CF6-80C2 Conference

Moscow, Russia
October 2012
Reliability
Scorecard
and
Critical Items
Jim Hoyer
October 8-10, 2012

GE Proprietary Information – The information contained in this document is General Electric Company (GE) proprietary information and is disclosed
in confidence. It is the property of GE and shall not be used, disclosed to others or reproduced without the express written consent of GE, including, but
without limitation, it is not to be used in the creation, manufacture, development, or derivation of any repairs, modifications, spare parts, designs, or
configuration changes or to obtain FAA or any other government or regulatory approval to 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 document shall appear in any such reproduction in whole or in part. The information contained
in this document may also be controlled by the U.S. export control laws. Unauthorized export or re-export is prohibited.
 CF6-80C2 Fleet Scorecard
Fleet Reliability Statistics (12 mo. rolling average – at end of August 2012)

IFSD ATO UER Restored T.O.W.

(Events/1000 EFH) (Events/1000 Departures) (Events/1000 EFH) (Cycles Since Shop Visit)

0.004 0.030 0.029 2579

0.006 0.008 0.050 0.060 0.035 0.040 2200 2000
Fleet Status
(at end of August 2012)
Total no. of engines: 3,731
Total aircraft: 1,120
Total no. of operators: 141
Total engine time: 190,578,870
Total cycles: 44,272,582
Hours per month*: 811,731
Cycles per month*: 178,342
Departures per month*: 68,895
Shop visits per month*: 46
Avg. Time-On-Wing*: 21,065 First Run)
12,243 (Restored)
Avg. Cycles-On-Wing*: 3952 (First Run)
* 12 month average 2529 (Restored)
2
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CF6-80C2 Significant Event Scorecard

Basic SE rate dropped during April-August - near all time low.

Total of 131 SE’s in last 12 months, average 10.9/month. During
2011 average was 10.6/month.
3
GE Proprietary Information September 2012
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CF6-80C2 Combined Significant Events
(FAA Reportable September 2011 – August 2012)

4
GE Proprietary Information September 2012
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CF6-80C2 Combined Significant Events
(FAA Reportable September 2011 – August 2012)
Other (1 Each) IFSD & Other
IFSD Interruption LOTC Stall TOA
Significant Event Cause Interruption Reportable
Fuel Pump 1
N1 Vibration 1
CRF Oil Vent Tube Crack 1
CRF Oil Leak 1
Fuel Filter DP Switch 1
Cable Connector 1
Inclement Weather Flameout 1
Nacelle 1
Lightening Strike 1
CRF Accelerometer 1
LPT S3 Nozzle 1
Combustor 1
Lube and Scav Pump 1
T25 Sensor (FADEC) 1
Fuel Manifold 1
MEC 1
Ice/Snow Ingestion 1
HPT S1 Blade 1
VSV S5 Lever Arm 1
HPT S2 Blade 1
HPT Thermal Shield 1
VSV S3 Lever Arm 1
VSV S5 Lever Arm 1
5
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CF6-80C2 In-flight Shutdown Scorecard
IFSD Rate (12 Month Rolling Average) Causes for IFSD's Sept 2011 – Aug 2012

28 IFSD’s YTD / 1 in August

-Basic rate is .0026 CRF Oil Leak
Single IFSD Causes
LPT S3 Nozzle

-Avg 3.5 / month

CRF Oil Vent Tube Crack Lube and Scav Pump
EGT System Oil Press. Transmitter
Fuel Pump Oil System

In 2011 Avg was 2.9/month HPT S1 Blade

6
GE Proprietary Information September 2012
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CF6-80C2 Aborted Take-off Scorecard
ATO Rate* (12 Month Rolling Average) Causes for ATO’s Sept 2011 – August 2012

* Events per 1000

aircraft departures

-Basic ATO Rate now at 0.005

-Total ATO Rate increasing EGT System
Single TOA Causes
Maintenance
during 1st half of 2012 FOD
Fuel Filter Clog
Oil Filter DP Indication
VSV S3 Lever Arm
-5/6 are non-engine caused
7
GE Proprietary Information September 2012
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CF6-80C2 Unplanned Engine Removal Scorecard
UER Rate (12 Month Rolling Average) Top Cause Rates for UERs in 2011

UER rate stable. Basic drops to a 3 year low - Mar 2009 (.022)
• Combustor splashplate and fan case corrosion – new AMM limits now
released

8
GE Proprietary Information September 2012
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CF6-80C2 Time-On-Wing & Shop Visits Scorecard
Top Shop Visit Causes (12 months)
100
100
9090 1st
8080 2nd
7070 3rd+
6060
5050
4040
3030
2020
1010
00

