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ENGINE - Fan Module (72-00-01) - CF6-80C2 Borescope Inspection for No. 3 Bearing Packing Flow Acceptability

GE PROPRIETARY INFORMATION The information contained in this document is GE proprietary information and is disclosed in con fi dence. It is the property of GE and shall not be used, disclosed to others or reproduced without the 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 approvaltodo so. If consent is givenfor reproductionin whole or in part,this notice andthe 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, withoutthe proper U.S.Government authorization (e.g., License, exemption, NLR, etc.), is strictly prohibited.GEAE authorizes the Federal Aviation Administration to incorporate this document by reference in an Airworthiness Directive. Copyright (2011) General Electric Company, U.S.A.

December 16, 2011 CF6-80C2 S/B 72-1427 PAGE 1 of 17

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ENGINE - Fan Module (72-00-01) - CF6-80C2 Borescope Inspection for No. 3 Bearing Packing Flow Acceptability

1. P LA N N I N G I N F O R M A T I O N A. E f f e cti v i ty CF6-80C2A1/A2/A3/A5/A5F/A8/B1/B1F/B2/B2F/B4/B4F/B5F/B6/B6F/B6FA/B7F/ B8F/D1F/K1F/L1F This Service Bulletin is applicable to all CF6-80C2 engines post-CF6-80C2 S/B 72-0266. B. D e s cr i pt i o n This Service Bulletin provides a borescope inspection (BSI) procedure to inspect for acceptable fl ow of No. 3 bearing packing either with the engine installed or assembled and removed. C. C o m p l i a n ce Category 7 GE recommends that you do this Service Bulletin at customer's option. N OT E : This Service Bulletin can be accomplished on wing or in shop. D. C o n c u r re n t R e q u i re m e n ts None. E. Re a s o n (1) Objective: Provide operators with a procedure to inspect for acceptable fl ow of the No. 3 bearing packing with the engine installed or assembled in shop. (2) Condition: Customers have requested an on-wing procedure to inspect for acceptable fl ow of No. 3 bearing packing. (3) Cause: It is possible to install the incorrect No. 3 bearing packing at shop visit. (4) Inspection: BSI procedure to inspect for acceptable fl ow of the No. 3 bearing packing without separating the fan frame from the core. This may be accomplished on wing or in shop.

December 16, 2011 CF6-80C2 S/B 72-1427 PAGE 2 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or fi rst page.

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ENGINE - Fan Module (72-00-01) - CF6-80C2 Borescope Inspection for No. 3 Bearing Packing Flow Acceptability
(5) Substantiation: Procedure has successfully demonstrated that the No. 3 bearing packing fl ow can be identi fi ed by visual measurement of certain No. 3 bearing packing hole diameter via BSI. N O T E : Acceptability of fl ow has been determined by analyzing worst case con fi gurations and determining the impact on part life. F. A p p rova l 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. G. M a n p owe r After you get access to the fan frame module, you will need approximately 1 man-hour to do the inspection portion of this Service Bulletin. H. We i g h t a n d B a l a n ce Weight and balance are not changed. I. Re f e re n ces (Use the latest version of these documents) Airbus A300-600, Aircraft Maintenance Manual (AMM) Airbus A310-300, Aircraft Maintenance Manual (AMM) Boeing 747-300/400, Aircraft Maintenance Manual (AMM) Boeing 767-300/400, Aircraft Maintenance Manual (AMM) CF6-80C2K1F C-X Aircraft Maintenance Manual (AMM) CF6-80C2L1F C-5M Aircraft Maintenance Manual (AMM) McDonnel Douglas MD-11, Aircraft Maintenance Manual (AMM) GEK 92451, CF6-80C2 Engine Manual (EM) GEK 112213, CF6-80C2L1F Engine Manual (EM) GEK 112721, CF6-80C2K1F Engine Manual (EM) CF6-80C2 S/B 72-0204, ENGINE - Fan Module - 3R Gasko Seal Bore Cooling Reduction CF6-80C2 S/B 72-0266, ENGINE - Introduction of Bore Cooling Hardware for Improved Performance

December 16, 2011 CF6-80C2 S/B 72-1427 PAGE 3 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or fi rst page.

