AD 2004-04-07 Airworthiness Directives; General Electric Company (GE) CF6-80 Series Turbofan Engines

This AD applies to the General Electric Company (GE) CF6-80 turbofan engine models listed in the following Table 1: Table 1.—Applicability Models, Part Numbers, Airplanes Models Stage 1 high pressure turbine (HPT) rotor disk part Nos. (PNs) Engines installed on but not limited to CF6-80A, CF6-80A1, CF6-80A2, CF6-80A3 9234M67G22/G24/G25/G26. 9362M58G02/G06/G07/G09. 9367M45G02/G04/G09 Airbus A310 and Boeing 767 airplanes. CF6-80C2A1, CF6-80C2A2, CF6-80C2A3, CF6-80C2A5, CF6-80C2A8, CF6-80C2A5F, CF6-80C2B1, CF6-80C2B2, CF6-80C2B4, CF6-80C2B6, CF6-80C2B1F, CF6-80C2B2F, CF6-80C2B4F, CF6-80C2B5F, CF6-80C2B6F, CF6-80C2B6FA, CF6-80C2B7F, CF6-80C2D1F 1862M23G01. 9392M23G10/G12/G21. 1531M84G02/G06/G08/G10 Airbus A300, A310, Boeing 747, 767, and McDonnell Douglas MD11 airplanes. CF6-80E1A2, CF6-80E1A4 1639M41P04 Airbus A330 airplanes. These engines are installed on, but not limited to, the airplanes listed in Table 1 of this AD.

You are responsible for having the actions required by this AD performed within the compliance times specified unless the actions have already been done. CF6-80A, -80A1, -80A2, and -80A3 Engines Stage 1 HPT Rotor Disks, P/N 9362M58G09, With Chamfered Breakedges (f) At the next piece-part exposure after the effective date of this AD, for stage 1 HPT rotor disks, P/N 9362M58G09, with SNs listed in Table 2 of this AD, do the following: Table 2.—SNs of CF6-80A Series Stage 1 HPT Rotor Disk P/N 9362M58G09—With Chamfered Breakedges   GWN03RD7 GWN042J3 GWN04HRD GWN04M9K GWN03TKG GWN04FW2 GWN04HRE GWN04M9L GWN03TKH GWN04FW3 GWN04HRF GWN04M9M GWN03TKJ GWN04FW4 GWN04HRG GWN04M9R GWN03W3M GWN04FW5 GWN04HRH GWN04M9T GWN03W3N GWN04H0M GWN04K8N GWN04M9W GWN03W3R GWN04HRA GWN04M9J (1) Visually inspect the rotor disks for the presence of a chamfer on the aft breakedges of the dovetail slot bottoms. Use paragraph 3.A. of GE Service Bulletin (SB) No. CF6-80A S/B 72-0788, Revision 2, dated December 17, 2003, to do the inspection. (2) For disks that have the chamfered breakedges, remark, fluorescent penetrant inspect (FPI), and eddy current inspect (ECI) the rotor disk. Use paragraph 3.A.(1)(a) through 3.A.(1)(b) of the Accomplishment Instructions of GE SB No. CF6-80A S/B 72-0788, Revision 2, dated December 17, 2003, to remark and inspect the rotor disk and remove from service as necessary. (3) For disks that do not have the chamfered breakedges, inspect, rework and remark the rotor disk. Use paragraph 3.A(2)(a) through 3.A(2)(b) of the Accomplishment Instructions of GE SB No. CF6-80A S/B 72-0788, Revision 2, dated December 17, 2003, to inspect, rework, and remark the disk and remove from service as necessary. Stage 1 HPT Rotor Disks, P/Ns 9234M67G22, G24, G25, G26, 9367M45G04, G09, 9362M58G02, G06, G07, and 9362M58G09 With SNs Not Listed in Table 2 of This AD (g) For stage 1 HPT rotor disks, P/Ns 9234M67G22, G24, G25, G26, 9367M45G04, G09, 9362M58G02, G06, G07, and 9362M58G09 with SNs not listed in Table 2 of this AD, inspect, rework, and remark the disks using paragraphs 3.A.(2) through 3.B.