CF 6

- 80E1 Service Bulletin No 73

- 0061 R04

Revised: 12/23/2009 Issued: 04/14/2003

SB 73

- 0061 R04 ENGINE FUEL AND CONTROL

- (72

- 00

- 02)

- Fuel Manifold Inspection and Clamp Replacement

CF6

- 80E1 SERVICE BULLETIN

- 73

- 0061 R04 Revised:

12/23/2009

SB 73

- 0061 R04 ENGINE FUEL AND CONTROL

- (72

- 00

- 02)

- FUEL MANIFOLD INSPECTION AND CLAMP

REPLACEMENT Issued:

04/14/2003

GE PROPRIETARY INFORMATION

The information contained in this publication 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 consent of GE, including, but without limitation, it is not to be used in the creation, manufacture, development, or derivation of any repairs, modifications, spare parts, designs, or configuration changes or to obtain FAA or any other government or regulatory

app roval to do so. If consent is given for reproduction in whole or in part, this notice and the notice set forth on this media shall appear in any such reproduction in whole or in part. This technical data is considered ITAR and/or EAR controlled pursuant to 22 CFR Part 120

- 130 and

15 CFR Parts 730

- 774 respectively. Transfer of this data by any means to a Non

- U.S. Person, whether in the United States or abroad, without the proper U.S. Government authorization (e.g., License, exemption, NLR, etc.), is strictly prohibited.

All technical documentation and information contained herein, with respect to assembly and disassembly, cleaning, inspection methods and limits, repair methods and limits, operational limits, life limits and the like, have been developed an d approved for use with engines and parts that have been manufactured and/or approved by GE and that have been maintained in

accordance with GE technical documentation and recommendations. GE has no contractual or legal obligation for, nor knowledge of, no n

- GE

- approved parts and repairs. Accordingly, this documentation is not intended to apply to non

- GE

- approved parts and repairs.

GEAE authorizes the Federal Aviation Administration to incorporate this document by reference

in an Airworthiness Directive.

Copyright (2009) General Electric Company, U.S.A.TRANSMITTAL INFORMATION

REVISION 4 TO SERVICE BULLETIN 73

- 0061

Revision 4 is issued to update paragraph 1., PLANNING INFORMATION, to correct the airworthiness directive (AD) paragraph reference for the alternative method of compliance (AMOC) in paragraph 1.F., Approval, to correct paragraph 2., MATERIAL INFORMATION, and to add a step to remove non PTFE tape in paragraph 3., ACCOMPLISHMENT

INSTRUCTI ONS.

Revision 3 was issued April 24, 2009. Revision 2 was issued August 30, 2007. Revision 1 was issued August 22, 2007. The original was issued April 14, 2003. Revision bars in the left margin identify changes.

1. PLANNING INFORMATION

A. Effectivity

* * * CF6

- 80E1A2, A3, A4, A4/B

The parts in Table 1 are affected by this Service Bulletin.

Table 1

Service

Bulletin Part Number Descriptio n

73

- 0026 P/N

1303M31G12 Left Side Fuel Manifold (fuel manifold)

73

- 0026 P/N

1303M32G12 Right Side Fuel Manifold (fuel manifold)

-- P/N J1220G10 Clamp (cushioned loop clamp)

73

- 0096 P/N

2420M70G01 Left Side Fuel Manifold (fuel manifold) with PTFE

Tape

73

- 0096 P/N

2420M71G01 Right Side Fuel Manifold (fuel manifold) with PTFE

Tape

B. Description

This Service Bulletin identifies repetitive inspection and cushioned loop clamp replacement for the fuel manifolds and applies to post

- CF6

- 80E1 S/B 73

- 0026 configurations. The inspection is necessary to detect wall thinning in the fuel manifolds that can result from relative motion between the cushioned loop clamp and

the fuel manifold.

