cf6-80c2 service bulletin - 72-1577 r01 revised: 08 ......cf6-80c2 airbus service bulletins (sbs) sb...

CF6-80C2 Airbus Service Bulletins (SBs)SB 72-1577 R01 ENGINE - Fuel Manifold and Drains (72-65-00) - HMU/MEC Idler AdapterInspection

Date Printed:2019/09/18

GE PROPRIETARY INFORMATION - Not to be used, disclosed toothers or reproduced without the express written consent ofGE. Technical data is considered ITAR and/or EAR controlled;transfer of this data to a Non-US Person, without USGauthorization, is strictly prohibited.

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CF6-80C2 SERVICE BULLETIN - 72-1577 R01Revised:

08/16/2019SB 72-1577 R01 ENGINE - FUEL MANIFOLD AND DRAINS(72-65-00) - HMU/MEC IDLER ADAPTER INSPECTION

Issued:10/31/2018

GE Designated: -CONFIDENTIAL-

The information contained in this document is GE proprietaryinformation and is disclosed in confidence. It is the property of GEand shall not be used, disclosed to others or reproduced without theexpress written consent of GE, including, but without limitation, it isnot to be used in the creation, manufacture, development, or derivationof any repairs, modifications, spare parts, designs, or configurationchanges or to obtain FAA or any other government or regulatory approvalto do so. If consent is given for reproduction in whole or in part,this notice and the notice set forth on each page of this documentshall appear in any such reproduction in whole or part.

This technical data is considered subject to the Export AdministrationRegulations (EAR) pursuant to 15 CFR Parts 730-774. Transfer of thisdata by any means to a Non-U.S. Person, whether in the United States orabroad, without the proper U.S. Government authorization (e.g.,License, exemption, NLR, etc.), is strictly prohibited.

Copyright (2019) General Electric Company, U.S.A.

TRANSMITTAL INFORMATIONREVISION 1 TO SERVICE BULLETIN 72-1577Revision 1 is issued to update paragraphs 1., , 2.,PLANNING INFORMATION

, and 3., .MATERIAL INFORMATION ACCOMPLISHMENT INSTRUCTIONSThe original was issued October 31, 2018. Revision bars in the leftmargin identify changes.1. PLANNING INFORMATION

A. Effectivity* * * CF6-80C2A1/A2/A3/A5/A8/B1/B2/B4/B6* * * CF6-80C2A5F/B1F/B2F/B4F/B5F/B6F/B6FA/B7F/B8F/D1F

This Service Bulletin is not applicable to these CF6-80C2engines:*CF6-80C2 engines, serial numbers 707-417 and up are not affected by thisService Bulletin.

*CF6-80C2 engines, which have not had a shop visit prior to November 1, 2018.

These serial numbers are the best available data.The accessory gearbox (AGB) adapters [hydromechanical unit(HMU)/main engine control (MEC) idler adapters] P/N ,9395M78G01P/N , P/N , P/N , P/N ,9395M78G02 9395M78G04 9395M78G05 9395M78G08and P/N are affected by this Service Bulletin.9395M78G10




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This Service Bulletin is applicable only for AGB adapters withTap-Lok inserts.

B. DescriptionThis Service Bulletin provides instructions to do an inspectionof the inserts on the HMU/MEC idler adapter and a pull check.

C. ComplianceCategory 2GE recommends that you do this Service Bulletin as soon aspossible without effect on revenue service but no later than1,200 flight hours from Service Bulletin issuance date withrepeat inspections not to exceed 1,200 flight hours betweeninspections. Terminating action to be completed no later thannext shop visit.Impact BThis recommendation is to address a condition that may result inan Increased Rate of In-Flight Shutdowns (IFSD), Take-Off Aborts(TOA), Air Turn Backs (ATB) or Diversions (DIV).

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

This Service Bulletin is offered to improve the reliability orperformance of your GE product, or to help prevent the occurrenceof the event or condition described in this Service Bulletin. Ifthe operator elects not to participate in the bulletin, thatdecision will be taken into consideration by GE in evaluatingfuture product performance issues that may arise in theoperator's fleet.

D. Concurrent RequirementsNone.

E. Reason(1) Objective:

To improve reliability and reduce significant events.To prevent a fuel leak and possible undercowl fire events in the CF6-80C2engines.

