2013 CF6-80E1 S/B 73-0121 Rev ision 01, FINAL REVIEW COPY PAGE 1 of 16ENGINE FUEL AND CONTROL - Fuel System (73-00-00) - Inspection of the Block Clamps and Epoxy Wear Sleeve/PTFE Coated Para-Aramid Tape Areas in the Fuel Manifolds

TRANSMITTAL INFORMATION REVISION 1 TO SERVICE BULLETIN 73-0121 Revision 1 is issued to update the Service Bulletin title, paragraphs 1., P LA N N I N G I N F O R M A T I O N , and 3., A C C O M P L I S H M E N T I N S T R U C T I O N S

. The original was issued July 02, 2013. 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 ff e ct i v i ty CF6-80E1A2, A3, A4, A4/B This Service Bulletin is applicable to post-CF6-80E1 S/B 73-0026 and pre-CF6-80E1 S/B 73-0099 CF6-80E1 engines. The left and right side fuel manifolds (fuel manifolds) post-CF6-80E1 S/B 73-0026 (drain-less) and pre-CF6-80E1 S/B 73-0099 con fi gurations are affected by this Service Bulletin. B. D e s c r i p t i o n This Service Bulletin provides a repetitive inspection procedure for epoxy wear sleeve (epoxy sleeve) or repaired fuel manifolds with PTFE coated para-aramid tape and tube clamp (block clamp) P/N 1153M26G15 replacement for the affected fuel manifolds con fi gurations. The inspection is necessary to detect damage of the epoxy sleeve or repaired fuel manifolds with PTFE coated para-aramid tape in the fuel manifolds, which can result from relative motion between the block clamp and the fuel manifold. C. C o m p l i a n c e Category 2 GE recommends that you do this Service Bulletin as soon as possible without effect on revenue service but before reaching the t hreshold inspection intervals for each fuel manifold as follows: Do an initial inspection within the fi rst six months after the issue date of this Service Bulletin and do the repetitive inspection at the same interval (every 7,500 fl ight hours) as the fuel manifold cushion clamps inspection. Refer to CF6-80E1 S/B 73-0061. N O T E 1 : For non-installed engines, accomplish the initial inspection prior to installation on wing, thereafter perform the repetitive inspection as instructed in this Service Bulletin. N O T E 2 : This Service Bulletin can be accomplished on wing or in shop.

July 02, 2013 CF6-80E1 S/B 73-0121 Revision 01, FINAL REVIEW COPY PAGE 2 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or fi rst page.ENGINE FUEL AND CONTROL - Fuel System (73-00-00) - Inspection of the Block Clamps and Epoxy Wear Sleeve/PTFE Coated Para-Aramid Tape Areas in the Fuel Manifolds

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 fl eet. D. C o n c u r re n t R e q u i re m e n t s None. E. R e a s o n (1) Objective: To improve reliability and reduce signi fi cant events. (2) Condition: Tube wall thinning on the fuel manifolds, if undetected, can result in a fuel leak. This fuel manifold system is common to the CF6-80C2 and CF6-80E1 engine programs. (3) Cause: Looseness of the clamp due to a poor fi t between the clamp and the epoxy wear sleeve or repaired fuel manifolds with PTFE coated para-aramid tape at the extremes of dimensional variation from manufacturing. Time exposure of the block clamp with the epoxy sleeve is also a contributor to cause wear of the epoxy sleeve with wear/damage affecting the fuel manifold (thins the tube wall beyond serviceable limits). (4) Con fi guration Description: The accomplishment of this Service Bulletin will result in the replacement of the worn epoxy wear sleeve or existing PTFE coated para-aramid tape with a new PTFE coated para-aramid tape. (5) Inspection: This inspection will allow detection of worn fuel manifolds on the epoxy sleeve area. The block clamps are replaced with serviceable block clamps to ensure that damaged block clamps are not installed on the engine. (6) Substantiation: Substantiation is based upon design analysis and fi eld inspection data analysis.