(2) of Accomplishment Instructions of GE SB No. CF6-80A S/B 72-0788, Revision 2, dated December 17, 2003, at the following: (1) For stage 1 HPT rotor disks not installed in engines with both new and old hardware, inspect, rework, remark, and remove from service as necessary before further flight. (2) For stage 1 HPT rotor disks that have been inspected before the effective date of this AD using any version of GE SB No. CF6-80A S/B 72-0779, inspect, rework, remark, and remove from service as necessary at the next Engine Shop Visit (ESV) using the compliance times in the following Table 3: Table 3.—Compliance Times For Inspection and Rework of CF6-80A Series Stage 1 HPT Rotor Disks, P/Ns 9234M67G22, G24, G25, G26, 9367M45G04, G09, 9362M58G02, G06, G07, and 9362M58G09 With SNs Not Listed in Table 2 of This AD—Previously Inspected Stage 1 HPT rotor disk cycles-since-last-inspection (CSLI) on the effective date of this AD Compliance time for inspection and rework (i) More than 1,500 CSLI At the next ESV after the effective date of this AD, but not to exceed 4,500 CSLI. (ii) 1,500 CSLI or fewer At the next ESV after the effective date of this AD, but not to exceed 3,500 CSLI. (3) For stage 1 HPT rotor disks that have not been inspected before the effective date of this AD using any version of GE SB No. CF6-80A S/B 72-0779, inspect, rework, remark, and remove from service as necessary at the next ESV using the compliance times in the following Table 4: Table 4. Compliance Times for Inspection and Rework of CF6-80A Series Stage 1 HPT Rotor Disks, P/Ns 9234M67G22, G24, G25, G26, 9367M45G04, G09, 9362M58G02, G06, G07, and 9362M58G09 With SNs Not Listed in Table 2 of This AD—Not Previously Inspected Stage 1 HPT rotor disk cycles-since-new (CSN) on the effective date of this AD Compliance time for inspection and rework (i) 10,000 or more CSN At the next ESV or within 1,000 cycles-in-service (CIS) after the effective date of this AD, whichever occurs first. (ii) 5,000 or more CSN but fewer than 10,000 CSN At the next ESV or within 2,400 CIS after the effective date of this AD, whichever occurs first, but before accumulating 11,000 CSN. (iii) Fewer than 5,000 CSN At the next ESV or within 3,500 CIS after the effective date of this AD, whichever occurs first, but before accumulating 7,400 CSN. Stage 1 HPT Rotor Disks, P/N 9367M45G02 (h) For stage 1 HPT rotor disks, P/N 9367M45G02, inspect the rotor disk dovetail slot bottoms and remove the disk from service as necessary using paragraphs 3.A. through 3.C.(10)(i) of Accomplishment Instructions of GE SB No. CF6-80A S/B 72-0779, Revision 1, dated January 22, 2004, at the following times: (1) For stage 1 HPT rotor disks not installed in engines with both new and old hardware, inspect and remove from service as necessary before further flight. (2) For stage 1 HPT rotor disks that have been inspected before the effective date of this AD using any version of GE SB No. CF6-80A S/B 72-0779, and had more than zero CSN at the time of that inspection, inspect and remove from service as necessary at each piece-part exposure. (3) For stage 1 HPT rotor disks that have not been inspected, or were only inspected with zero CSN before the effective date of this AD using any version of GE SB No. CF6-80A S/B 72-0779, inspect and remove from service as necessary at the next ESV using the compliance times in the following Table 5: Table 5. Compliance Times for Inspection of CF6-80A Series Stage 1 HPT Rotor Disks, P/N 9367M45G02—Not Previously Inspected Stage 1 HPT rotor disk CSN on the effective date of this AD Compliance time for initial inspection (i) 10,000 or more CSN At the next