(2) Condition:A threaded insert in the HMU/MEC idler adapter flange pulled-out, causing afuel leak.

(3) Cause:The repair of the insert was done incorrectly.

(4) Inspection:The inspection will detect if the inserts are installed correctly.

(5) Substantiation:Substantiation is by comparative analysis and fleet experience.

F. ApprovalThis Service Bulletin contains no modification information thatrevises the approved configuration and therefore does not requireFAA or regulatory approval.

G. ManpowerAfter you get access to the AGB assembly, you will need 1man-hour to do the shim check. If the assembly passes the shimcheck, no additional manpower is required. If the assembly failsthe shim check, 4 additional man-hours will be needed to do theprotrusion and pull-out test of the inserts.

H. Weight and BalanceWeight and balance are not changed.




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I. References (Use the latest version of these documents)Airbus A300-600 Aircraft Maintenance Manual (AMM)Airbus A310 Aircraft Maintenance Manual (AMM)Boeing 747-200/300 Aircraft Maintenance Manual (AMM)Boeing 747-400 Aircraft Maintenance Manual (AMM)Boeing 767 Aircraft Maintenance Manual (AMM)McDonnell Douglas MD-11 Aircraft Maintenance Manual (AMM)GEK 9250, Commercial Engine Standard 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)

J. Publications AffectedNone.

K. InterchangeabilityNot applicable.

L. Software Accomplishment SummaryNot applicable.

2. MATERIAL INFORMATIONA. Material - Price and Availability

(1) Parts necessary to do this Service Bulletin:None.

(2) Other Spare Parts:

Part NumberQty/Eng Part Name

Unit ($)Price

PkgQty

Lead TimeDays

1453M60P04 (AR) Gasket, Seal 28.00 (10) 5

9117M58P07 (AR) Insert, OversizeScrew (SecondOversize)Thread-Self-Tapping

50.25 (1) Quote

9117M35P08 (AR) Insert, OversizeScrew (ThirdOversize)Thread-Self-Tapping

72.50 (10) 5

NOTE:Prices are provided for planning purposes and are subject to change.(3) Consumables:

Code Number Description

C03-001 Primer, Zinc Chromate

C04-035 Solvent, General (isopropyl alcohol)

C10-067 Tape, Platers (tape) (or equivalent)

C10-182 Cloth, Cleaning for Aircraft Structural (clean cloth)

B. Industry Support InformationNone.

C. Configuration ChartNone.

D. Parts DispositionRemove and replace inserts if a failure of the pull-out testoccurs.




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E. Tooling - Price and AvailabilityDescription Refer To

Locally Manufactured Pull-OutTest Tool

Figure 2

Tool Number Description

-- Screw Extractor [for use in a 0.250 inch (6.35 mm)hole]

-- High Speed Hand Drill

-- Appropriate Size Uncoated, Straight Flute or TwistDrill Bit with a Point Angle of 115 to 140 Degrees

-- 1/4-28 Tap-Lok Insertion Driver Tool

3. ACCOMPLISHMENT INSTRUCTIONSA. GeneralNOTE:This Service Bulletin contains two options.

(1) Option 1 - repetitive shim check, to be performed within 1,200 flight hourswith repeat inspections not to exceed 1,200 flight hours betweeninspections. Refer to paragraph 3.B., .Option 1 - Containment Action

(2) Option 2 - one-time pull check of the installed inserts on the HMU/MECidler adapter to be performed no later than next engine shop visit. Referto paragraph 3.C., .Option 2 - Terminating Action

B. Option 1 - Containment Action(1) Do a shim check at the eight bolt locations as follows:NOTE:Removal of the bracket is optional. The shim check can be done with and

without the bracket installed.(a) Optional Procedure. Remove the bracket. Refer to Item 3Figure 1,

(Bolt) and Item 4 (Bracket).1 Remove the three bolts that attach the bracket.2 Remove the bracket.3 Install the bolts again and torque the bolts to 110 to 140 lb in.

