CF 6

- 80C2 Service Bulletin No 73

- 0326 R04

Revised: 12/23/2009 Issued: 03/05/2003

SB 73

- 0326 R04 ENGINE

- Fuel and Control (72

- 00

- 02)

- Fuel Manifold Inspection and Clamp Replacement

CF6

- 80C2 SERVICE BULLETIN

- 73

- 0326 R04 Revised:

12/23/2009

SB 73

- 0326 R04 ENGINE

- FUEL AND CONTROL (72

- 00

- 02)

- FUEL MANIFOLD INSPECTION AND CLAMP

REPLACEMENT Issued:

03/05/2003

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

- 0326

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, to correct the Service Bulletin number for installing of the non PTFE tape, and to add instructions to remove non PTFE tape from the manifold in paragraph
3., ACCOMPLISHMENT INSTRUCTIONS.

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 Marc h 05, 2003. Revision bars in the left margin identify changes.

1. PLANNING INFORMATION

A. Effectivity

* * * CF6

- 80C2A1, A2, A3, A5, A8, A5F, B1, B2, B4, B6, B1F, B2F, B4F, B5F, B6F, B6FA, B7F, B8F, D1F, L1F, K1F

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

Table 1

Service

Bulletin Part

Number Description Fuel Manifold

Position Drained/

Drainless Taped/ No

Tap e

-- 1303M31G10 Fuel Manifold Left Side Drained No Tape

-- 1303M32G10 Fuel Manifold Right Side Drained No Tape

73

- 0253 1303M31G12 Fuel Manifold Left Side Drainless No Tape

73

- 0253 1303M32G12 Fuel Manifold Right Side Drainless No Tape

73

- 0365 2420M70G01 Fuel Manifold Left Side Drainless PTFE Taped

73

- 0365 2420M71G01 Fuel Manifold Right Side Drainless PTFE Taped

-- J1220G10 Cushioned Loop Clamp -- -- --

B. Description

This Service Bulletin identifies a repetitive inspection of the fuel manifold and the replacement of the cushioned loop clamp. This Service Bulletin applies for all fuel manifold configurations in CF6

- 80C2 engines, except for drained manifolds with PTFE

ta pe installed. The inspection is necessary to detect wall thinning in the fuel manifold that can result from relative motion between the cushioned loop clamp and the fuelmanifold.

C. Compliance

Category 2

GE 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

- 80C2 S/B 73

- 0253 (non PTFE taped drainless fuel manifolds): AD 2009

- 05

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

are also listed in CF6

- 80C2 engine manual (EM), 05

- 21

- 73, LIFE LIMITS

- FUEL

MANIFOLD

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

- CF6

- 80C2 S/B 73

- 0253 pre

- CF6

- 80C2 S/B

73

- 0365 (Non PTFE Taped Drainless Fuel Manifolds) P/N 1303M31G12 and P/N

1303M32G12

.

Pre

- CF6

- 80C2 S/B 73

- 0253 (non PTFE taped drained fuel manifold):

(1) Engines with used clamps installed at the last inspection or overhaul, inspect the manifold and replace the clamps within 4,500 hours since the last inspection or overhaul using paragraph 3.B., ACCOMPLISHMENT INSTRUCTIONS

.

(2) Engines with new clamps installed at the last inspection or overhaul, inspect the manifold and replace the clamps within 7,500 hours since the last inspection or overhaul using paragraph 3.B., ACCOMPLISHMENT INSTRUCTIONS

.

(3) After the initial inspection and clamp r eplacement, reinspect the manifold and replace the clamps at an interval not greater than 7,500 hours since the last inspection using paragraph 3.B., ACCOMPLISHMENT INSTRUCTIONS

.

Post

- CF6

- 80C2 S/B 73

- 0253 post

- CF6

- 80C2 S/B 73

- 0365 (PTFE taped drainless fuel manifolds): For inspection requirements, refer to the CF6

- 80C2 EM, 05

- 21

- 73, LIFE

LIMITS

- FUEL MANIFOLD

- MANDATOR Y INSPECTION AND MAINTENANCE INTERVALS. Refer to the paragraph 3.C., Inspection of post

- CF6

- 80C2 S/B 73

- 0253 post

- CF6

- 80C2 S/B 73

- 0365 (Drainless PTFE Taped Fuel Manifolds) 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 RequirementsGE recommends this Service Bulletin be accomplished concurrently with CF6

- 80C2

S/B 73

- 0365

.

E. Reason

(1) Objective:

To reduce significant events.

(2) Condition:

The tube wall thinning on the fuel manifolds, if undetected, can result in a fuel

leak. One event resulted in an under

- cowl fire.

(3) Cause:

The cushion material on the cushioned loop clamps erodes and becomes contaminated with foreign abrasive material. The abrasive material in the cushioned loop clamp wears against the fuel manifold 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.

Service Bulletin 73

- 0326, Revision 3, ACCOMPLISHMENT INSTRUCTIONS paragraph 3.D.(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).

Service Bulletin 73

- 0326, Revision 4, ACCOMPLISHMENT INSTRUCTIONS paragraphs 3.D.(3), is approved by the Manager, Engine Certification Office, ANE

140, by letter dated December 22, 2009 as an AMOC 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 manifold, for each engine.

