AL ERT OPERATORS TRANSMI SSI ON - ALERT OPERATORS TRANSMI SSI ON

SUBJECT: ATA 71 - A330 CF6 - 80E1 Upper aft mount bolt inspection OUR REF.: A71L002 - 13 dated 08 Apr 2013. 1. AIRCRAFT AFFECTED All A330 powered with GE CF6 - 80E1. 2. REFERENCED DOCUMENTATION 2.1 APPENDIX Appendix 1: Airbus Technical report Reference G54RP1310441 - GE CF6 - 80E1 - ATA 54 - 51 - 18 Fractured Bolts on Aft Engine Mount Upper Beam. 2.2 REFERENCES A330 GE IPC 71 - 22 - 41 Item 20 BOLT - DBL HEX HD. A330 GE AMM 24 - 42 - 00 - 861 - 801 - A Energize the Ground Service Network. A330 GE AMM 78 - 31 - 00 - 040 - 802 Deactivation of the Thrust Reverser Sy stem for Maintenance. A330 GE AMM Figure 05 - 24 - 50 - 991 - 03100 - 06 - A / SHEET 1 - Access Doors/ Panels, Engine 1 P yl on. A330 GE AMM Figure 05 - 24 - 50 - 991 - 03200 - 06 - A / SHEE T 1 - Access Doors/ Panels, Engine 2 P yl on. A330 GE AMM 78 - 31 - 00 - 440 - 802 - A Reactivation of the Thrust Reverser Sy stem after Maintenance. A330 GE AMM 24 - 42 - 00 - 862 - 801 - A De - energize the Ground Service Network. 3. REASON 3.1 FACTS During the scheduled rep lacement of a CF6 - 80E1 engine#1 on an A330 aircraft, one bolt part number 1672M36P01 (IPC 71 - 22 - 41 Item 20 BOLT - DBL HEX HD) on the aft engine mount upper beam was found totally broken. The bolt reportedl y "fell down" upon removal of the lower beam. The bol t in question is one of the four bolts that attach the upper beam to the pylon. This was the original engine on the aircraft and had no removal since entry into service.Since EI S, amongst numerous scheduled or unscheduled CF6 - 80E1 engine removals this is

the only case reported. Extensive investigation on the fractured bolt and the upper beam revealed:

- A fatigue origin area with crack propagation from the boundary of the bolt.

- Visual examination of the bolt reveals spiral groove with cold work and mic rostructural distortion underlying that extended axially along the shank. The crack initiated at the edge of the groove.

- Once initiated, the complete fracture of the bolt was reached very quickl y (quick propagation).

- The upper beam revealed a score mar k on counter - bore edge. To be noted that the 3 other bolts were found in good condition. Preliminary

root - cause understanding is that unusual contact with the counter - bore edge of the beam induced a very

significant groove on the bolt during its installat ion, which eventuall y led to the bolt fracture. As the root - cause is still under investigation, including the installation sequence specific to this aircraft - engine model, the AOT is not applicable for other A330 propulsion sy stems. 3.2 CONSEQUENCES Failure of one p yl on - upper beam bolt is a failsafe case taken into account in certification anal ys is. During this abnormal flight condition the structure is designed to continue to sustain residual fatigue loads and limit loads during a minimum of one insp ection interval (9,500 FC) as required per ALI task 545111 - 02 - 01. Furthermore, the engine mount structure is not designed to sustain the residual fatigue and limit loads on 2 bolts or less. 3.3 AIM The aim of this AOT is to ask operators to perform a on etime ultrasonic inspection of the four aft mount - pylon bolts of each engine. That makes a total of eight aft mount pylon bolts inspected b y aircraft. This will allow detection of cracks completel y sheared through the bolt section. 4. SHORT TERM ACTION 4.1 PLANNING AND MANPOWER 4.1.1 ACCOMPLI SHMENT TIMESCAL E Airbus requires that the inspection as per procedure described in paragraph 4.2, is carried out at first opportunity

and no later than 1000FH after receipt of this "Alert Operators Transmission".4.1.2 MANPOWER

The estimated time to get access and perform the inspection is 2.5MH per engine. The estimated time to apply the corrective actions in case of findings is 25Mh per engine. 4.2 DESCRIPTION 4.2.1 ACCESS Make sure that the safet y devices and the warning notices are in position before you start a task on or near:

- The flight control.

- The flight control surfaces.

- The landing gear and the related doors.

- Components that move. Movement of components can kill or injure persons. Energize the ground service network as per AMM TASK 24 - 42 - 00 - 861 - 801. Make sure that the engine 1(2) shutdown occurred not less than 5 minutes before you do the inspection. Put a WARNI

NG NOTICE(S) to tell persons not to start the engines. Get Access to the Avio nics Compartment:

- Put an ACCESS PLATFORM 3M (10 FT) - ADJUSTABLE in position at access door 811

- Open access door 811.