(12.4 to 15.8 Nm).(b) Do the shim check with a shim stock of 0.004 inch (0.10 mm) on the

adapter flange-gasket interface. Refer to and do as follows:Figure 11 Insert a shim of 0.004 inch (0.10 mm) between the gasket and the

HMU/MEC idler adapter flange at each of the eight bolt locations andas follows:a If you cannot insert the shim of 0.004 inch (0.10 mm) between

the gasket and the flange for each of the eight bolt locations,this is considered a PASS.1) Install the bracket back if you removed it. The installation

of the bracket, as specified in step 3.B.(1)(b) , is1bnecessary to complete this inspection.

b Install the bracket again. Refer to Item 3 (Bolt) andFigure 1,Item 4 (Bracket) and do as follows:1) Remove the three bolts at the bracket location.2) Install the bracket with the three bolts.3) Torque the three bolts to 110 to 140 lb in. (12.4 to 15.8

Nm).c If you can insert the shim of 0.004 inch (0.10 mm) between the

gasket and the flange at any of the eight bolt locations morethan 0.100 inch (2.54 mm) in depth, this is considered a FAIL.Complete the shim check at each of the remaining bolt locations.Note locations which fail and continue with step 3.B.(1)(c).

(c) If the shim check fails, torque the bolt again to 110 to 140 lb in.(12.4 to 15.8 Nm) at each bolt locations that failed the shim check. Dothe shim check again with a shim of 0.004 inch (0.10 mm) on the adapterflange-gasket interface.

(d) If the shim check fails once more after you torque the bolt again, do




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paragraph 3.C., .Option 2 - Terminating ActionC. Option 2 - Terminating Action

(1) Remove the fuel pump tube and fuel tube. Refer to Item 1 (FuelFigure 1,Pump Tube) and Item 2 (Fuel Tube) and Table 1 for applicable AMM removalinstructions.

NOTE:The rigid fuel pump tube and fuel tube that are installed in the HMU/MECidler adapter pads are connected to the fuel pump (bypass and discharge).The fuel pump tube and fuel tube must be removed from the two sides toget access to the AGB pads.

Table 1. Fuel Pump Tube, Fuel Tube Removal, and Installation ReferenceTable

AMM Procedure Reference

Boeing747-400 AMM(FADEC)

1. Remove the bypass tube form thehydromechanical unit (HMU) adapter on theAGB and remove the discharge tube from theHMU adapter on the AGB.

Refer to the Boeing 747-400AMM, 73-11-01, TASK73-11-01-004-001-J00,Subtask73-11-01-034-008-J00,paragraphs (2)(b) and(2)(c).

2. Install the bypass tube in the HMUadapter on the AGB and install thedischarge tube in the HMU adapter on theAGB.

Refer to the Boeing 747-400AMM, 73-11-01, TASK73-11-01-404-016-J00,Subtasks73-11-01-224-046-J00,73-11-01-224-041-J00, and73-11-01-434-027-J00.

Boeing747-200/300AMM(PMC)

1. Remove the bypass tube from the mainengine control (MEC) adapter on the AGB andremove the discharge tube from the MECadapter on the AGB.

Refer to the Boeing747-200/300 AMM, 73-11-01,paragraphs 4.C.(3) and (4).

2. Install the bypass tube in the MECadapter on the AGB and install thedischarge tube in the MEC adapter on theAGB.

Refer to the Boeing747-200/300 AMM, 73-11-01,paragraphs J.(1), (2), and(3).

Boeing 767AMM(PMC)

1. Remove the bypass tube from the MECadapter on the AGB and remove the dischargetube from the MEC adapter on the AGB.

Refer to the Boeing 767 AMM,73-11-01, TASK73-11-01-004-001-H00,Subtask73-11-01-034-010-H00,paragraphs (2)(b) and(2)(c).

2. Install the bypass tube in the MECadapter on the AGB and install thedischarge tube in the MEC adapter on theAGB.

Refer to the Boeing 767 AMM,73-11-01, TASK73-11-01-404-039-H00,Subtasks73-11-01-224-027-H00,73-11-01-224-028-H00, and73-11-01-434-029-H00.

Boeing 767AMM(FADEC)

1. Remove the bypass tube from the HMUadapter on the AGB and remove the dischargetube from the HMU adapter on the AGB.

Refer to the Boeing 767 AMM,73-11-01, TASK73-11-01-004-001-H03,Subtask73-11-01-034-008-H03,paragraphs (2)(c) and(2)(d).

