CF6-80C2 Alert Service Bulletin No 73- A0401 R00

Revised: 08/14/2012 Issued: 08/14/2012 SB 73-A0401 R00 ENGINE FUEL AND CONTROL - Ge neral (73-00-00) - IDG Fuel-Oil Cooler Forward Flange Bracket and Spray Shield Replacement

CF6-80C2 ALERT SERVICE BULLETIN - 73- A0401 R00 Revised: 08/14/2012 SB 73-A0401 R00 ENGINE FUEL AND CONTROL - GENERAL (73-00-00) - IDG FUEL-OIL COOLER FORWARD FLANGE BRACKET AND SPRAY SHIELD REPLACEMENT Issued: 08/14/2012

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The information contained in this document is GE proprietary information and is disclosed in confidence. It is the property of GE and shall not be used, disclosed to others or reproduced without the express written consen t of GE, including, but without limitation, it is not to be used in the creation, manufacture, de velopment, or derivation of a ny repairs, modifications, spare parts, designs, or configuration changes or to obtain FAA or any other government or regulatory approval to do so. If consent is given for reprodu ction in whole or in pa rt, this notice and the notice set forth on each page of this document shall appear in an y such reproduction in whole or in part.
This technical data is considered EAR contro lled 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. Governme nt authorization (e.g., License, exemption, NLR, etc.), is strictly prohibited.

Copyright (2012) General El ectric Company, U.S.A.

1. PLANNING INFORMATION A. Effectivity * * * CF6-80C2A1/A2/A3/A5/A5F/A8/B1/B1F/B2/B2F/B4/B4F/B6/B6F/B7F/D1F The old bracket P/N 1321M88P001A and spray shield P/N 1606M57G01 or P/N 1775M61G01 of the integrated drive generator (I DG) fuel-oil cooler are affected bythis Alert Service Bulletin. B. Description This Alert Service Bulletin provides in structions to replace the bracket P/N 1321M88P001A and spray shield P/N 1606M57G01 or P/N 1775M61G01 with a new bracket P/N 2021M83G01 , as previously recommended by CF6-80C2 S/B 73-0242

. C. Compliance Category 2 GE recommends that you do this Alert Se rvice Bulletin as soon as possible without effect on revenue service but befo re February 7, 2013. If CF6-80C2 S/B 73-0242 was previously incorporated, then this Aler t Service Bulletin doe s not need to be accomplished. NOTE: This Alert Service Bulletin can be accomplished on wing or in shop. This Alert Service Bulletin is offered to im prove the reliability or performance of your GE product, or to help prevent the occurr ence of the event or condition described in this Alert Service Bulletin. If the operator el ects not to participate in the bulletin, that decision will be taken into considera tion by GE in evaluating future product performance issues that may arise in the operator’s fleet. D. Concurrent Requirements None. E. Reason (1) Objective: To improve maintainability and reduce significant events. (2) Condition: During engine operation, fuel leakage was reported on the IDG fuel-oil cooler forward flange, coming from the fuel-in tube. (3) Cause: Inappropriate reassembly of the IDG fuel-o il cooler forward flange hardware after maintenance activities has been identified as the cause of the fuel leakage on engines with a separate spray sh ield and bracket configuration. (4) Improvement:The new bracket integrates the function of both bracket and spray shield into one part, which simplifies installation of th e IDG fuel-oil cooler forward flange hardware and eliminates the possibility of misassembly. (5) Substantiation: Substantiation is by comparative analysis. F. Approval This Alert Service Bulletin contains no modification information that revises the approved configuration and therefor e does not require FAA approval. G. ManpowerAfter you get access to the IDG fuel-oil cooler, you will need approximately 0.5 manhour for each engine or component. H. Weight and Balance Weight and balance are not changed. I. References (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) McDonnell Douglas MD-11 Airc raft Maintenance Manual (AMM) GEK 9250, Commerial Engine St andard Practices Manual (SPM) GEK 92451, CF6-80C2 Engine Manual (EM) GEK 92452-1, CF6-80C2A (PMC) Illustrated Parts Catalog (IPC) GEK 92452-2, CF6-80C2B (PMC) Illustrated Parts Catalog (IPC) GEK 92452-3, CF6-80C2D (FADEC) Illustrated Parts Catalog (IPC) GEK 92452-4, CF6-80C2B (FADEC) Illustrated Parts Catalog (IPC) GEK 92452-5, CF6-80C2A (FADEC) Illustrated Parts Catalog (IPC) CF6-80C2 S/B 73-0242 , FUEL AND CONTROL - (73-00-00) - Spray Shields andSupport Bracket - Improvement J. Publications Affected None. K. Interchangeability Not applicable. L. Software Accomplishment Summary Not applicable. 2. MATERIAL INFORMATION A. Material - Price and Availability (1) Parts necessary to do this Alert Service Bulletin:

Part Number Qty/ Eng Part Name Unit ($) Price Pkg Qty Lead Time Days For CF6-80C2A1/A2/A3/A5/A8/B1/B2/B4/B6 engines: 2021M83G01 (1) Bracket Quote (-) Quote MS9557-10 (4) Bolt, Machine Quote (-) Quote J219P05 (1) Gasket, Seal Quote (-) Quote For CF6-80C2B1F/B2F/B4F/B6F/B7F/A5F/D1F engines: 2021M83G01 (1) Bracket Quote (-) Quote 1977M27P001A (1) Bracket, Support Quote (-) Quote MS9557-10 (4) Bolt, Machine Quote (-) Quote MS9557-06 (3) Bolt, Machine Quote (-) Quote MS21043-4 (3) Nut, Selflocking Quote (-) Quote

J219P05 (1) Gasket, Seal Quote (-) Quote NOTE: Prices are provided for planni ng purposes and are subject to change. (2) Other Spare Parts: None. (3) Consumables: Code Number Description C02-019 Oil, Engine L ubricating (lubricant)B. Industry Support Information GE Aviation will provide a 50 percent back-end parts credit for the brackets required to comply with this Alert Service Bullet in. Please e-file claims via Customer Web Center (CWC) or send claims to the addre ss below via mail, fax, or e-mail. Please include the engine serial number, date of compliance, and a reference to CS-13766- C4A and Alert Service Bulletin (CF6-80C2 S/B 73-A0401 ) with all claims. CF6 Warranty/Guarantee Administration GE Aviation Product Support Operation One Neumann Way, Room 444 Cincinnati, OH 45215-1988 U.S.A. OR Fax: (513) 552-5081 OR E-mail: FaxGEAEWarranty@fnl.ae.ge.com C. Configuration Chart None. D. Parts Disposition Discard old parts. E. Tooling - Price and Availability None. 3. ACCOMPLISHMENT INSTRUCTIONS A. General (1) Get access to the affected bracket and spray shield as follows: (a) For on-wing replacement, refer to the applicable AMM instructions to open the engine fan cowl, core cowl, and thrust reverser. (b) For in-shop replacement, refe r to the CF6-80C2 EM, 72-00-05, DISASSEMBLY (EFFECT A, B, or C). B. Removal and Installation for CF6- 80C2A1/A2/A3/A5/A8/B1/B2/B4/B6 Engines(1) Remove the old bracket (1, Figure 1, Sheet 1) and spray shield (2) as follows: (a) Remove the bolts (3) and washers (4) th at attach the spray shield (2) and bracket (1) to the IDG fuel-oil cooler. (b) Remove the spray shield (2). (c) Remove the bolts (5) and washers (6) that attach the bracket (1) to the IDG fuel-oil cooler support bracket. Keep the bolts (5) and washers (6) for reinstallation. (d) Remove the bracket (1). (e) Remove the seal gasket (05-120, 73-00- 00) from the IDG fuel-oil cooler forward flange. CAUTION: WHEN YOU INSTALL THE SEAL GASKET, MAKE SURE THAT THE PACKING IS NOT DAMAGED. IF YOU DO NOT OBEY THIS PRECAUTION, HIGH PRESSURE FUEL LEAKS CAN OCCUR. (f) Do an inspection of the new seal ga sket (05-120, 73-00-00) for damage. If nicks or tears are found, discar d the seal gasket (05-120). WARNING: REFER TO THE PRODUCT LA BEL AND THE MANUFACTURER’S (MATERIAL) SAFETY DATA SH EET FOR INSTRUCTIONS ON THE HAZARDS, STORAGE, SAFE HANDLING AND PROPER USE OF THIS PRODUCT. (g) Lubricate the seal gasket (05-120) wi th lubricant (C02-019) and install it on the IDG fuel-oil cooler forward flange. (2) Install the new bracket ( 1, Figure 1, Sheet 2) as follows: (a) Attach the bracket (1) to the IDG fuel -oil cooler with the new bolts (2). Torque the bolts (2) to 55-70 lb in. (6.2-7.9 N·m). (b) Install the bracket (1) to the IDG fuel-o il cooler support bracket with bolts (3) and washers (4). Torque the bolts (3) to 55-70 lb in. (6.2-7.9 N·m). (3) Do a leak check. Refer to paragraph 3.D., Leak Check. C. Removal and Installation for CF6- 80C2B1F/B2F/B4F/B6F/B 7F/A5F/D1F Engines (1) Remove the old bracket (1, Figure 2, Sheet 1) and spray shield (2) as follows: (a) Remove the bolt (4), nut (5), and washer (6) that attach the loop clamp on the hydromechanical unit (HMU) fu el tube to the support bracket (3). Keep the bolt (4), nut (5), and washer (6) for reinstallation.