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F. A p p rov a l (FAA Approval Statement TBD by FAA-DER prior to issue) Statement 1: This Service Bulletin has been reviewed by the FAA and the repair(s) and modi fi cation(s) herein comply with the applicable Federal Aviation Regulations and are FAA APPROVED for installation in the model(s) listed in this Service Bulletin. OR Statement 2: This Service Bulletin contains no modi fi cation information that revises the approved con fi guration and therefore does not require FAA approval. G. M a n p o w e r After you get access to the fuel manifolds and block clamps, you will need approximately 1.0 man-hour to inspect the fuel manifolds and replace the block clamps if damaged, for each engine. If removal and installation of the fuel manifolds are necessary, you will need approximately 10 man-hours. H. We i g h t a n d B a l a n c e Weight and balance are not changed. I. R e f e re n c e s (Use the latest version of these documents) CF6-80E1 Airbus A330 Aircraft Maintenance Manual (AMM) (April 01, 2014 or later approved revision) CF6-80E1 S/B 73-0026, ENGINE FUEL AND CONTROL - Core Module (72-00-02) - Delete Fuel Drain System for the Fuel and Drain Manifold CF6-80E1 S/B 73-0061, ENGINE FUEL AND CONTROL - (72-00-02) - Fuel Manifold Inspection and Clamp Replacement CF6-80E1 S/B 73-0096, FUEL AND CONTROL - Core Engine Module (72-00-02) - Fuel Manifold PTFE Tape Installation for Post-CF6-80E1 S/B 73-0026 Engines CF6-80E1 S/B 73-0099, ENGINE FUEL AND CONTROL - Fuel System (73-00-00) - Introduction of New Fuel Manifold System GEK 9250, Commercial Engine Standard Practices Manual (SPM) GEK 99378, CF6-80E1 Illustrated Parts Catalog (IPC)

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N O T E : The reference documents listed below are for the engine manufacturer's internal use only:
BPP: 13-72-00-02
J. P u b l i cat i o n s Aff e ct e d None. K. I n t e rc h a n g e a b i l i ty Not applicable. L. S o ftw a re A c c o 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 at e r i a l

- P r i c e a n d Av a i l a b i l i ty (1) Parts necessary to do this Service Bulletin: None. (2) Other Spare Parts:

P a rt N u m b e r Q ty / E n g P a rt N a m e U n i t ( $ ) P r i c e P kg Q ty L e a d Ti m e D ays 1153M26G15* (4) Clamp, Tube 154.00 (1) 5 1303M31G12** (1) Manifold, Fuel Left Side - (-) - 1303M32G12** (1) Manifold, Fuel Right Side - (-) - 2420M70G01 (1) Manifold, Fuel Left Side 14,780.00 (1) 5 2420M71G01 (1) Manifold, Fuel Right Side 12,570.00 (1) 5 *Quantity required per engine if all the block clamps are found unserviceable after inspection. **Refer to CF6-80E1 IPC for latest con fi guration. GE recommends that fuel manifolds P/N 1303M31G12 and P/N 1303M32G12 are reworked per CF6-80E1 S/B 73-0096 to add PTFE tape prior to use.

N O T E : Prices are provided for planning purposes and are subject to change.

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(3) Consumables:
C o d e N u m b e r D e s c r i p t i o n C04-001 Solvent, General [methyl ethyl ketone (MEK)] C04-002 Solvent, General (solvent) C04-014 Solvent, General (denatured alcohol) C04-113 Abrasive, Grit, Aluminum Oxide, 220 Mesh (aluminun oxide) C10-225 Tape, Silicone, Para-Aramid Fiber Cloth, PTFE Coated (PTFE coated para-aramid tape) C10-182 Cloth, Cleaning for Aircraft Structural (cloth)

B. I n d u s t ry S u p p o rt I n f o r m at i o n None. C. C o n fi g u rat i o n C h a rt None. D. P a rt s D i s p o s i t i o n If fuel manifolds are found unserviceable after the inspection, they can be replaced or sent for repair to a certi fi ed repair station. E. T o o l i n g - P r i c e a n d Ava i l a b i l i ty None. 3. A C C O M P L I S H M E N T I N S T R U C T I O N S A. G e n e ra l (1) Get access to affected fuel manifolds and inspect the epoxy wear sleeve or PTFE coated para-aramid tape. Refer to CF6-80E1 Airbus A330 AMM, 73-11-44. (2) Remove the four block clamps (3, Figure 1) from the fuel manifolds (1 and 2) as follows: (a) Remove nuts (4), bolts (5), washers (6), and link brackets (7 and 8) from the block clamps (3).