2. Install the bypass tube in the HMUadapter on the AGB and install thedischarge tube in the HMU adapter on theAGB.

Refer to the Boeing 767 AMM,73-11-01, TASK73-11-01-404-018-H03,Subtasks




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73-11-01-224-028-H03,73-11-01-224-029-H03, and73-11-01-434-032-H03.

McDonnellDouglasMD-11 AMM(FADEC)

1. Remove the return fuel tube and thecontrol fuel tube from the fuel pump andthe AGB.

Refer to the McDonnellDouglas MD-11 AMM, 73-12-01,TASK 73-12-01-000-801,Subtask 73-12-01-030-001.

2. Install the return fuel tube and thecontrol fuel tube in the fuel pump and theAGB.

Refer to the McDonnellDouglas MD-11 AMM, 73-12-01,TASK 73-12-01-400-801,Subtask 73-12-01-820-020,paragraphs (7)(c), (7)(d),and (7)(e) and Subtask73-12-01-430-001, paragraphs(9), (10), and (11).

AirbusA300-600(FADEC)

1. Remove the fuel pump discharge tube andthe fuel return tube attached to the fuelpump and the HMU adapter.

Refer to the Airbus A300-600AMM, 73-12-01, TASK73-12-01, Page 401,paragraphs 2.B.(3) and (4).

2. Install the fuel pump discharge tube andthe fuel return tube attached to the fuelpump and the HMU adapter.

Refer to the Airbus A300-600AMM, 73-12-01, TASK73-12-01, paragraphs2.C.(9), (10), and (11).

AirbusA300-600(PMC)

1. Remove the fuel pump discharge tube andthe fuel return tube attached to the fuelpump and the MEC adapter.

Refer to the Airbus A300-600AMM, 73-12-01, TASK73-12-01, paragraphs 2.B.(3)and (4).

2. Install the fuel pump discharge tube andthe fuel return tube attached to the fuelpump and the MEC adapter.

Refer to the Airbus A300-600AMM, 73-12-01, TASK73-12-01, paragraphs2.C.(9), (10), and (11).

Airbus A310(PMC)

1. Remove the fuel pump discharge tube andthe fuel return tube attached to the fuelpump and the MEC adapter.

Refer to the Airbus A310AMM, 73-12-01, TASK73-12-01, paragraphs 2.B.(3)and (4).

2. Install the fuel pump discharge tube andthe fuel return tube attached to the fuelpump and the MEC adapter.

Refer to the Airbus A310AMM, 73-12-01, TASK73-12-01, paragraphs2.C.(9), (10), and (11).

(2) Do a standard insert inspection. Refer to the CF6-80C2 EM, 72-65-02,INSPECTION.

(3) Do a protrusion check at all eight bolt locations as follows:(a) Do an inspection of the eight inserts to make sure that they do not

protrude above the idler adapter flange face as follows:1 Put a straight edge across the surface. If the insert is below the

bottom of the straight edge, the insert is correct.2 If you find protruded insert(s), replace the protruded insert(s).

Refer to paragraph 3.C.(5).(b) Do a check for insert looseness. Refer to Item 3 (Bolt) andFigure 1,

do as follows:1 Insert the bolt and do a check for insert movement. If you find

movement, replace the insert. Refer to paragraph 3.C.(5).(c) If you do not find protrusion or movement, continue with the pull-out

test. Refer to paragraph 3.C.(4).(4) Do a pull-out test at all eight bolt locations as follows:

(a) Use the locally manufactured pull-out test tool. Refer to andFigure 2do as follows:1 Insert a 1/4-28 bolt and torque to 190 to 210 lb in. (21.4 to 23.7




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Nm).2 Loosen and remove the 1/4-28 bolt.

(b) Do a check of the insert again for protrusion. Refer to paragraph3.C.(3) and do as follows:1 If you find protruded insert(s), replace the protruded insert(s).

Refer to paragraph 3.C.(5).2 If you do not find protrusion, install the removed fuel pump tube

and fuel tube. Refer to Item 1 (Fuel Pump Tube) and ItemFigure 1,2 (Fuel Tube), Table 1 for applicable AMM installation instructions,and do as follows:a Put a mark 72-1577 on the HMU/MEC idler adapter to show

compliance with this Service Bulletin. Use a light vibro-peen onthe area showed on Refer to the SPM, 70-16-04,Figure 3.VIBRO-PEEN MARKING.