C. Compliance

Category 2GE recommends that you do this Service Bulletin as soon as possible without effect on

revenue service but before the inspection intervals for each manifold configuration as

follows:

Post

- CF6

- 80E1 S/B 73

- 0026 (non PTFE taped drainless fuel manifolds): AD 2009

- 05

- 02 specifies initial and repeat inspection requirements. Repeat inspection requirements

are also listed in CF6

- 80E1 engine manual (EM) 05

- 21

- 73, LIFE LIMIT

- FUEL

MANIFOLD

- MANDATORY INSPECTION AND MAINTENANCE INTERVALS. Refer to paragraph 3.A., Inspection of post

- CF6

- 80E1 S/B 73

- 0026 pre

- CF6

- 80E1 S/B

73

- 0096 (Non PTFE Taped Drainless Fuel Manifold) P/N 1303M31G12 and P/N

1303M32G12

.

Post

- CF6

- 80E1 S/B 73

- 0026 post

- CF6

- 80E1 S/B 73

- 0096 (PTFE taped drainless fuel manifolds): for inspection requirements, refer to the CF6

- 80E1 EM, 05

- 21

- 73, LIFE

LIMIT

- FUEL MANIFOLD

- MAND ATORY INSPECTION AND MAINTENANCE INTERVALS. Refer to paragraph 3.B., Inspection of post

- CF6

- 80E1 S/B 73

- 0026

post

- CF6

- 80E1 S/B 73

- 0096 (PTFE Taped Drainless Fuel Manifold) P/N

2420M70G01 and P/N 2420M71G01

.

NOTE : This Service Bulletin can be accomplished in shop or on wing.

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 f leet.

D. Concurrent Requirements.

Do application of PTFE tape per CF6

- 80E1 S/B 73

- 0096 to those fuel manifolds that do not have it when you do this Service Bulletin.

E. Reason

(1) Objective:

To reduce significant events.

(2) Condition:

Tube wall thinning on the fuel manifolds, if undetected, can result in a fuel leak.

One event on a CF6

- 80C2 engine resulted in an undercowl fire. This fuel manifold system is common to the CF6

- 80C and CF6

- 80E engine programs.

(3) Cause:

The cushion material on the cushioned loop clamps erodes and becomes contaminated with foreign abrasive material. The abrasive material in thecushioned loop clamp wears against the fuel manifolds and thins the tube wall beyond serviceable limits.

(4) Inspection:

This inspection will allow detection of worn fuel manifolds. The cushioned loop clamps are replaced with new parts to ensure that contaminated cushioned loop clamps are not installed on the engine.

(5) Substantiation:

Substantiation is based upon design analysis and field inspection data analysis.

F. Approval

This Service Bulletin has been reviewed by the appropriate governmental authority and the repair(s) and modification(s) herein comply with the applicable Aviation Regulations and are APPROVED for installation in the model(s) listed in this Service

Bulletin.

CF6

- 80E1 S/B 73

- 0061, Revision 3, ACCOMPLISHMENT INSTRUCTIONS paragraph 3.C.(2), is approved by the Manager, Engine Certification Office, ANE

140, by letter dated April 21, 2009 as an Alternative Method of Compliance to AD

2009

- 05

- 02, paragraphs 2.(h)(1) through 2.(h)(3).

CF6

- 80E1 S/B 73

- 0061, Revision 4, ACCOMPLISHMENT INSTRUCTIONS paragraph 3.C.(3), is approved by the Manager, Engine Certification Office, ANE

- 140, by letter dated December 22, 2009 as an Alternative Method of Compliance to AD

2009

- 05

- 02, paragraph (h)(5).

G. Manpower

After you get access to the fuel manifolds and cushioned loop clamps, you will need approximately 2 man

- hours to replace cushioned loop clamps and inspect the fuel manifolds, for each engine.

If the removal and installation of the fuel manifolds are necessary, you will need approximately 10 man

- hours.

H. Weight and Balance

Weight and balance are not changed.

I. References (Use the latest version of these documents)

Airworthiness Directive (AD) 2009

- 05

- 02 Airbus Industrie A330

- 200/

- 300 Aircraft Maintenance Manual (AMM) Commercial Engine Standard Practices Manual (SPM),

GEK 9250

CF6

- 80E1 Engine Manual (EM), GEK 99376CF6

- 80E1 Engine Manual (EM), GEK 99376, Chapter 05

- 21

- 73, Life Limits

- Fuel

Manifold

- Mandatory Inspection and Maintenance Intervals CF6

- 80E1 Illustrated Part Catalog (IPC), GEK 99378

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

- 0096 , FUEL AND CONTROL

- Core Engine Module (72

- 00

- 02)

- Fuel Manifold PTFE Tape Installation

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 Service Bulletin:

Part Number Qty/ Eng Part Name Unit ($) Price Pkg Qty Lead Time Day s

RPK426G01 * (1) Kit 162.00 (1) 10

*The Kit contains 24 cushioned loop clamps P/N J1220G10

.