Performance

Combustor
Blade
Airworthiness

Vibration
LLP

OilOilleak
FOD

Repair Quality
Convenience

leak
HPT S1 Blade

Airworthiness
Soft Time /

Vibration
Performance

Combustor

Bearing

HPC VSV
LLP

FOD

HPC VSV
Customer

Repair

System
System
Soft Time /

Directive
Restore

Directive
Restore

Bearing

CRF CRF
HPT S1
Time-on-wing continues to increase for first run and restored engines
Average flight leg increasing
• Resulting in higher hours on wing and slightly lower cycles

Majority of shop visits are planned

• Normal performance restoration and LLP are top shop visit causes
9
GE Proprietary Information September 2012
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CF6-80C2 Conference
Moscow, Russia
October 2012

Time-on-Wing Variation

GE Proprietary Information – The information contained in this document is General Electric Company (GE) proprietary information and is disclosed
in confidence. It is the property of GE and shall not be used, disclosed to others or reproduced without the express written consent of GE, including, but
without limitation, it is not to be used in the creation, manufacture, development, or derivation of any repairs, modifications, spare parts, designs, or
configuration changes or to obtain FAA or any other government or regulatory approval to 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 document shall appear in any such reproduction in whole or in part. The information contained
in this document may also be controlled by the U.S. export control laws. Unauthorized export or re-export is prohibited.
Time-on-Wing Variation
January 2006 – December 2010
Evaluated 747-400, 767-300/400, MD-11 and A300/ A310 TOW
variation
Based on restored and 1st run engines
Data separated by flight leg
• Short = 1st quartile, Medium = 2nd and 3rd quartile, Long = 4th quartile

747 Restored 767 Restored MD-11 Restored *

Long FL: >7.9 hours Long FL: >6.5 hours Long FL: >6.0 hours
Medium FL: 5.2 to 7.9 hours Medium FL: 2.3 to 6.5 hours Medium FL: 4.5 to 6.0 hours
Short FL: <5.2 hours Short FL: <2.3 hours Short FL: <4.5 hours
747 1st Run 767 1st Run A300/A310 Restored *
Long FL: >7.9 hours Long FL: >4.5 hours Long FL: >3.5 hours
Medium FL: 5.8 to 7.9 hours Medium FL: 3.2 to 4.5 hours Medium FL: 1.9 to 3.5 hours
Short FL: <5.8 hours Short FL: <3.2 hours Short FL: <1.9 hours
* CF6-80C2 MD-11 and
A300/A310 had only restored
shop visits (no 1st run)
11
GE Proprietary Information September 2012
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B747-400
CF6-80C2B1F/B5F
Restored (post SV 1+)
Time-on-Wing Variation
Long FL: >7.9 hours
Medium FL: 5.2 to 7.9 hours
Short FL: <5.2 hours

Long FL Long FL
ECSV Q4

Medium FL ECSV Q2-3

Medium FL

Short
FL ECSV Q1 Short FL

747-400 All ECSV All 747-400 All

0 5000
5000 10000
10000 15000
15000 20000
20000 25000 30000 35000
25000 30000 35000 00 1000
1000 2000
2000 3000
3000 4000
4000 5000
5000 6000
6000 7000
7000
RestoredETSV
TSVAll (Hours) Restored
ECSVCSV
All (Cycles)
12
GE Proprietary Information September 2012
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B747-400
CF6-80C2B1F/B5F
1st Run Time-on-Wing Variation
Long FL: >7.9 hours
Medium FL: 5.8 to 7.9 hours
Short FL: <5.8 hours

Long FL Long FL

Medium FL Medium FL

Short FL Short FL

747-400 All 747-400 All

0 10000 20000 30000 40000 500 2500 3500 4500 5500 6500
1st Run TSV (Hours) 1st Run CSV (Cycles)
13
GE Proprietary Information September 2012
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B767-300/400
Restored (SV 1+)
Time-on-Wing Variation
CF6-80C2B6F/B7F/B8F
Long FL: >6.5 hours
Medium FL: 2.3 to 6.5 hours
Short FL: <2.3 hours

Long FL Long FL

Medium
FL
Medium FL

Short Short FL
FL
767-300/
767-300/ 400 All
400 All

00 5000
5000 10000
10000 15000
15000 20000
20000 25000
25000 30000
30000 35000
35000 00 2500 5000
5000 7500 10000
10000

Restored TSV (Hours) Restored CSV (Cycles)

14
GE Proprietary Information September 2012
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B767-300/400
1st Run Time-on-Wing Variation
CF6-80C2B6F/B7F/B8F