(5) Do the insert replacement as follows:WARNING:REFER TO THE PRODUCT LABEL AND THE MANUFACTURER'S (MATERIAL) SAFETY

DATA SHEET FOR INSTRUCTIONS ON THE HAZARDS, STORAGE, SAFE HANDLINGAND PROPER USE OF THIS PRODUCT.

(a) Use a clean cloth (C10-182) to clean the flange surface with isopropylalcohol (C04-035) and remove the fuel residue.

CAUTION:THE FOREIGN MATERIAL INTO THE ENGINE FUEL SYSTEM CAN CAUSEOPERATIONAL ISSUES THAT INCLUDE THE LOSS OF THRUST CONTROL ANDIN-FLIGHT SHUTDOWNS (IFSD).

(b) Cover all open ports to make sure that no foreign material enters intothe engine hardware. You can use an approved tape (C10-067) for thispurpose.

(c) Use a screw extractor to unscrew the damaged threaded insert and removeit.

(d) Refer to the SPM, 70-48-03, TAP-LOK INSERTS, Table 2 for recommendeddrill/hole size and TAP-LOK insert for second or third TAP-LOK insertreplacement.

NOTE:For insert replacement, only a second or third TAP-LOK insertreplacement applies. First replacement is not applicable.

(e) Hold the drill perpendicular to the flange face.(f) Center the drill bit in the insert hole.(g) With a high speed drill and a light feed force, drill the hole to size.

The hole will go through the flange to the back side.NOTE:The use of a cutting fluid is not necessary.(h) Deburr the hole to remove burrs or high metal on the two sides of the

flange. You can introduce a chamfer of up to 0.010 inch (0.25 mm) toremove burrs.

WARNING:REFER TO THE PRODUCT LABEL AND THE MANUFACTURER'S (MATERIAL) SAFETYDATA SHEET (SDS) FOR INSTRUCTIONS ON THE HAZARDS, STORAGE, SAFEHANDLING AND PROPER USE OF THIS PRODUCT.

(i) Coat the surface of the hole and the insert threads with zinc chromateprimer (C03-001).

(j) Use the 1/4-28 Tap-Lok insertion driver tool to drive the insert to0.005-0.040 inch (0.13-1.02 mm) below the flange surface.

(k) Thoroughly clean the area to remove all chips and debris.(l) Wipe the flange surface with a clean cloth (C10-182) to remove all fine

particles.(m) Put a mark 72-1577 on the HMU/MEC idler adapter to show compliance with

this Service Bulletin. Use a light vibro-peen next to the idler adapterpart number. Refer to the SPM, 70-16-04, VIBRO-PEEN MARKING.

(n) Remove the protective covers used to close the open ports.WARNING:REFER TO THE PRODUCT LABEL AND THE MANUFACTURER'S (MATERIAL) SAFETY

DATA SHEET FOR INSTRUCTIONS ON THE HAZARDS, STORAGE, SAFE HANDLINGAND PROPER USE OF THIS PRODUCT.

(o) Use a clean cloth (C10-182) with isopropyl alcohol (C04-035) to wipethe flange surface and remove fine particles and tape (C10-067) residue




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if used.(6) Do an inspection of the fuel pump tube/fuel tube and adapter flange-gasket.

Refer to the CF6-80C2 EM, 72-00-05, INSPECTION/CHECK.(7) Install back the fuel pump tube and fuel tube. Refer to Item 1Figure 1,

(Fuel Pump Tube) and Item 2 (Fuel Tube) and Table 1 for applicable AMMinstallation instructions.

Location of the HMU/MEC Fuel Control Idler AdapterFigure 1 (Sheet 1)




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Location of the HMU/MEC Fuel Control Idler AdapterFigure 1 (Sheet 2)




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Pull-Out Test ToolFigure 2 (Sheet 1)




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Pull-Out Test ToolFigure 2 (Sheet 2)




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Marking AreasFigure 3

4. APPENDIX A - Inspection Criteria Flow Down Chart




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Criteria Flow Down ChartFigure 4

GE Designated: - CONFIDENTIAL Subject to the restrictions on the media

cf6-80c2 service bulletin - 72-1577 r01 revised: 08 ......cf6-80c2 airbus service bulletins (sbs) sb...

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