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(b) Remove the block clamps (3) from the epoxy wear sleeve or PTFE coated para-aramid tape. The epoxy wear sleeve or PTFE coated para-aramid tape location is between the block clamps (3) and fuel manifolds (1 and 2). (3) Do an inspection for serviceability of the block clamps (3). Refer to Table 1 and Figure 2 for block clamp wear examples. N O T E : If chafi ng is found during the fuel manifold inspection, complete inspection report. Refer to paragraph 3.B., F u e l M a n i f o l d C h afi n g I n s p e ct i o n R e p o rt

. Table 1 - Block Clamp Inspection Criteria and Action
C o n d i t i o n M ax i m u m S e rv i c e a b l e L i m i t C o r re ct i ve A ct i o n Cracks or pieces missing Not serviceable Replace the block clamp Nicks or gouges 0.010 inch (0.25 mm) in depth if not on clamping surface. Not permitted on clamping surface. Replace the block clamp

Scratches 0.005 inch (0.13 mm) in depth if not on the clamping surface. Not permitted on clamping surface. Replace the block clamp

Loose or loss of clamping ability Not serviceable Replace the block clamp Loose or missing rivet Not serviceable Replace the block clamp

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(4) Do an inspection of the epoxy sleeve areas. Refer to Table 2. Table 2 - Epoxy Sleeve Inspection Criteria and Action
C o n d i t i o n M ax i m u m S e rv i c e a b l e L i m i t C o r re ct i v e A ct i o n (a) Visual evidence of unbonded areas between the epoxy wear sleeve and the fuel manifold is not permitted. (b) Epoxy wear that is more than 0.005 inch (0.13 mm) in depth and more than 30 percent of the surface area is not permitted. Epoxy sleeve has no visual evidence of damage and it is within serviceable limits. Refer to CF6-80E1 Airbus A330 AMM, 73-11-44, Manifold - Fuel Supply Line - Inspection/Check (epoxy wear-sleeve inspection criteria).

(c) Epoxy chipped areas more than 20 percent of the sleeve area is not permitted. No corrective action. Continue with the installation of serviceable block clamps (3, Figure 1). Proceed to paragraph 3.A.(6).

(a) Visual evidence of unbonded areas between the epoxy wear sleeve and the fuel manifold is not permitted. Repair the epoxy sleeve. Proceed to paragraph 3.A.(5).

(b) Epoxy wear that is more than 0.005 inch (0.13 mm) in depth and more than 30 percent of the surface area is not permitted. N O T E : After fuel manifold repair using para-aramid tape per the aforementioned AMM instructions, repaired fuel manifold can continue in service up to 7,500 fl ight hours. Epoxy sleeve has visual evidence of damage and it is out of serviceable limits. Refer to CF6-80E1 Airbus A330 AMM, 73-11-44, Manifold - Fuel Supply Line - Inspection/Check (epoxy wear-sleeve inspection criteria).

(c) Epoxy chipped areas more than 20 percent of the sleeve area is not permitted. Epoxy sleeve wear through to parent metal of the fuel manifolds. See paragraph (4.1).(f).3

. Remove the epoxy sleeve and inspect the fuel manifolds:

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C o n d i t i o n M ax i m u m S e rv i c e a b l e L i m i t C o r re ct i v e A ct i o n (4.1) Do a general inspection to the parent metal of the fuel manifolds (1 and 2, Figure 1) as follows:

W

A R N I N G : REFER TO THE PRODUCT LABEL AND THE MANUFACTURER’S (MATERIAL) SAFETY DATA SHEET FOR INSTRUCTIONS ON THE HAZARDS, STORAGE, SAFE HANDLING AND PROPER USE OF THIS PRODUCT. (a) Clean the outer surface of the epoxy sleeve with MEK (C04-001) or solvent (C04-002). (b) Let the cleaned surfaces air dry. (c) Lightly sand the surface to remove the glossy surface of the existing composite or resin surface with aluminum oxide (C04-113) or its equivalent. (d) Remove the remaining dust with a cloth (C10-182). (e) Clean the surface with a clean cloth made of moist with denatured alcohol (C04-014) or its equivalent, until the last clean cloth wipes clean. (f) Do a visual inspection of the fuel manifolds (1 and 2) with a bright light at all block clamps (3) places. If the fuel manifolds (1 and 2) have any sign of wear, measure the tube as follows or with an equivalent method that can fi nd decreased wall thickness: 1 Measure the outside diameter of the tube adjacent to the worn area. Record the indication. 2 Measure the outside diameter of the tube in the worn area, fi nd the smallest diameter. Record the indication.