Long FL: >4.5 hours

Medium FL: 3.2 to 4.5 hours
Short FL: <3.2 hours

Long FL Long FL

Medium FL Medium FL

Short FL Short FL

767-300/
767-300/400 All 400 All

00 10000
10000 20000
20000 30000
30000 40000
40000 2100 3000
3000 4000
4000 5000
5000 6000
6000
1st Run TSV (Hours) 1st Run CSV (Cycles)
15
GE Proprietary Information September 2012
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MD-11
Restored (SV 1+)
Time-on-Wing Variation
CF6-80C2D1F
Long FL: >6.0 hours
Medium FL: 4.5 to 6.0 hours
Short FL: <4.5 hours

Long FL Long FL

Medium FL Medium FL

Short FL Short FL

MD-11 All MD-11 All

0
0 5000
5000 10000
10000 15000
15000 20000
20000 25000
25000 00 1000
1000 2000
2000 3000
3000 4000
4000 5000
5000

Restored TSV (Hours) Restored CSV (Cycles)

16
GE Proprietary Information September 2012
Subject to restrictions on the cover or first page GE Aviation
A300/A310
Restored (SV 1+)
Time-on-Wing Variation
CF6-80C2A1, A2, A3, A5, A5F, A8
Long FL: >3.5 hours
Medium FL: 1.9 to 3.5 hours
Short FL: <1.9 hours

Long FL Long FL

Medium Medium
FL FL

Short Short
FL FL

A300/ A300/
A310 All A310 All

00 5000 10000
10000 15000 20000
20000 25000 30000
30000 00 1000
1000 2000
2000 3000
3000 4000
4000 5000
5000 6000
6000 7000
7000
Restored TSV (Hours) Restored CSV (Cycles)
17
GE Proprietary Information September 2012
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CF6-80C2 Conference
Moscow, Russia
October 2012

Significant Events by Module

GE Proprietary Information – The information contained in this document is General Electric Company (GE) proprietary information and is disclosed
in confidence. It is the property of GE and shall not be used, disclosed to others or reproduced without the express written consent of GE, including, but
without limitation, it is not to be used in the creation, manufacture, development, or derivation of any repairs, modifications, spare parts, designs, or
configuration changes or to obtain FAA or any other government or regulatory approval to 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 document shall appear in any such reproduction in whole or in part. The information contained
in this document may also be controlled by the U.S. export control laws. Unauthorized export or re-export is prohibited.
Significant Events by Module
60
TOA
50 Stall
Other Reportable
40 LOTC
Interruption
30 IFSD & Interruption
IFSD
20

10

0 CRF

Fan
Thrust Reverser
HPC
Gearbox

LPT
FOD

HPT
Undetermined
Aircraft Sys.

Under Investigation
C&A and Engine Systems

19
GE Proprietary Information September 2012
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Controls and Accessories and Engine
Systems – Significant Events
12
TOA
10 Other Reportable
LOTC
8 Interruption
IFSD & Interruption
6 IFSD

0
ECU
HMU

Other (1 Each)
Undetermined

Investigation
Fuel Filter

Fuel Filter DP
Maintenance
Clog

Switch
Under

20
GE Proprietary Information September 2012
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FOD – Significant Events
12
TOA
10 LOTC
Interruption
IFSD & Interruption
8 IFSD

Unknown
Ice/Snow
Bird

Hardbody

21
GE Proprietary Information September 2012
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Gearbox – Significant Events
5
TOA
LOTC
4 Interruption
IFSD
3

0
Control Alt.
AGB Carbon

IGB Teflon
Starter Air
Maintenance

IGB Spline
Gearbox
Transfer

Wear
Valve
Drive

Seal
Seal

22
GE Proprietary Information September 2012
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CRF Module – Significant Events
4
Interruption
IFSD & Interruption
3 IFSD

0 4B Bearing

5R Bearing

4R Bearing
Maintenance

CRF Oil Leak

23
GE Proprietary Information September 2012
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HPC Module – Significant Events
9
8 TOA
7 Stall
LOTC
6 Interruption
5 IFSD & Interruption
IFSD
4
3
2
1
0

HPC S10 Blade

4R Vent Seal
Contaminated
FOD

Maintenance

PMA
HPC

24
GE Proprietary Information September 2012
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HPT Module – Significant Events
3

IFSD & Interruption

IFSD
2

0
HPT S1

Diffuser
Thermal

HPT Aft
Blade

Shield

Seal
HPT

25
GE Proprietary Information September 2012
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LPT Module – Significant Events
3

Interruption
IFSD
2

0
LPT S3

Coking
Nozzle

Blades

TRF Oil
D-Sump Oil

LPT S4

Tube
Tube

26
GE Proprietary Information September 2012
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Fan Module – Significant Events