(b) For CF6-80C2B1F/B2F/B4F/B6F/B7F e ngine models only, remove the bolt (7), nut (8), and washer (9) that attach the loop clamp on the servo fuel heater oil tube to the angle bracket (10). (c) For CF6-80C2B1F/B2F/B4F/B6F/B7F engi ne models only, remove the bolts (11) and nuts (12) that attach the angle bracket (10) to the support bracket (3). (d) Remove the bolts (13) that attach the br acket (1), spray shield (2), and support bracket (3) to the IDG fuel-oil cooler. (e) Remove the spray shield (2) and support bracket (3). (f) Remove the bolts (14) and washers (15) that attach the bracket (1) to the IDG fuel-oil cooler support bracket. (g) Remove the bracket (1). (h) Remove the seal gasket (07-073, 73-00- 00) from the IDG fuel-oil cooler forward flange. CAUTION: WHEN YOU INSTALL THE SEAL GASKET, MAKE SURE THAT THE PACKING IS NOT DAMAGED. IF YOU DO NOT OBEY THIS PRECAUTION, HIGH PRESSURE FUEL LEAKS CAN OCCUR. (i) Do an inspection of the new seal ga sket (07-073, 73-00-00) for damage. If nicks or tears are found, discar d the seal gasket (07-073). WARNING: REFER TO THE PRODUCT LA BEL AND THE MANUFACTURER’S (MATERIAL) SAFETY DATA SH EET FOR INSTRUCTIONS ON THE HAZARDS, STORAGE, SAFE HANDLING AND PROPER USE OF THIS PRODUCT. (j) Lubricate the seal gasket (07-073) wi th lubricant (C02-019) and install it on the IDG fuel-oil cooler forward flange. (2) Install the new bracket (1, Figure 2, Sheet 2) as follows: (a) Attach the new bracket (1) to the IDG fuel-oil cooler with the new bolts (9). Torque the bolts to 55-70 lb in. (6.2-7.9 N·m). (b) Install the bracket (1) to the IDG fuel-o il cooler support brac ket with the bolts (10) and washers (11). Torque the bolts (10) to 55-70 lb in. (6.2-7.9 N·m). (c) Attach the new support bracket (2) to th e bracket (1) with the new bolts (12) and nuts (13). Torque the bolts ( 12) to 55-70 lb in. (6.2-7.9 N·m). (d) Attach the loop clamp on the HMU fuel tube to the support bracket (2) with the bolt (3), nut (4), and washer (5). To rque the nut (4) to 33-37 lb in. (3.7-4.2N·m). (e) For CF6-80C2B1F/B2F/B4F/B6F/B7F engi ne models only, attach the loop clamp on the servo fuel heater oil tube to the support bracket (2) with the bolt (6), nut (7), and washer (8). Torque the nut (7) to 33-37 lb in. (3.7-4.2 N·m). (3) Do a leak check. Refer to paragraph 3.D., Leak Check. D. Leak Check (1) Do an idle leak check to inspect the IDG fuel-oil cooler forward flange for fuel leaks as follows: (a) For on-wing modificatio n, refer to the applicable AMM. (b) For in-shop modification, refer to the CF6-80C2 EM, 72-00-00, TESTING 004, EFFECT C - ENGINE TESTING (for A FADEC, B FADEC, D FADEC) or 72-00-00, TESTING 004, E FFECT P - ENGINE TESTING (for A PMC and B PMC).IDG Fuel-Oil Cooler Spray Shield and Bracket Replacement Figure 1 (Sheet 1)IDG Fuel-Oil Cooler Spray Shield and Bracket Replacement Figure 1 (Sheet 2)IDG Fuel-Oil Cooler Spray Shield and Bracket Replacement Figure 2 (Sheet 1)IDG Fuel-Oil Cooler Spray Shield and Bracket Replacement Figure 2 (Sheet 2)

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