ESV or within 1,000 CIS after the effective date of this AD, whichever occurs first. (ii) 5,000 or more CSN but fewer than 10,000 CSN At the next ESV or within 2,400 CIS after the effective date of this AD, whichever occurs first, but before accumulating 11,000 CSN. (iii) Fewer than 5,000 CSN At the next ESV or within 3,500 CIS after the effective date of this AD, whichever occurs first, but before accumulating 7,400 CSN. (4) Thereafter, inspect at each piece-part exposure, and remove the rotor disk from service if necessary. CF6-80C2 Series Engines Stage 1 HPT Rotor Disks, P/N 1531M84G10, With Chamfered Breakedges (i) At the next piece-part exposure after the effective date of this AD, for stage 1 HPT rotor disks, P/N 1531M84G10, with SNs listed in Table 6 of this AD, do the following: Table 6.—SNs of CF6-80C2 Series Stage 1 HPT Rotor Disks, P/N 1531M84G10, With Chamfered Breakedges GWN03111 GWN0369J GWN03K3F GWN03RPD GWN049JM GWN03114 GWN036JG GWN03K3G GWN03RPE GWN049M7 GWN03501 GWN036JH GWN03K3H GWN03RPF GWN049M8 GWN03699 GWN036JJ GWN03K3K GWN03RPG GWN049M9 GWN03752 GWN036JK GWN03K3L GWN0402A GWN04AEP GWN03753 GWN036JL GWN03K3M GWN0402E GWN04AER GWN03754 GWN036JM GWN03K3N GWN0402F GWN04AET GWN03755 GWN036JN GWN03K3R GWN0402G GWN04ALR GWN03756 GWN0375A GWN03K3T GWN0402H GWN04ALT GWN03757 GWN0375C GWN03K3W GWN0402J GWN04ALW GWN03759 GWN0375D GWN03K40 GWN0402K GWN04AM0 GWN03981 GWN0375E GWN03K6J GWN0402L GWN04AM1 GWN03982 GWN037H2 GWN03K7R GWN0402M GWN04AM2 GWN03983 GWN0398A GWN03K7T GWN0402N GWN04AM3 GWN03984 GWN0398C GWN03KR1 GWN0402P GWN04AM4 GWN03985 GWN039PF GWN03KR2 GWN040R5 GWN04CGJ GWN03986 GWN039PG GWN03KR3 GWN0418A GWN04CGL GWN03987 GWN039PH GWN03KR4 GWN0418C GWN04CGN GWN03988 GWN039PJ GWN03KR5 GWN0418D GWN04CGT GWN03989 GWN039PK GWN03KR6 GWN0418E GWN04CGW GWN04026 GWN039PL GWN03KR7 GWN0418F GWN04CH3 GWN04027 GWN039PM GWN03KR8 GWN0418G GWN04CH5 GWN04028 GWN039PN GWN03KRA GWN0418H GWN04CH8 GWN04029 GWN03A4J GWN03KRC GWN0418J GWN04CH9 GWN04189 GWN03A4K GWN03KRD GWN0418K GWN04CHA GWN04190 GWN03A4L GWN03L2D GWN0418L GWN04CHC GWN04191 GWN03A4M GWN03L2E GWN0418M GWN04D52 GWN04366 GWN03A4N GWN03L2F GWN0418N GWN04D54 GWN04722 GWN03A4P GWN03LNF GWN0418P GWN04D55 GWN04726 GWN03A4R GWN03LNJ GWN0418R GWN04D56 GWN04729 GWN03A4T GWN03LNK GWN0418T GWN04D57 GWN031N2 GWN03A4W GWN03M88 GWN0418W GWN04D58 GWN031N3 GWN03C12 GWN03M89 GWN044DP GWN04D59 GWN031N4 GWN03C13 GWN03M8C GWN0454E GWN04DPW GWN031N5 GWN03C14 GWN03M8D GWN0454F GWN04DR4 GWN031N6 GWN03CA0 GWN03M8E GWN0454G GWN04DR9 GWN031N7 GWN03DC9 GWN03M8F GWN0454H GWN04DRE GWN031N8 GWN03DCA GWN03M8J GWN0454J GWN04DRJ GWN031N9 GWN03DCC GWN03M8K GWN0454K GWN04E9K GWN031NA GWN03DCD GWN03NHN GWN0454L GWN04E9L GWN031NC GWN03DCE GWN03NHP GWN0454M GWN04E9M GWN032G1 GWN03DCF GWN03NHR GWN0454N GWN04E9N GWN032G2 GWN03DCG GWN03NHT GWN045T0 GWN04EM5 GWN032G3 GWN03DCH GWN03R73 GWN045T1 GWN04EMA GWN032G4 GWN03DCJ GWN03R74 GWN045T2 GWN04EMK GWN032G5 GWN03DCK GWN03R75 GWN045T3 GWN04EML GWN032G6 GWN03DCL GWN03R76 GWN045T4 GWN04EMM GWN032G7 GWN03DCM GWN03R77 GWN045T5 GWN04F8N GWN032G8 GWN03DCN GWN03R78 GWN045T6 GWN04F8P GWN032G9 GWN03DCP GWN03R79 GWN045T7 GWN04FTJ GWN032GE GWN03DCR GWN03R7A GWN045T8 GWN04FTL GWN0335P GWN03DME GWN03R7C GWN045T9 GWN04FTM GWN0335R GWN03DMF GWN03R7D GWN045TA GWN04FTN GWN033C5 GWN03ER7 GWN03R7E GWN045TC GWN034KR GWN03ER8 GWN03R7F GWN045TD GWN034KT GWN03ER9 GWN03R7G GWN045TE GWN0350M GWN03ERA