If fuel manifold removal and installation is 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 A300

- 600 Aircraft Maintenance Manual (AMM) Airbus Industrie A300

- 600 FADEC Aircraft Maintenance Manual (AMM)

Airbus Industrie A310

- 200/

- 300 Aircraft Maintenance Manual (AMM) Boeing 747

- 200/

- 300 Aircraft Maintenance Manual (AMM) Boeing 747

- 400 Aircraft Maintenance Manual (AMM) Boeing 767

- 200/

- 300 Aircraft Maintenance Manual (AMM) GEK 9250, Commercial Standard Practices Manual (SPM) GEK 92451, CF6

- 80C2 Engine Shop Manual (EM) McDonnell Douglas MD11 Aircraft Maintenance Manual (AMM) GEK 112721, CF6

- 80C2K1F Engine Manual (EM) GEK 112213, CF6

- 80C2L1F Engine Manual (EM)

CF6

- 80C2 S/B 73

- 0253 , FUEL AND CONTROL

- Core Module (72

- 00

- 02)

- Delete Fuel Drain System for the Fuel Manifold

CF6

- 80C2 S/B 73

- 0365 , 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 Quote (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 ** (**) **

1303M31G10 * (1) Manifold, Fuel Left

Side ** (**) **

1303M32G10 * (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) 7

*Parts are field use and are to be used on pre

- CF6

- 80C2 S/B 73

- 0253 engines only. **See IPC for latest configuration. GE recommends you do application of PTFE tape per CF6

- 80C2 S/B 73

- 0365

.

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

NOTE: If necessary, replace the left side fuel manifold P/N 1303M31G10 with left side

fuel manifold P/N 1303M31G12 or P/N 2420M70G01

.

NOTE: If necessary, replace the right side fuel manifold P/N 1303M32G10 with right

side fuel manifold P/N 1303M32G12 or P/N 2420M71G01

.

(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 manifold 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 the fuel manifold is found unserviceable after inspection it can be replaced or sent for repair to a certified repair station. Discard old cushioned loop clamps.

E. Tooling

- Price and Availability

Special tools are not required to do this Service Bulletin.

3. ACCOMPLISHMENT INSTRUCTIONS

A. Inspection of post

- CF6

- 80C2 S/B 73

- 0253 pre

- CF6

- 80C2 S/B 73

- 0365 (Non PTFE Taped Drainless Fuel Manifolds) P/N 1303M31G12 and P/N 1303M32G12

NOTE: Refer to paragraph 1.D., Concurrent Requirements , for additional recommendations 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 dry. If tape or contamination remains after cleaning, clean once more.

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

.(5) Install 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 pre

- CF6

- 80C2 S/B 73

- 0253 pre

- CF6

- 80C2 S/B 73

- 0365 (Non PTFE Taped Drained Fuel Manifold) P/N 1303M31G10 and P/N 1303M32G10

NOTE: Refer to paragraph 1.D., Concurrent Requirements

, for additional recommendations for these fuel manifold part numbers.

(1) Remove the cushioned loop clamp bolt (1, Figure 2) at each of the friction damper bracket (2) locations (24 places). It is not necessary to remove the cushioned loop clamp bolt (5) that secures the cushioned loop clamp (7) on the fuel manifold (4) and the cushioned loop clamp (8) on the fuel drain manifold (9) locations (28 place s).

(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 dry. If tape or contamination remains after cleaning, clean once more.

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

(5) Install 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).

C. Inspection of post

- CF6

- 80C2 S/B 73

- 0253 post

- CF6

- 80C2 S/B 73

- 0365 (PTFE Taped Drainless Fuel Manifolds) P/N 2420M70G01 and P/N 2420M71G01

NOTE: This procedure may also be used for pre

- CF6

- 80C2 S/B 73

- 0253 (drained) post

- CF6

- 80C2 S/B 73

- 0365 (PTFE taped) manifolds P/N 2420M72G01 and P/N

2420M73G01 , although on wing inspection for this configuration is not required.

(1) Remove the cushioned loop clamp bolt (1, Figure 1) at each of the friction 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 unbonded areas between the tape and the manifold, 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

- 80C2 S/B 73

- 0365 . 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.D. If the fuel manifold passes the inspection, apply the PTFE tape (C10

- 230) per CF6

- 80C2 S/B

73

- 0365 . Install new cushioned loop clamp. Tighten bolts to 33

- 37 lb in. (3.7

- 4.2 N·m).

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

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

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) or (4, Figure 2) with a bright light at all the clamp places. Most chafing occurs on the inboard side of the fuel manifold near the cushioned loop clamp tabs. Pay specific attention to these areas ( Figure 2, Detail D). If the fuel manifo lds have any signs of wear ( Figure 3)

, measure the tube as follows 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.D.(2)(b) from the undamaged tube measurement recorded in step 3.D.(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 equal to or less than 0.010 inch (0.25 mm) can continue its operation up to 50 cycles before the fuel manifolds must be replaced. For fuel manifolds 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.

E. 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 Inspected ESN TSN Or

TSSV CSN Or

CSSV Chafing Location (Aft Looking Forward) Event Result

(Leak/Chafing

- Include Depth)

Post

- S/B 73

- 0253 (no drain system)

Pre

- S/B 73

- 0253 (with drain system)Configuration of Fuel Manifold Post

- CF6

- 80C2 S/B 73

- 0253 (D rainless Fuel Manifold) Figure 1 (Sheet 1)Configuration of Fuel Manifold Post

- CF6

- 80C2 S/B 73

- 0253 (Drainless Fuel Manifold) Figure 1 (Sheet 2)Configuration of Fuel Manifold Post

- CF6

- 80C2 S/B 73

- 0253 (Drainless Fuel Manifold) Figure 2 (Sheet 1)Configuration of Fuel Manifold Pre

- CF6

- 80C2 S/B 73

- 0253 (Drained Fuel Manifold) Figure 2 (Sheet 2)Location of Clamp wear on the Fuel Manifold Figure 2 (Sheet 3)Inspection of Fuel Manifold Figure 3

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.