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 39.1 (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.
CFM International Turbine Engines - CFM56 Series
AD/CFM56/23 Engine Main Fuel Pumps 9/2004
Applicability: CFM INTERNATIONAL CFM56-2C, CFM56-3 series and CFM56-5 series turbofan engines fitted with fuel pumps with solid bronze bearings.
Note 1: These engines are installed on, but not limited to, Airbus Industrie A319 and A320, Boeing 737, and McDonnell Douglas DC-8 aeroplanes.
Requirement: 1. Replace main fuel pumps equipped with solid bronze bearings with pumps equipped with bi-metal aluminium/bronze bearings in according with the applicable Service Bulletin as listed below.
Service Bulletin (CFM56-2C) 73-0104 Revision 3 dated December 17, 2003
Service Bulletin (CFM56-3) 73-0120 Revision 5 dated December 17, 2003
Service Bulletin (CFM56-5A) 73-0126 Revision 4 dated December 17, 2003.
2. Do not install a main fuel pump with bronze bearings.
Note 2: FAA AD 2004-10-13 Amdt 39-13643 and DGAC AD F-2004-095 refer.
Compliance: For requirement 1: Either at next engine shop visit, or at next main fuel pump replacement, or before January 1st, 2007, whichever occurs first.
For the purpose of this Directive, an engine shop visit is defined as any maintenance that includes the separation of an engine casing flange.
For requirement 2: After the effective date of this Directive.
This Airworthiness Directive becomes effective on 2 September 2004.
CFM International Turbine Engines - CFM56 Series
AD/CFM56/23 (continued)
Background: This amendment requires removing from service main fuel pumps with bronze gear- stage bearings and installing main fuel pumps with bi-metal, aluminum/bronze bearings. This amendment results from several reports of main fuel pump bronze bearing failures. The issue of this Directive is to prevent main fuel pump bearing failures resulting in fuel nozzle clogging, low pressure turbine (LPT) case burn- through, and damage to the aeroplane.
Bernard Malcolm Hole
Delegate of the Civil Aviation Safety Authority 14 July 2004
The above AD is notified in the Commonwealth of Australia Gazette on 11 August 2004.
Overview
The Airworthiness Directive (AD) issued by the Civil Aviation Safety Authority (CASA) under subregulation 39.1(1) of the Civil Aviation Safety Regulations 1998 (CASR 1998) targets safety concerns associated with certain CFM International turbine engines used in various aircraft. Enacted on 2 September 2004, this AD was introduced in response to multiple reports of failures in main fuel pump bronze gear-stage bearings, which had led to issues such as fuel nozzle clogging, low-pressure turbine case burn-through, and potential damage to the aircraft. The directive mandates the replacement of these problematic fuel pumps with those equipped with bi-metal, aluminium/bronze bearings, as per specified service bulletins, and prohibits the installation of any main fuel pumps with bronze bearings. The objective of this AD is to mitigate the risks associated with these bearing failures, ensuring the continued airworthiness and safety of the affected aircraft.
Scope and Application
The Airworthiness Directive AD/CFM56/23 issued by the Civil Aviation Safety Authority (CASA) under the Civil Aviation Safety Regulations 1998, applies to specific turbofan engines manufactured by CFM International, namely the CFM56-2C, CFM56-3, and CFM56-5 series, when these engines are equipped with fuel pumps that have solid bronze bearings. These engines are notably installed in Airbus Industrie A319 and A320, Boeing 737, and McDonnell Douglas DC-8 aircraft. The directive mandates that the identified engines must either have their main fuel pumps replaced with ones equipped with bi-metal aluminium/bronze bearings, in accordance with the specified Service Bulletins, or be prohibited from having main fuel pumps with bronze bearings installed. The compliance timeline requires the replacement to occur by the next engine shop visit, the next main fuel pump replacement, or before January 1, 2007, whichever is earliest. The directive came into effect on 2 September 2004 and was published in the Commonwealth of Australia Gazette on 11 August 2004.
Key Provisions
The Airworthiness Directive (AD) under section 39.1(1) of the Civil Aviation Safety Regulations 1998 (CASR 1998) mandates specific actions to be taken for certain CFM International turbine engines. The AD applies to CFM56-2C, CFM56-3, and CFM56-5 series turbofan engines equipped with fuel pumps featuring solid bronze bearings, which are installed on aircraft such as Airbus Industrie A319 and A320, Boeing 737, and McDonnell Douglas DC-8 aeroplanes (Applicability). The primary requirement is to replace main fuel pumps with solid bronze bearings with pumps equipped with bi-metal aluminium/bronze bearings, as detailed in the relevant Service Bulletins (Requirement 1). These Service Bulletins include CFM56-2C 73-0104 Revision 3, CFM56-3 73-0120 Revision 5, and CFM56-5A 73-0126 Revision 4. Additionally, it is prohibited to install any main fuel pump with bronze bearings (Requirement 2). Compliance with these requirements must occur either at the next engine shop visit, the next main fuel pump replacement, or before January 1st, 2007, whichever comes first for the replacement requirement, and immediately for the prohibition on installing bronze-bearing pumps (Compliance).
The AD imposes specific obligations on the operators and maintenance personnel of affected aircraft. Operators must ensure that the required changes to the fuel pumps are implemented within the specified timeframes. Maintenance personnel must follow the instructions detailed in the Service Bulletins to correctly replace the fuel pumps. These personnel must also adhere to the prohibition on installing any main fuel pump with bronze bearings. Non-compliance with these obligations could result in unsafe conditions that might lead to serious aviation incidents, including fuel nozzle clogging and damage to the aeroplane.
Failure to comply with the requirements of this AD can result in severe consequences. The AD itself does not specify particular penalties or offences, but non-compliance with CASR 1998 generally can lead to significant civil and criminal penalties. Civil penalties may include fines, while criminal penalties can include imprisonment, reflecting the seriousness of ensuring airworthiness and safety in aviation operations. These potential penalties underscore the importance of adhering to the AD to prevent unsafe conditions and ensure the continued safety of aircraft operations.