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ENGINE - Fan Module (72-00-01) - CF6-80C2 Borescope Inspection for No. 3 Bearing Packing Flow Acceptability
CF6-80C2 S/B 72-1405, ENGINE - No. 1, 2, and 3 Bearing Areas Fan Module (72-00-01) - Shop Inspection for Correct No. 3 Bearing Packing CF6-80C2 S/B 75-0157, AIR - Bore Cooling Valves (72-00-01) - Elimination (Block II) CF6-80C2 S/B 75-0198, AIR - Bore Cooling Air System (72-00-01) - Elimination N OT E : The reference document listed below is for the engine manufacturer's internal use only: BPP: CF6-11-72-23-01 J. P u b l i cat i o n s Af f e cte d None. 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 a te ri a l

- P ri ce a n d Ava 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 Qty/ E n g P a rt N a m e U n i t ( $ ) P ri ce P kg Q ty L e a d T i m e D a ys 1538M82P01 (2) Gasket, Air Fan Quote (-) Quote 9381M44P05 (6) Screw Quote (-) Quote J219P06 (2) Gasket, Seal Quote (-) Quote MS9557-10 (8) Bolt, Double Hexagon Head Machine Quote (-) Quote

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

December 16, 2011 CF6-80C2 S/B 72-1427 PAGE 4 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or fi rst page.

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ENGINE - Fan Module (72-00-01) - CF6-80C2 Borescope Inspection for No. 3 Bearing Packing Flow Acceptability
(3) Consumables: C od e N u m b e r D es c ri p ti o n C01-006 RTV, Silicone Elastomer (silicone) (black) C04-001 Solvent, General [methyl ethyl ketone (MEK)] C04-030 Solvent, General (solvent)
B. I n d u st ry S u p p o rt I n fo rm at i o n None. C. C o n fi g u ra ti o n C h a rt None. D. P a rts D i s p os i t i o n None. E. T oo l i n g - P ri ce a n d A va i l a b i l i ty T

oo l N u m b e r D es c ri p t i o n

-- Borescope N OT E : Borescope with head capable of measuring hole diameter (such as shadowscope or stereoscope). 3. AC 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. I n s p e ct i o n of th e N o
. 3 B e a r i n g P a c k i n g N OT E : This Service Bulletin only determines acceptability of fl ow provided by the No. 3 bearing packing. The CF6-80C2 S/B 72-1405 needs to be completed next time the fan frame is separated from the core to identify the No. 3 bearing packing con fi guration. (1) If procedure is done with the engine installed on wing, gain access to the fan frame. Refer to applicable AMM. (2) Verify there are either blank-off plates or air tubes connecting to the fan case at either 3:00 o'clock or 9:00 o'clock and at 5:00 o'clock position. Refer to Figure 1. (3) Determine fan frame part number.