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C o n d i t i o n M ax i m u m S e rv i c e a b l e L i m i t C o r re ct i v e A ct i o n
Subtract the worn area indication recorded in step 3.A.(4.1)(f)2 from the undamaged area indication recorded in step 3.A.(4.1)(f)1 and do as follows:
a A fuel manifold with wear that is less than or equal to 0.0035 inch (0.089 mm) can continue its operation until the next inspection. Proceed to paragraph 3.A.(5). b A fuel manifold with wear that is more than 0.0035 inch (0.089 mm) but less than or equal to 0.010 inch (0.25 mm) can continue its operation for another 50 cycles before the fuel manifolds have to be replaced. Proceed to paragraph 3.A.(5). For fuel manifold removal and installation, refer to CF6-80E1 Airbus A330 AMM, 73-11-44, Manifold - Fuel Supply Line - Removal/Installation. 3

c A fuel manifold with wear that is more than 0.010 inch (0.25 mm) is unserviceable and must be replaced immediately. For fuel manifold removal and installation, refer to CF6-80E1 Airbus A330 AMM, 73-11-44, Manifold - Fuel Supply Line - Removal/Installation. (5) Remove the epoxy material from the fuel manifolds (refer to instructions of Table 2 paragraph 4.1) and apply PTFE coated para-aramid tape (C10-225) to serviceable fuel manifolds (1 and 2, Figure 1). Refer to CF6-80E1 Airbus A330 AMM, 73-11-44, Manifold - Fuel Supply Line - Inspection/Check. (6) Install the four block clamps (3, Figure 1) on the fuel manifolds (1 and 2) with the nuts (4), bolts (5), washers (6), and link brackets (7 and 8). Torque the nuts (4) to 33-37 lb in. (3.7-4.2 N·m).

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(7) Close access to the affected fuel manifolds (1 and 2). Refer to CF6-80E1 Airbus A330 AMM, 73-11-44. B. F u e l M a n i f o l d C h afi n g I n s p e ct i o n R e p o rt (1) If chafi ng is found during the fuel manifold inspection, please send the following information to AOC at 513-552-3272 or email to geae.aoc@ge.com to the attention of the hardware owner.

Fuel Manifold (Left Side) Part Number Fuel Manifold (Right Side) Part Number Engine Serial Number Engine Time Since New OR Engine Time Since Last Shop Visit Engine Cycle Since New OR Engine Cycle Since Last Shop Visit Chafi ng location Block clamp replaced (unserviceable) Yes No

Event Result (Leak/Chafi ng - include depth)
C. R e p a i r o f t h e F u e l M a n i f o l d s t h at H ave P T F E C o at e d P a ra - A ra m i d T a p e ( C 1 0

- 2 2 5 ) at t h e B l o c k C l a m p L o cat i o n s (1) If the fuel manifolds (1 and 2, Figure 1) have been previously repaired with PTFE coated para-aramid tape (C10-225) at the block clamp (3) locations, inspect the fuel manifolds (1 and 2) and block clamps (3) as follows: (a) Remove the four block clamps (3) from the fuel manifolds (1 and 2). Refer to paragraph 3.A.(2). (b) Do an inspection for serviceability of the block clamps (3). Refer to paragraph 3.A.(3). (2) Inspect the PTFE coated para-aramid tape (C10-225) at the fuel manifolds (1 and 2). Refer to Figure 3 and as follows: (a) No chafi ng, scratches, nicks, or tears o n the PTFE coated para-aramid tape (C10-225) are permitted.

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(b) No more than one depression because of block clamp (3, Figure 1) force is permitted. C A U T I O N : IF ANY DAMAGE IS FOUND ON THE PARENT METAL OF THE FUEL MANIFOLDS (1 AND 2, FIGURE 1). FOLLOW THE CRITERIA OF TABLE 2 PARAGRAPH 4.1. (c) If you see the conditions described in paragraphs 3.C.(2)(a) and 3.C.(2)(b) in the PTFE coated para-aramid tape (C10-225), replace the damaged PTFE coated para-aramid tape (C10-225) with new PTFE coated para-aramid tape (C10-225) to serviceable fuel manifolds (1 and 2) as speci fi ed in CF6-80E1 Airbus A330 AMM, 73-11-44. N O T E : If you add new PTFE coated para-aramid tape (C10-225), the repaired fuel manifolds (1 and 2, Figure 1) can continue for another 7,500 fl ight hours. (d) Install serviceable block clamps (3) on the fuel manifolds (1 and 2). Refer to paragraph 3.A.(6). (3) Close access to affected fuel manifolds (1 and 2). Refer to CF6-80E1 Airbus A330 AMM, 73-11-44.

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Block Clamp and Epoxy Wear Sleeve/PTFE Coated Para-Aramid Tape Location Figure 1, ( Sheet 1 of 2 )

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Block Clamp and Epoxy Wear Sleeve/PTFE Coated Para-Aramid Tape Location Figure 1, ( Sheet 2 )

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Block Clamp and Epoxy Sleeve Wear Examples (Not Serviceable Condition) Figure 2

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PTFE Coated Para-Aramid Tape Application Figure 3

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