GWN03R7H GWN045TF GWN0350N GWN03FTN GWN03R9G GWN045TG GWN0350P GWN03FTP GWN03R9H GWN045TH GWN0350R GWN03FTR GWN03R9J GWN046F6 GWN0350T GWN03FTT GWN03R9K GWN046F7 GWN0350W GWN03FTW GWN03R9L GWN046F8 GWN035M5 GWN03FW0 GWN03R9M GWN047LG GWN035M6 GWN03H56 GWN03R9N GWN047LH GWN035M7 GWN03H57 GWN03R9P GWN047LJ GWN035M8 GWN03H58 GWN03R9R GWN047LK GWN035M9 GWN03HTL GWN03R9T GWN047LL GWN035MA GWN03HTM GWN03R9W GWN048CD GWN035MC GWN03HTN GWN03RA0 GWN048CF GWN035MD GWN03HTP GWN03RA1 GWN048CG GWN035TH GWN03HTR GWN03RA2 GWN048CH GWN035TJ GWN03HTT GWN03RA3 GWN048CJ GWN035TK GWN03J8T GWN03RA4 GWN048CK GWN035TL GWN03J8W GWN03RA5 GWN048CM GWN035TM GWN03J90 GWN03RA6 GWN048CN GWN0369A GWN03J91 GWN03RA7 GWN048CP GWN0369C GWN03J92 GWN03RA8 GWN048CR GWN0369D GWN03JNN GWN03RP7 GWN049GH GWN0369E GWN03JNP GWN03RP9 GWN049GJ GWN0369G GWN03K3C GWN03RPA GWN049GK GWN0369H GWN03K3D GWN03RPC GWN049JL (1) Visually inspect the rotor disks for the presence of a chamfer on the aft breakedges of the dovetail slot bottoms. Use paragraph 3.A. of GE SB No. CF6-80C2 S/B 72-1089, Revision 2, dated December 18, 2003, to do the inspection. (2) For disks that have the chamfered breakedges, remark, FPI, and ECI the rotor disk. Use paragraph 3.A.(1)(a) through 3.A.(1)(b) of the Accomplishment Instructions of GE SB No. CF6-80C2 S/B 72-1089, Revision 2, dated December 18, 2003, to remark and inspect the rotor disk, and remove from service as necessary. (3) For disks that do not have the chamfered breakedges, inspect, rework and remark the rotor disk. Use paragraph 3.A.(2)(a) through 3.A.(2)(b) of the Accomplishment Instructions of GE SB No. CF6-80C2 S/B 72-1089, Revision 2, dated December 18, 2003, to inspect, rework and remark the disk and remove from service as necessary. Stage 1 HPT Rotor Disks, P/Ns 9392M23G10, G12, G21, 1531M84G02, G06, G08, and 1531M84G10 With SNs Not Listed in Table 6 of This AD (j) For stage 1 HPT rotor disks, P/Ns 9392M23G10, G12, G21, 1531M84G02, G06, G08, and 1531M84G10 with SNs not listed in Table 6 of this AD, inspect, rework, and remark the disks using paragraphs 3.A.(2) through 3.B.(2) of Accomplishment Instructions of GE SB No. CF6-80C2 S/B 72-1089, Revision 2, dated December 18, 2003, at the following: (1) For stage 1 HPT rotor disks not installed in engines with both new and old hardware, inspect, rework, remark, and remove from service as necessary before further flight. (2) For stage 1 HPT rotor disks that have been inspected before the effective date of this AD using GE SB No. CF6-80C2 S/B 72-A1024, Revision 1, dated November 3, 2000, or any version of GE ASB No. CF6-80C2 S/B 72-A1026, inspect, rework, remark, and remove from service as necessary at the next ESV using the compliance times in the following Table 7: Table 7.—Compliance Times for Inspection and Rework of CF6-80C2 Series Stage 1 HPT Rotor Disks, P/Ns 9392M23G10, G12, G21, 1531M84G02, G06, G08, and 1531M84G10 With SNs Not Listed in Table 6 of This AD—Previously Inspected Stage 1 HPT rotor disk cycles-since-inspection (CSI) on the effective date of this AD Compliance time for inspection and rework (i) More than 1,500 CSLI At the next ESV or within 4,500 CSLI after the effective date of this AD, whichever occurs first. (ii) 1,500 CSLI or fewer At the next ESV or within 3,500 CSLI after the effective date of this AD, whichever occurs first. (3) For stage 1 HPT rotor disks that have not been inspected before the effective date of this AD using GE SB No. CF6-80C2 S/B 72-A1024, Revision 1, dated November 3, 2000, or any version of GE ASB No. CF6-80C2 S/B 72-A1026, inspect, rework, remark, and remove from service as necessary at the next ESV using the compliance times in the following Table 8: Table 8.