NOTE: Prices are provided solely for planning purposes, and are subject to change.

(2) Other Spare Parts:

If unserviceable chafing is found on the fuel manifolds, the following parts may be required:

Part

Number Qty/

Eng Part Name Unit ($)

Price Pkg

Qty Lead Time Day s

1303M31G12 (1) Manifold, Fuel Left Side * (*) *

1303M32G12 (1) Manifold, Fuel Right

Side * (*) *

2420M70G01 (1) Manifold, Fuel Left Side 12,060.00 (1) 7

2420M71G01 (1) Manifold, Fuel Right

Side 10,250.00 (1) 7NOTE: Prices are provided solely for planning purposes, and are subject to change.

*See IPC for latest configurations. GE recommends fuel manifold P/Ns

1303M31G12 and 1303M32G12 are reworked per CF6

- 80E1 S/B 73

- 0096 to add

PTFE tape prior to use.

(3) Consumables:

Code Number Description

C04

- 035 Solvent, General (Isopropyl Alcohol)

C10

- 230 Tape, PTFE Film, Silicone Adhesive (PTFE tape)

B. Industry Support Information

GEAE may provide financial support. Contact your Customer Support Manager (CSM) for more information. Fuel manifolds found with unserviceable chafing may be sent to Elano Corporation for Repair. Send the fuel manifolds along with a Charge

Purchase Order (specifying the number of this Service Bulletin) to:

Unison Industries, LLC Attn: Customer Support 2070 Heller Drive Alpha, OH 45301

- 0217 U.S.A.

Phone: (937) 490

- 7055 Fax: (937) 490

- 7081

C. Configuration Chart

Not applicable.

D. Parts Disposition

If fuel manifolds are found unserviceable after the inspection they can be replaced or sent for repair to a certified repair station. Discard the old cushioned clamps.

E. Tooling

- Price and Availability

None.

3. ACCOMPLISHMENT INSTRUCTIONS

A. Inspection of post

- CF6

- 80E1 S/B 73

- 0026 pre

- CF6

- 80E1 S/B 73

- 0096 (Non PTFE Taped Drainless Fuel Manifold) P/N 1303M31G12 and P/N 1303M32G12

NOTE: Refer to paragraph 1.D., Concurrent Requirements on an additional recommendation for these fuel manifold part numbers.

(1) Remove the cushioned loop clamp bolt (1, Figure 1) at each of the friction damper bracket (2) locations (24 places).(2) Remove and discard the cushioned loop clamp (3) from the 24 places on the fuel manifolds (4).

WARNING: ISOPROPYL ALCOHOL IS TOXIC AND FLAMMABLE. USE PERSONAL

PROTECTION EQUIPMENT. USE IN A WELL

- VENTILATED AREA.

(3) If tape is present on the fuel manifold (4), remove it. Isopropyl alcohol (C04

- 035) can be used to help in tape removal. Let it dry. If tape or contamination remains after cleaning, clean once more.

(4) Inspect the manifold at each clamp location. Refer to paragraph 3.C., General Inspection Procedure.

(5) Install the cushioned loop clamp bolt (1) and new cushioned loop clamp (3) in all friction damper bracket (2) locations (24 places). Tighten the bolts to 33

- 37 lb in. (3.7

- 4.2 N·m).

B. Inspection of post

- CF6

- 80E1 S/B 73

- 0026 post

- CF6

- 80E1 S/B 73

- 0096 (PTFE Taped Drainless Fuel Manifold) P/N 2420M70G01 and P/N 2420M71G01

(1) Remove the cushioned loop clamp bolt (1, Figure 1) at each of the f riction damper bracket (2) locations (24 places).

(2) Remove the cushioned loop clamp (3) from the 24 places on the fuel manifolds (4).

(3) The table that follows provides inspection instructions for manifolds with PTFE tape under the clamp.

