AD/CF6/73 Fuel Manifold Clamps (Cth)

AIRWORTHINESS DIRECTIVE

For the reasons set out in the background section, the CASA delegate whose signature appears below issues the following Airworthiness Directive (AD) under subregulation 39.001(1) of CASR 1998.  The AD requires that the action set out in the requirement section (being action that the delegate considers necessary to correct the unsafe condition) be taken in relation to the aircraft or aeronautical product mentioned in the applicability section: (a) in the circumstances mentioned in the requirement section; and (b) in accordance with the instructions set out in the requirement section; and (c) at the time mentioned in the compliance section.

General Electric Turbine Engines - CF6 Series

AD/CF6/73 Fuel Manifold Clamps 5/2009

Applicability:

General Electric (GE) CF6-80C2A1, -80C2A2, -80C2A3, -80C2A5, -80C2A8,
-80C2A5F, -80C2B1, -80C2B2, -80C2B4, -80C2B6, -80C2B1F, -80C2B1F1,
-80C2B1F2, -80C2B2F, -80C2B3F, -80C2B4F, -80C2B5F, -80C2B6F, -80C2B6FA, -80C2B7F, -80C2B8F, -80C2D1F, -80C2L1F, -80C2K1F turbofan engine models with fuel manifold part numbers (P/Ns) 1303M31G12 and 1303M32G12, installed in drainless fuel manifold assemblies (introduced by GE Aircraft Engines (GEAE) Service Bulletin (SB) CF6-80C2 SB 73-0253).

Note 1:  These engines are installed on, but not limited to, Boeing 747, 767, MD11, and Airbus A300-600 and A310 aeroplanes.

This AD also applies to GE CF6-80E1A1, -80E1A2, -80E1A3, -80E1A4, -80E1A4/B turbofan engine models with fuel manifold P/Ns 1303M31G12 and 1303M32G12, installed in drainless fuel manifold assemblies (introduced by GEAE SB CF6-80E1 SB 73-0026).

Note 2:  These engines are installed on Airbus A330 aeroplanes.

Requirement:

1.    Remove and discard all loop clamps, P/N J1220G10, or part manufacturer approval (PMA) equivalent, that hold the fuel manifold to the compressor rear frame (CRF) friction damper brackets.  Inspect the fuel manifold for wear at each clamp location as specified in Requirements 2 and 3 of this AD.  Replace the discarded loop clamps with new, zero-time clamps.

2.    Remove any tape at any clamp location.  Visually inspect the full circumference of the manifold for wear at each clamp location.  If any wear is found, follow Requirement 3 of this AD.

3.    When the fuel manifold shows any signs of wear, determine the depth of the wear as follows:

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

(b)   Measure the worn area at the smallest diameter.

(c)   Subtract the measurement of the worn tube diameter from the unworn diameter measurement.  Allowable wear is 0.0035 inch.

4.    Replace fuel manifolds with wear greater than 0.010 inch.

5.    Replace fuel manifolds with wear greater than 0.0035 inch but less than 0.010 inch.

6.    Revise the air carrier's approved CAMP and Instructions for Continued Airworthiness (ICA) Chapter 5, Airworthiness Limitation Section for the
CF6-80C2 and CF6-80E1 series engines to require:

a)    Repetitive inspections of fuel manifolds, P/Ns 1303M31G12 and 1303M32G12, installed in drainless fuel manifold assemblies introduced by CF6-80C2 SB 73-0253 and CF6-80E1 SB 73-0026, as detailed in Requirements 1 through 5 of this AD, at 7,500 FH intervals.

b)    Mandatory removal of all loop clamps that hold the fuel manifold, P/Ns 1303M31G12 and 1303M32G12, to the CRF damper brackets, at each inspection.

c)    Replacement of all loop clamps with new, zero-time loop clamps, at each inspection.

GEAE SB CF6-80C2 SB 73-0326, dated 5 March 2003, and GEAE SB CF6-80E1
SB 73-0061, dated 14 April 2003; and the following GE engine manuals pertain to the subject of this AD:

CF6-80C2 Engine Manual GEK 92451.
CF6-80C2L1F Engine Manual GEK 112213.
CF6-80C2K1F Engine Manual GEK 112721.
CF6-80E1 Engine Manual GEK 99376.

Note 3:  FAA AD 2009-05-02 Amdt 39- 15826 dated 17 February 2009 refers.

Compliance:

For Requirements 1 through 3 - As detailed in Table 1 of this AD.

If:	Then replace clamps and inspect within:
a)    The engine was previously inspected using GEAE SB CF6-80C2 SB 73-0326, dated 5 March 2003, for CF6-80C2 engines; or GEAE SB CF6-80E1 SB 73-0061, dated 14 April 2003, for CF6-80E1 engines.	1,750 flight hours (FH) time-since-last-inspection (TSLI) or within 4 months after the effective date of this AD.

b)    Used loop clamps or clamps of unknown heritage were installed at last shop visit.	1,750 FH time-since-last-shop-visit or within 4 months after the effective date of this AD.
c)    The engine is a first-run engine or is an engine with zero-time, new loop clamps previously installed on-wing or at shop visit.;	7,500 FH time-since-new or since zero-time, new loop clamps were installed (regardless if previously inspected per GEAE SB CF6-80C2 SB 73-0326 or GEAE SB CF6-80E1 SB 73-0061).
		d)    The engine has already exceeded the 1,750 FH initial inspection threshold on the effective date of this AD, but has fewer than 4,500 flight hours TSLI.	4,500 FH TSLI, or 4 months after the effective date of this AD, whichever occurs first.
				e)    The engine has already exceeded the 4,500 FH initial inspection threshold on the effective date of this AD.	4 months after the effective date of this AD.

For Requirement 4 - Before further flight.

For Requirement 5 - Within 50 flight cycles.

For Requirement 6 - Within 30 days of the effective date of this AD.

This Airworthiness Directive becomes effective on 7 May 2009.

Background:

This AD results from reports of fuel leaks during engine operation.  This AD is intended to prevent fuel leaks that could result in an under-cowl fire and damage to the aeroplane.

James Coyne
Delegate of the Civil Aviation Safety Authority

27 March 2009