—Compliance Times for Inspection and Rework of CF6-80C2 Series Stage 1 HPT Rotor Disks, P/Ns 9392M23G10, G12, G21, 1531M84G02, G06, G08, and 1531M84G10 With SNs Not Listed in Table 6 of This AD—Not Previously Inspected Stage 1 HPT rotor disk cycles-since-new (CSN) on the effective date of this AD Compliance time for inspection and rework (i) 10,000 or more CSN At the next ESV or within 1,000 CIS after the effective date of this AD, whichever occurs first. (ii) 5,000 or more CSN but fewer than 10,000 CSN At the next ESV or within 2400 CIS after the effective date of this AD, whichever occurs first, but before accumulating 11,000 CSN (iii) Fewer than 5,000 CSN. At the next ESV or within 3,500 CIS after the effective date of this AD, whichever occurs first, but before accumulating 7,400 CSN. Stage 1 HPT Rotor Disks, P/N 1862M23G01 (k) For stage 1 HPT rotor disk, P/N 1862M23G01, inspect the rotor disk dovetail slot bottoms and remove the disk from service as necessary using paragraphs 3.A. through 3.C.(10)(i) of Accomplishment Instructions of GE ASB No. CF6-80C2 S/B 72-A1026, Revision 2, dated January 22, 2004, at the following times: (1) For stage 1 HPT rotor disks not installed in engines with both new and old hardware, inspect and remove from service as necessary before further flight. (2) For stage 1 HPT rotor disks that have been inspected before the effective date of this AD using any version of GE ASB No. CF6-80C2 S/B 72-A1026, and had more than zero CSN at the time of that inspection, inspect and remove from service as necessary at each piece-part exposure. (3) For stage 1 HPT rotor disks that have not been inspected, or were only inspected with zero CSN before the effective date of this AD using any version of GE ASB No. CF6-80C2 S/B 72-A1026, inspect and remove from service as necessary at the next ESV using the compliance times in the following Table 9: Table 9.—Compliance Times for Inspection of CF6-80C2 Series Stage 1 HPT Rotor Disks, P/N 1862M23G01—Not Previously Inspected Stage 1 HPT rotor disk CSN on the effective date of this AD Compliance time for initial inspection (i) 10,000 or more CSN At the next ESV or within 1,000 CIS after the effective date of this AD, whichever occurs first. (ii) 5,000 or more CSN but fewer than 10,000 CSN At the next ESV or within 2,400 CIS after the effective date of this AD, whichever occurs first, but before accumulating 11,000 CSN. (iii) Fewer than 5,000 CSN At the next ESV or within 3,500 CIS after the effective date of this AD, whichever occurs first, but before accumulating 7,400 CSN. (4) Thereafter, inspect at each piece-part exposure, and remove the rotor disk from service if necessary. CF6-80E1A2, A4 Engines Stage 1 HPT Rotor Disks, P/N 1639M41P04 (l) For stage 1 HPT rotor disks, P/N 1639M41P04, remove the rotor disks from service using paragraphs 3.A.(1) through 3.A.(2) of Accomplishment Instructions of GE SB No. CF6-80E1 S/B 72-0251, dated January 22, 2004, at the following times: (1) For stage 1 HPT rotor disks currently in service, remove the disk using the compliance times in the following Table 10: Table 10.