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ENGINE - Fan Module (72-00-01) - CF6-80C2 Borescope Inspection for No. 3 Bearing Packing Flow Acceptability
(4) Do BSI as follows: (a) If the engine contains a blank-off plate on the fan case at the 3:00 o’clock (fan frame strut No. 4) or 9:00 o’clock (fan frame strut No. 10), and 5:00 o’clock (fan frame strut No. 6) position: 1 Disassemble fl owpath fairing at either the 3:00 o'clock (fan frame strut No. 4) or 9:00 o'clock (fan frame strut No. 10) position from case by removing four screws and tapered bushings. Do not attempt to remove the fl owpath fairing. Slide it inward on the fan frame struts as necessary to do the step below. 2 Remove the blank-off plate by removal of the three double hexagon head machine bolts (bolts), washers, and nuts that attach the blank-off plate and air fan gasket (gasket) to the strut at 3:00 o'clock (fan frame strut No. 4) or 9:00 o'clock (fan frame strut No. 10) position. Discard the gasket. 3 Insert borescope with a head capable of measuring hole diameter (such as a stereoscope or shadowscope head) to the aft side of the fan frame strut (Figure 1 and Figure 2). 4 Following the trailing edge of the fan frame strut, continue to thread borescope until the No. 3 bearing packing is reached. One hole in the forward side of the No. 3 bearing packing will be visible. N O T E : The No. 3 bearing packings that have a 3:00 o'clock or 9:00 o'clock hole diameter of 0.89-0.91 in. (22.6-23.1 mm) may not be completely visible at the 3:00 o'clock (fan frame strut No. 4) or 9:00 o'clock (fan frame strut No. 10) position due to the size of the fan frame hole. 5 Use the borescope to measure the No. 3 bearing packing cooling hole diameter. If fan frame part number series is identi fi ed as 9382M37GXX, record hole diameter in A P P E N D I X B . For all other fan frame part number series, use A P P E N D I X A . Record the hole diameter in the applicable A P P E N D I X A or A P P E N D I X B . If No. 3 bearing packing hole is not completely visible at the 3:00 o'clock (fan frame strut No. 4) or 9:00 o'clock (fan frame strut No. 10) position then mark as 0.89-0.91 in. (22.6-23.1 mm) in the applicable A P P E N D I X A or A P P E N D I X B

.

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ENGINE - Fan Module (72-00-01) - CF6-80C2 Borescope Inspection for No. 3 Bearing Packing Flow Acceptability

6 Remove the borescope and re-install the blank off plate, as follows: W

A R N I N G : DO NOT USE CLEANING SOLVENTS NEAR FLAMES OR HEAT OR LET THEM STAY ON YOUR SKIN. ALSO, MAKE SURE YOU HAVE A GOOD FLOW OF CLEAN AIR. THIS MATERIAL IS FLAMMABLE AND DANGEROUS TO YOUR SKIN, EYES, AND LUNGS. W

A R N I N G : METHYL ETHYL KETONE (C04-001) IS TOXIC. USE PERSONAL PROTECTION EQUIPMENT. USE IN A WELL VENTILATED AREA.
a Clean the mating surfaces of the gasket and blank-off plate with solvent (C04-030) or MEK (C04-001). W

A R N I N G : RTV-732 IS TOXIC AND FLAMMABLE. USE PERSONAL PROTECTION EQUIPMENT. USE IN A WELL VENTILATED AREA. b Apply silicone (C01-006) to the mating surfaces of the gasket and blank-off plate.
c Put the blank-off plate on the bolt-holes between the aft fan case T rings at the 3:00 o’clock (fan frame strut No. 4) or 9:00 o’clock (fan frame strut No. 10) position. d Attach the blank-off plate with the gasket and bolts, washers, and nuts.
e Torque the nuts to 100-130 lb in. (11.3-14.7 N·m). 7 Slide the fairing down the fan frame strut and attach to the fan case with four tapered bushings and self-retaining screws. Replace any screw that requires more than a 15.00 lb (67 N) insertion force. Torque the screws to 55-70 lb in. (6.2-7.9 N·m). WA R N I N G : METHYL ETHYL KETONE (C04-001) IS TOXIC. USE PERSONAL PROTECTION EQUIPMENT. USE IN A WELL VENTILATED AREA. 8 Use a clean cloth moistened with MEK (C04-001) to clean the areas in and around the gaps between the fl owpath fairings and the fan frame strut, and the gaps between the fl owpath fairings and the aft fan case. WA R N I N G : RTV-732 IS TOXIC AND FLAMMABLE. USE PERSONAL PROTECTION EQUIPMENT. USE IN A WELL VENTILATED AREA. 9 Apply a bead of silicone (C01-006) between the fan frame strut and the fl owpath fairing and between the aft fan case and the fl owpath fairing. Apply silicone (C01-006) in the contour of all adjacent surfaces. December 16, 2011 CF6-80C2 S/B 72-1427 PAGE 7 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or fi rst page.