- Open the protective door of the AC/DC emergency power - center 740VU. Open, safety

and tag these circuit breakers:

- For FIN 4030EM1 ( DEMOUNTABLE POWER PLANT, ENG1): o Panel: 722VU / Designation: FADEC B ENG 1 / FIN: 13KS1 / Location: D44 o Panel: 742VU / Designation: FADEC A ENG 1 / FIN: 12KS1 / Location: Q73

- FOR FIN 4030EM2 (DEMOUNTABLE POWER PLANT, ENG2) o Panel: 7 22VU / Designation: FADEC B ENG 2 / FIN: 13KS2 / Location: K49 o Panel: 742VU / Designation: FADEC A ENG 2 / FIN: 12KS2 / Location: Q74 Make the thrust reverser unserviceable as per AMM TASK 78 - 31 - 00 - 040 - 802. Put an ACCESS PLATFORM 5M (16 FT) - ADJ USTABLE in position at the pylon leading edge (zones 453, 463). Remove the access panels:

- For p yl on 1: 453BL and 453BR

- For p yl on 2: 463BL and 463BR(Refer to AMM Figure 05 - 24 - 50 - 991 - 03100 - 06 - A / SHEET 1 and - Figure 05 - 24 - 50 - 991 -

03200 - 06 - A / SHEET 1 for the locations of the Access Doors/ Panels, respectively on Engine 1 Pylon and Engine 2 P yl on). Perform the inspection as per paragraph 4.2.2 and contact Airbus in case of findings as per paragraph 4.2.3. Make the thrust reverser serviceable as per AMM TASK 78 - 31 - 00 - 440 - 802 Remove the safet y clips and the tags and close these circuit breakers:

- For FIN 4030EM1 (DEMOUNTABLE POWER PLANT, ENG1): o Panel: 722VU / Designation: FADEC B ENG 1 / FIN: 13KS1 / Location: D44 o Panel: 742VU / Designation: FADEC A ENG 1 / FIN: 12KS1 / Location: Q73

- FOR FIN 4030EM2 (DEMOUNTABLE POWER PLANT, ENG2) o Panel: 722VU / Designation: FADEC B ENG 2 / FIN: 13KS2 / Location: K49 o Panel: 742VU / Designation: FADEC A ENG 2 / FIN: 12KS2 / Location: Q 74 Make sure that the work area is clean and clear of tools and other items Install the access panels:

- For p yl on 1: 453BL and 453BR

- For p yl on 2: 463BL and 463BR (Refer to AMM Figure 05 - 24 - 50 - 991 - 03100 - 06 - A / SHEET 1 and - Figure 05 - 24 - 50 - 991 - 03200 - 06 - A / SHEET 1 for the locations of the Access Doors/ Panels, respectively on Engine 1 Pylon and Engine 2 P yl on). Close the protective door of the AC/DC emergency power - center 740VU. Remove the WARNING NOTICE(S) in the cockpit. Close access door 811. R emove the access platform(s). Remove the ground support and maintenance equipment, the special and standard tools and all other items. De - energize the ground service network as per AMM TASK 24 - 42 - 00 - 862 - 801 4.2.2 INSPECTI ON REQUIREMENTS Perform a onetim e ultrasonic inspection of the four aft mount - pylon bolts of each engine. Please refer to Appendix 1 to be provided with all the inspection instructions and tooling requirements for application of this AOT. 4.2.3 FINDINGSIn case of a fractured bolt is id entified, before next flight contact Airbus since specific

instructions would be provided with regards to components removal / installation. Findings of a fracture bolt shall require the following actions:

- Removal of the engine.

- Removal of the aft mount hardware for shop inspection and potential repair. 5. FURTHER INFORMATION 5.1 FOLLOW - UP PLAN Further actions may

be considered based upon results of the ongoing investigations. 5.2 IMPACTED DOCUMENTATION N/A 6. AOT APPROVAL The technical content of this document is approved under the authorit y of DOA nr. EASA.21J.031. 7. REPORTI

NG Operators are requested to acknowledge receipt of this AOT within 48 hours after receipt to: Emilie GAILLANOU, SEEE E - mail: emilie.gaillanou@airbus.com Fax number +33 (0)5 61 39 36 14 Questions about this AOT and inspection results with or without findings are to be sent to Airbus Customer Services engineering as soon as possible, after the AOT application, to the attention of: Marie LALO Repair & S ys tem Nacelles Customer Engineering Support - SEEE6 CUSTOMER SERVI CES Phone: +33 (0)5 62 11 83 03 Fax: +33 (0)5 61 93 36 14 mailto: marie.lalo@airbus.comBest Regards,

Jean - Lu c MOUYSSET Philippe GOURDON VI CE PRESIDENT ENGINEERING SUPPORT VI CE PRESIDENT A330/A340 PROGRAMME CUSTOMER SERVI CES CUSTOMER SERVI CES