AD 2005-17-05 Airworthiness Directives; General Electric Company (GE) CF6-80C2 and CF6-80E1 Turbofan Engines

This AD applies to certain GE CF6-80C2 and CF6-80E1 turbofan engines that have a high pressure compressor rotor (HPCR) stage 11-14 spool shaft with a part number (P/N) listed in Table 1 of this AD and that had a seal wire groove repaired using a circumferential cut at a location specified in Table 2 of this AD. The affected stage 11-14 spool shafts are identified by serial number (SN) in the GE service information described in paragraphs (f) and (j) of this AD. These engines are installed on, but not limited to, Airbus Industrie A300, A310, and A330 series airplanes and Boeing 747, 767, and MD-11 series airplanes. Table 1.—Stage 11-14 Spool Shaft P/Ns by Engine Model and Forging Group Designations Engine model Stage 11-14 Spool Shaft P/Ns Forging group designations CF6-80C2 9380M30G07, 9380M30G08, 9380M30G09, 9380M30G10, 9380M30G12, 1509M71G02, 1509M71G03, 1509M71G04, and 1509M71G05 Group 1. CF6-80C2 1531M21G01, 1531M21G02, 1531M21G04, 1509M71G06, 1509M71G07, 1509M71G08, 1509M71G11, 1509M71G12, 1703M74G01, and 1703M74G03 Group 2. CF6-80E1 1509M71G11, 1509M71G12, 1509M71G13, 1644M99G03, 1703M74G01, and 1703M74G03 Not Applicable.