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ENGINE - Fan Module (72-00-01) - CF6-80C2 Borescope Inspection for No. 3 Bearing Packing Flow Acceptability

1 0 Repeat steps 3.A.(4)(a)1 through 3.A.(4)(a)9 for 5:00 o’clock (fan frame strut No. 6) position. N O T E : If fan frame part number series is 9382M37GXX, then only No. 3 bearing packings with hole diameter of 0.12-0.13 in. (3.1-3.3 mm) will be visible at the 5:00 o'clock (fan frame strut No. 6) position. If No. 3 bearing packing is not visible at the 5:00 o'clock (fan frame strut No. 6) position, mark as HOLE NOT VISIBLE in A P P E N D I X B

. 1 1 Determine fl ow of installed No. 3 bearing packing per Table 1. Refer to Table 2 if the fan frame part number series is 9382M37GXX. If the hole diameter measured at any one of the 3:00 o'clock (fan frame strut No. 4) or 9:00 o'clock (fan frame strut No. 10) or 5:00 o'clock (fan frame strut No. 6) positions is determined to be ACCEPTABLE FLOW then the fl ow provided by the No. 3 bearing packing is acceptable and this Service Bulletin has been complied with. If none of these positions are determined to be ACCEPTABLE FLOW then this Service Bulletin has not been complied with. (b) If the engine contains a bore air tube on the fan case at the 3:00 o'clock (fan frame strut No. 4) or 9:00 o'clock (fan frame strut No. 10), and 5:00 o’clock (fan frame strut No. 6) position: 1 Remove the end of bore air tube at 3:00 o'clock (fan frame strut No. 4) or 9:00 o'clock (fan frame strut No. 10) position. 2 Insert borescope with a head capable of measuring hole diameter (such as a stereoscope or shadowscope head) to the aft side of the 3:00 o’clock (fan frame strut No. 4) or 9:00 o’clock (fan frame strut No. 10) position (Figure 1 and Figure 2). 3 Following the trailing edge of the fan frame strut, continue to thread borescope until the No. 3 bearing packing is reached. One hole in the forward diameter of the No. 3 bearing packing will be visible. N O T E : The No. 3 bearing packings that have a 3:00 o'clock or 9:00 o'clock hole diameter of 0.89-0.91 in. (22.6-23.1 mm) may not be completely visible at the 3:00 o’clock (fan frame strut No. 4) or 9:00 o’clock (fan frame strut No. 10) position due to the size of the fan frame hole. 4 Use the borescope to measure the No. 3 bearing packing cooling hole diameter. If fan frame part number series is identi fi ed as 9382M37GXX, record hole diameter in A P P E N D I X B . For other fan frame part number series, use A P P E N D I X A . Record the hole diameter in the applicable A P P E N D I X A or A P P E N D I X B . If No. 3 bearing packing hole is not completely visible at the 3:00 o'clock (fan frame strut No. 4) or 9:00 o'clock (fan frame strut No. 10) position then mark as 0.89-0.91 in. (22.6-23.1 mm) in the applicable A P P E N D I X A or A P P E N D I X B

.

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ENGINE - Fan Module (72-00-01) - CF6-80C2 Borescope Inspection for No. 3 Bearing Packing Flow Acceptability

5 Remove the borescope and re-install the bore tube at either the 3:00 o’clock (fan frame strut No. 4) or 9:00 o’clock (fan frame strut No. 10) position. Refer to the CF6-80C2 EM, 72-00-01, ASSEMBLY 003. 6 Repeat steps 3.A.(4)(b)1 through 3.A.(4)(b)5 for 5:00 o'clock (fan frame strut No. 6) position. N O T E : If fan frame part number series is 9382M37GXX, then only No. 3 bearing packings with hole diameter of 0.12-0.13 in. (3.1-3.3 mm) will be visible at the 5:00 o'clock (fan frame strut No. 6) position. If No. 3 bearing packing is not visible at the 5 o'clock position, then mark as HOLE NOT VISIBLE in A P P E N D I X B