Condition Action

PTFE tape (C10

- 230) has no visual

evidence of unbonded areas between the tape and the manifold, no damage*

detected by unmagnified visual inspection and no loose tape material. Install a new cushioned loop clamp (3). Make sure tape extends beyond edge of the clamp. Tighten bolts to 33

- 37 lb in. (3.7

- 4.2 N·m).

PTFE tape (C10

- 230) has visual evidence

of unbo nded areas between the tape and the fuel manifold (4), or has damage* detected by unmagnified visual inspection or loose tape material, but has no parent metal exposed through the tape. Remove tape. Apply new PTFE tape (C10

- 230) per CF6

- 80E1 S/B 73

- 0096 . Install new cushioned loop clamp (3). Make sure tape extends beyond edge of the clamp. Tighten bolts to 33

- 37 lb in. (3.7

- 4.2 N·m).

PTFE tape (C10

- 230) wear through to parent metal of the tube. Remove tape and inspect per general inspection procedure 3.C. If the fuel manifold passes the inspection, apply the PTFE tape (C10

- 230) per CF6

- 80E1 S/B

73

- 0096 . Install new cushioned loop clamp (3). Tighten bolts to 33

- 37 lb in. (3.7

- 4.2N·m).

* Damage condition is defined as wrinkles, tears or evidence of wear. It does not include compression or burnishing.

C. General Inspection Procedure (to be done as directed by paragraphs 3.A. and 3.B.)

WARNING: ISOPROPYL ALCOHOL IS TOXIC AND FLAMMABLE. USE PERSONAL

PROTECTION EQUIPMENT. USE IN A WELL

- VENTILATED AREA.

NOTE: Isopropyl alcohol (C04

- 035) can be used to help in tape removal. Allow time to dry. If tape or contamination remains after cleaning, clean once again.

(1) Clean the fuel manifolds at the 24 clamp places. Refer to the SPM, 70

- 21

- 23,

CLEANING METHOD 23

- HAND

- WIPE DEGREASING, or equivalent

method.

(2) Do a visual inspection of the fuel manifolds (4, Figure 1) with a bright light at all clamp places. Most chafing location occurs on the inboard side of the manifold near the loop clamp tabs. Pay specific attention to these areas ( Figure 1, Detail A). If the fuel manifolds (4) have any signs of wear ( Figure 2), measure the tube as

f ollows or with an equivalent method that can detect reduced wall thickness:

(a) Measure the outside diameter of the tube adjacent to the worn area. Record the reading.

(b) Measure the outside diameter of the tube in the worn area; find the smallest diameter. Record the reading.

(c) Subtract the measurement of the worn tube recorded in step 3.C.(2)(b) from the undamaged tube measurement recorded in step 3.C.(2)(a).

(d) Permitted wear is less than or equal to 0.0035 inch (0.089 mm).

(3) 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 up to 50 cycles before

the fuel m anifolds have to be replaced. For fuel manifold removal and installation, refer to the applicable AMM.

(4) 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 the applicable AMM.

D. Reporting Fuel Manifold Chafing Inspection Results

If chafing is found while performing the fuel manifold inspection, please send the following information for each engine to your CSM. The CSM will forward the results to the Product Support Engineering (PSE) hardware owner.

Date ESN TSN CSN Chafing Event ResultInspected Or

TSSV Or

CSSV Location (Aft Looking Forward) (Leak/Chafing

-

Include Depth)

Post

- S/B 73

- 0026 (no drain system)

Configuration of Fuel Manifold Post

- CF6

- 80E1 S/B 73

- 0026 (D rainless Fuel Manifold) Figure 1 (Sheet 1)Configuration of Fuel Manifold Post

- CF6

- 80E1 S/B 73

- 0026 (Drainless Fuel Manifold) Figure 1 (Sheet 2)Location of Cushioned Loop Clamp wear on the Fuel Manifold Figure 1 (Sheet 3)Visual Inspection of Fuel Manifold Figure 2

GE PROPRIETARY INFORMATION

- Subject to the restrictions on the media.

Date Printed: GE PROPRIETARY INFORMATION

- Not to be used, disclosed to others or

reproduced without the express written consent of GE. Technical data is considered {Page}{cd} ITAR and/or EAR controlled; transfer of this data to a Non

- US Person, without USG authorization, is stric tly prohibited.