—Compliance Times for Removal of CF6-80E1 Stage 1 HPT Rotor Disks, P/N 1639M41P04 Stage 1 HPT rotor disk CSN on the effective date of this AD Compliance time for removal of disk (i) More than 10,000 CSN At the next ESV or within 600 CIS after the effective date of this AD, whichever occurs first. (ii) More than 5,000 CSN but fewer than or equal to 10,000 CSN At the next ESV or within 2,500 CIS after the effective date of this AD, whichever occurs first, but before accumulating 10,600 CSN. (iii) Fewer than or equal to 5,000 CSN At the next ESV or within 3,500 CIS after the effective date of this AD, whichever occurs first, but before accumulating 7,500 CSN. (2) After the effective date of this AD, do not install any stage 1 HPT rotor disk, P/N 1639M41P04, into any engine. Definitions (m) For the purpose of this AD, the following definitions apply: (1) An engine shop visit (ESV) is defined as the removal of an engine from an aircraft for maintenance in which a major engine flange is disassembled after the effective date of this AD. The following actions, either separately or in combination with each other, are not considered ESVs for the purpose of this AD. (i) The removal of the upper compressor stator case solely for airfoil maintenance. (ii) The module level inspection of the high-pressure compressor rotor 3-9 spool. (iii) The replacement of stage 5 high-pressure compressor variable stator vane bushings or lever arms. (2) Piece-part exposure is defined as when: (i) The stage 1 HPT rotor disk is considered completely disassembled according to the manufacturer's engine manual or other FAA-approved engine manual; and (ii) The disk has accumulated more than 100 cycles-in-service since the last piece-part inspection, provided that the part was not damaged or the disassembly is not related to the cause for its removal from the engine. Reporting Requirements (n) Within five calendar days of the inspection, report the results of inspections that equal or exceed the reject criteria to: Engine Certification Office, FAA, Engine and Propeller Directorate, 12 New England Executive park, Burlington, MA 01803-5299; telephone (781) 238-7128; fax (781) 238-7199. Reporting requirements have been approved by the Office of Management and Budget and assigned OMB control number 2120-0056. Be sure to include the following information: (1) Engine model in which the stage 1 HPT rotor disk was installed. (2) Part Number. (3) Serial Number. (4) Part CSN. (5) Part CSLI. (6) Date and location where inspection was done. (o) We recommend that you record the inspection information and results on GE Form 1653-1, entitled CF6-80A/80C Stage 1 HPT Disk Dovetail Slot Bottom Inspection. This form is available in any version of GE SB CF6-80A S/B 72-0779, or GE ASB CF6-80C2 S/B 72-A1026. We also recommend that a copy of the data be sent to GE Airline Support Engineering, General Electric Aircraft Engines, Customer Support Center, 1 Neumann Way, Mail Drop RM285, Cincinnati, OH, 45215. Alternative Methods of

This AD results from the manufacturer's investigation and development of a rework procedure that chamfers the aft breakedge of the dovetail slot bottom. The actions specified in this AD are intended to detect and prevent cracks in the bottoms of the dovetail slots that could propagate to failure of the disk and cause an uncontained engine failure.