. 7 Determine fl ow of installed No. 3 bearing packing per Table 1. Refer to Table 2 if fan frame part number series is 9382M37GXX. If the hole diameter measured at any one of the 3:00 o'clock (fan frame strut No. 4) or 9:00 o'clock (fan frame strut No. 10) or 5:00 o'clock (fan frame strut No. 6) positions is determined to be ACCEPTABLE FLOW then the fl ow provided by the No. 3 bearing packing is acceptable and this Service Bulletin has been complied with. If none of these positions are determined to be ACCEPTABLE FLOW then this Service Bulletin has not been complied with.

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ENGINE - Fan Module (72-00-01) - CF6-80C2 Borescope Inspection for No. 3 Bearing Packing Flow Acceptability
Table 1 - Fan frame part number is not series 9382M37GXX S t ru t N o
. N o
. 3 B e a ri n g P a ck i n g H o l e D i a m e te r C F 6

- 8 0 C 2 P M C C e rt/ 7 2

- 2 0 4/ 7 5
- 1 9 8 ( N o Tu b e s ) C F 6

- 8 0 C 2 B F P ost 7 5
- 0 1 5 7 C O N F I G 2 ( N o T u b es ) C F 6

- 8 0 C 2 P M C P o st 7 2

- 0 2 6 6 ( Tu b e s a n d V a l ve s ) C F 6

- 8 0 C 2 B F C e rt/ 7 5
- 0 1 5 7 C O N F I G 1 (T u b es ) C F 6

- 8 0 C 2 A F/ D 1 F A l l ( Tu b e s a n d V a l ve s ) C F 6

- 8 0 C 2 L 1 F/ k 1 F A l l

0.89-0.91 inch (22.6-23.1 mm)* Acceptable Flow Acceptable Flow Acceptable Flow Acceptable Flow Acceptable Flow ** 0.77-0.79 inch (19.6-20.1 mm) Acceptable Flow Acceptable Flow Acceptable Flow Acceptable Flow Acceptable Flow Acceptable Flow 4 or 10 0.12-0.13 inch (3.1-3.3 mm)   **  Acceptable Flow ** ** 0.77-0.79 inch (19.6-20.1 mm) Acceptable Flow Acceptable Flow Acceptable Flow Acceptable Flow Acceptable Flow Acceptable Flow 0.30-0.32 inch (7.6-8.1 mm) Acceptable Flow   Acceptable Flow **  ** 6 0.12-0.13 inch (3.1-3.3 mm)   Acceptable Flow Acceptable Flow Acceptable Flow **  *No. 3 bearing packings with hole diameters that measure 0.89-0.91 inch (22.6-23.1 mm) may not be completely visible due to fan frame hole diameter. **Refer to paragraph 3.A.(4).(a)1 1 or 3.A.(4).(b)7 as appropriate.

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ENGINE - Fan Module (72-00-01) - CF6-80C2 Borescope Inspection for No. 3 Bearing Packing Flow Acceptability
Table 2 - Fan frame part number series is 9382M37GXX