You are responsible for having the actions required by this AD performed within the compliance times specified unless the actions have already been done. CF6-80C2 Engines (f) For CF6-80C2 series engines with HPCR stage 11-14 spool shaft SNs listed in 1.A.(2) of GE Aircraft Engines (GEAE) Service Bulletin (SB) No. CF6-80C2 S/B 72-1052, Revision 02, dated May 25, 2005, inspect the spool shaft for the location of the circumferential cut repair at the next piece-part exposure. (1) If the stage and location of the repair is specified in the engine records, inspect prior to exceeding the cycles-since-repair (CSR) limit specified in the column titled, Replace By (CSR), in Table 2. (2) For the purposes of this AD, CSR limit is defined as the current cycles-since-new (CSN) minus the CSN at the time of the repair. (3) If the CSR limit cannot be determined from the engine records, then CSN must be used. (4) If the stage or location of the repair is not known from the engine records, remove the spool shaft for inspection before exceeding 4,200 CSR for the Group 1 or before exceeding 10,000 CSR for Group 2. Use 3.A.(1) of the Accomplishment Instructions of GEAE SB No. CF6-80C2 S/B 72-1052, Revision 02, dated May 25, 2005, for the inspection. Table 2 follows: Table 2.—Repair and Replacement Limits for Spool Shafts by Forging Group and Location of the Circumferential Cut Repair Engine model Forging group (from Table 1) Stage Location of circumferential cut repair Repair by (CSR) limit Replace by (CSR) limit (1) CF6-80C2 Group 1 14 (i) Aft Seal Wire Groove Not in Area X 3,600 4,200   (ii) Aft Seal Wire Groove—In Area X None—Replace spool 4,200   (iii) Forward Seal Wire Groove—Not in Area X 7,100 7,100   (iv) Forward Seal Wire Groove—In Area X None—Replace spool 7,100 (2) CF6-80C2 Group 1 13 (i) Aft Seal Wire Groove—Not in Area X 7,100 7,100   (ii) Aft Seal Wire Groove—In Area X 2,740 7,100   (iii) Forward Seal Wire Groove—Not in Area X 7,100 7,100   (iv) Forward Seal Wire Groove—In Area X 7,100 7,100 (3) CF6-80C2 Group 1 12 Aft Seal Wire Groove—In Area X 7,100 7,100 (4) CF6-80C2 Group 2 14 (i) Aft Seal Wire Groove—Not in Area X 13,700 13,700   (ii) Aft Seal Wire Groove—In Area X None—Replace spool 13,700   (iii) Forward Seal Wire Groove—In Area X 9,830 10,000 (5) CF6-80C2 Group 2 13 (i) Aft Seal Wire Groove—In Area X 9,830 10,000   (ii) Forward Seal Wire Groove—In Area X 9,830 10,000 (6) CF6-80C2 Group 2 12 Aft Seal Wire Groove—In Area X 9,830 10,000 (7) CF6-80E1 Not Applicable 14 (i) Aft Seal Wire Groove—Not in Area X 11,600 11,600   (ii) Aft Seal Wire Groove—In spool Area X None—Replace spool 11,600   (iii) Forward Seal Wire Groove—In Area X 8,080 11,600 (8) CF6-80E1 Not Applicable 13 (i) Aft Seal Wire Groove—In Area X 8,080 11,600   (ii) Forward Seal Wire Groove—In Area X 8,080 11,600 (9) CF6-80E1 Not Applicable 12 Aft Seal Wire Groove—In Area X 8,080 11,600 (g) If you have a Group 2 spool shaft, and the circumferential cut repair is in the Stage 14 forward location, and not in Area X, no further action is required by this AD. However, GEAE recommends that you repair these spools at the next exposure of the spool shaft. Replacement of the Spool Shaft (h) After the effective date of this AD, replace spool shafts as follows: (1) If the spool shaft exceeds the CSR limit in the column titled, Repair by (CSR), in Table 2 of this AD, replace the spool shaft within 420 cycles-in-service (CIS) or prior to exceeding the CSR limit in the column titled, Replace by (CSR), in Table 2 of this AD, whichever occurs later. (2) If the spool shaft exceeds the CSR limit in the column titled, Replace by (CSR), in Table 2 of this AD, replace the spool shaft within 420 CIS or within the published part life limit, whichever occurs first. Repair of the Spool Shaft (i) You may repair the spool if the CSR on the spool shaft are fewer than or equal to the limit in the column titled, Repair by (CSR), in Table 2 of this AD. Use 3.B. of the Accomplishment Instructions of GEAE SB No. CF6-80C2 S/B 72-1052, Revision 02, dated May 25, 2005, for the repair. CF6-80E1 Engines (j) For CF6-80E1 series engines with HPCR stage 11-14 spool shafts with SNs listed in 1.A.(2) of GEAE SB No. CF6-80E1 S/B 72-0232, Revision 01, dated February 5, 2004, do the following: (1) Inspect the spool shaft for the location of the cut circumferential repair at the next piece-part exposure, but before exceeding 11,600 CSR. Use 3.A.(1) of the Accomplishment Instructions of GEAE SB No. CF6-80E1 S/B 72-0232, Revision 01, dated February 5, 2004 for the inspection. (2) For the purposes of this AD, CSR limit is defined as the current CSN minus the CSN at the time of the repair. (3) If the CSR limit cannot be determined from the engine records, then CSN must be used. (4) If the circumferential cut repair is in the Stage 14 forward location, and not in Area X, no further action is required by this AD. However, GEAE recommends that you repair these spools at the next exposure of the spool shaft. Replacement of the Spool Shaft (k) After the effective date of this AD, replace spool shafts as follows: (1) If the spool shaft exceeds the CSR limit in the column titled, Repair by (CSR), in Table 2 of this AD, replace the spool shaft within 420 CIS or prior to exceeding the CSR limit in the column titled, Replace by (CSR), in Table 2 of this AD, whichever occurs later. (2) If the spool shaft exceeds the CSR limit in the column titled, Replace by (CSR), in Table 2 of this AD, replace the spool shaft within 420 CIS or within the published part life limit, whichever occurs first. Repair of the Spool Shaft (l) You may repair the spool shaft if the CSR on the spool shaft are fewer than or equal to the limit in the column titled, Repair by (CSR), in Table 2 of this AD. Use 3.B. of the Accomplishment Instructions of GEAE SB CF6-80E1 S/B 72-0232, Revision 01, dated February 5, 2004, for the repair. Alternative Methods of

This AD results from an updated stress analysis. We are issuing this AD to prevent failure of the HPCR stage 11-14 spool shaft due to low-cycle fatigue that could result in an uncontained engine failure.