S t ru t N o
. N o
. 3 B e a ri n g P a ck i n g H o l e D i a m e te r C F 6

- 8 0 C 2 P M C C e rt/ 7 2

- 2 0 4/ 7 5
- 1 9 8 ( N o Tu b e s ) C F 6

- 8 0 C 2 B F P ost 7 5
- 0 1 5 7 C O N F I G 2 ( N o T u b es ) C F 6

- 8 0 C 2 P M C P o st 7 2

- 0 2 6 6 ( Tu b e s a n d V a l ve s ) C F 6

- 8 0 C 2 B F C e rt/ 7 5
- 0 1 5 7 C O N F I G 1 (T u b es ) C F 6

- 8 0 C 2 A F/ D 1 F A l l ( Tu b e s a n d V a l ve s ) C F 6

- 8 0 C 2 L 1 F/ K 1 F A l l

0.89-0.91 inch (22.6-23.1 mm)* Acceptable Flow Acceptable Flow Acceptable Flow Acceptable Flow Acceptable Flow ** 0.77-0.79 inch (19.6-20.1 mm) Acceptable Flow Acceptable Flow Acceptable Flow Acceptable Flow Acceptable Flow Acceptable Flow 4 or 10 0.12-0.13 inch (3.1-3.3 mm)   **  Acceptable Flow ** ** Hole Not Visible Acceptable Flow   Acceptable Flow **  ** 6 0.12-0.13 inch (3.1-3.3 mm)   Acceptable Flow Acceptable Flow Acceptable Flow **  *No. 3 bearing packings with hole diameters that measure 0.89-0.91 inch (22.6-23.1 mm) may not be completely visible due to fan frame hole diameter. **Refer to paragraph 3.A.(4).(a)1 1 or 3.A.(4).(b)7 as appropriate.

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ENGINE - Fan Module (72-00-01) - CF6-80C2 Borescope Inspection for No. 3 Bearing Packing Flow Acceptability

Fan Frame Borescope Entry Point (in all 3 sheets) Figure 1, ( Sheet 1 of 3 )

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ENGINE - Fan Module (72-00-01) - CF6-80C2 Borescope Inspection for No. 3 Bearing Packing Flow Acceptability

Fan Frame Borescope Entry Point Figure 1, ( Sheet 2 )

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ENGINE - Fan Module (72-00-01) - CF6-80C2 Borescope Inspection for No. 3 Bearing Packing Flow Acceptability

Fan Frame Borescope Entry Point Figure 1, ( Sheet 3 )

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ENGINE - Fan Module (72-00-01) - CF6-80C2 Borescope Inspection for No. 3 Bearing Packing Flow Acceptability

No. 3 Bearing Packing Hole Measure Inspection Figure 2

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ENGINE - Fan Module (72-00-01) - CF6-80C2 Borescope Inspection for No. 3 Bearing Packing Flow Acceptability

4. A P P E N D I X A No. 3 bearing packing hole diameter record. 0.89-0.91 inch (22.6-23.1 mm)* 0.77-0.79 inch (19.6-20.1 mm) 0.12-0.13 inch (3.1-3.3 mm) Hole Diameter 3:00 o’clock

(Fan Frame Strut No. 4) OR Hole Diameter 9:00 o’clock (Fan Frame Strut No. 10)
0.77-0.79 inch (19.6-20.1 mm) 0.30-0.32 inch (7.6-8.1 mm) 0.12-0.13 inch (3.1-3.3 mm) Hole Diameter 5:00 o’clock

(Fan Frame Strut No. 6) *No. 3 bearing packings with hole diameters that measure 0.89-0.91 inch (22.6-23.1 mm) may not be completely visible due to fan frame hole diameter.

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ENGINE - Fan Module (72-00-01) - CF6-80C2 Borescope Inspection for No. 3 Bearing Packing Flow Acceptability

5. A P P E N D I X B No. 3 bearing packing hole diameter record when fan frame part number series is 9382M37GXX. 0.89-0.91 inch (22.6-23.1 mm)* 0.77-0.79 inch (19.6-20.1 mm) 0.12-0.13 inch (3.1-3.3 mm) Hole Diameter 3:00 o’clock

(Fan Frame Strut No. 4) OR Hole Diameter 9:00 o’clock (Fan Frame Strut No. 10)

Hole Not Visible 0.12-0.13 inch (3.1-3.3 mm) Hole Diameter 5:00 o’clock

(Fan Frame Strut No. 6) *No. 3 bearing packings with hole diameters that measure 0.89-0.91 inch (22.6-23.1 mm) may not be completely visible due to fan frame hole diameter.

December 16, 2011 CF6-80C2 S/B 72-1427 PAGE 17 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or fi rst page.