8
7 TOA
6 Interruption
5
4
3
2
1
0
FOD

Fumes
Oil
27
GE Proprietary Information September 2012
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Oil System – Significant Events
3
Interruption
IFSD & Interruption
IFSD
2

0
Oil Filter DP

Oil Pressure
Transmitter
Indication

28
GE Proprietary Information September 2012
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CF6-80C2 Conference
Moscow, Russia
October 2012

Shop Visits by Module

GE Proprietary Information – The information contained in this document is General Electric Company (GE) proprietary information and is disclosed
in confidence. It is the property of GE and shall not be used, disclosed to others or reproduced without the express written consent of GE, including, but
without limitation, it is not to be used in the creation, manufacture, development, or derivation of any repairs, modifications, spare parts, designs, or
configuration changes or to obtain FAA or any other government or regulatory approval to 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 document shall appear in any such reproduction in whole or in part. The information contained
in this document may also be controlled by the U.S. export control laws. Unauthorized export or re-export is prohibited.
Shop Visits by Module… 2006-2010
1600

1400
3rd+
1200
2nd
1000 1st

800

600

400

200 `

0
Engine Level

Externals
Oil System
Combustor

Gearbox
LPT
HPT

CRF
HPC

Fan

30
GE Proprietary Information September 2012
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Engine Level Shop Visits… 2006-2010
500
450
400 3rd+
350 2nd
300 1st
250
200
150
100
50 `
0
LLP (Multiple)

FOD (Multple Modules)

Maintenance Error
Vibration

Undefined

Undetermined

EGT Overtemp
Customer Soft Time /

Metal on MCD

Other (1 Each)
Performance Restore

Convenience

31
GE Proprietary Information September 2012
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HPT Shop Visits… 2006-2010
300

250
3rd+
2nd
200
1st

150

100

50
`
0

Thermal Shield
Maint. Error
Vibration
S1 Blade

S1 Nozzle

S2 Blade

S2 Nozzle
LLP

S1 Shroud

S2 Shroud
Fwd. Outer Seal
A.D.

Other (1 Each)
FOD
32
GE Proprietary Information September 2012
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HPC Shop Visits… 2006-2010
180

160
3rd+
140
2nd
120 1st

100

80

60

40

20

0
S11 Vane Rail Wear

Vibration
Blade - General
S1 Blade

S4 Blade

S5 Blade

S12 Blade

S13 Blade

HPC Contamination
LLP
A.D.

Other (1 Each)
FOD

VSV System

33
GE Proprietary Information September 2012
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CRF Shop Visits… 2006-2010
120

100 3rd+
2nd
80 1st

60

40

20

0
CRF Oil leak

Bearing
4B Bearing

4R Bearing

5R Bearing
Metal on

Other (1
Quality
Repair

Each)
MCD
34
GE Proprietary Information September 2012
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Fan Shop Visits… 2006-2010
45
40
35 3rd+
30 2nd
25 1st
20
15
10
5
0

N3 Brg Air/ Oil Seal

Oil Leak

Brg Repair Quality

Maint. Error
Vibration
Oil Fumes
LLP
Fan Case

A.D.

Other (1 Each)
Fan Stator
FOD

35
GE Proprietary Information September 2012
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Combustor Shop Visits… 2006-2010
70

60
3rd+
50 2nd
1st
40

30

20

10
`
0

FERRULE

Maintenance
LINER

DOME

NOZZLE
SPLASHPLATE

Error
36
GE Proprietary Information September 2012
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LPT Shop Visits… 2006-2010
25

20
3rd+
2nd
15
1st

10

Bearing Repair

Maintenance Error
Vibration
LPT Blade

S2 Nozzle

6R Bearing
LLP

TRF Crack
A.D.

LPT Stator

Other (1 Each)
S3 NGV

FOD
37
GE Proprietary Information September 2012
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Oil System Shop Visits… 2006-2010
120

100
3rd+
2nd
80
1st

60

40

20

0
CRF Oil leak

Fan Case Oil

Maintenance
Consumption

Pressure

Other (1 Each)
Unknown
(Unknown)
High Oil

Oil Leak
Leak

Error
Oil

38
GE Proprietary Information September 2012
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Gearbox Shop Visits… 2006-2010
30

25
3rd+
20 2nd
1st
15

10

0
IGB Spline

Control Alt.

Control Alt.

AGB Bearing
Maintenance
IGB Teflon

LLP
Transfer
Gearbox

Other (1
each)
Wear

Drive
Seal

Error
39
GE Proprietary Information September 2012
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Externals Shop Visits… 2006-2010
8
7 3rd+
6 2nd
1st
5
4
3
2
1
0
Borescope

Hydraulic
EGT Probe

Maintenance
Cooling Duct

Other (1
Manifold

each)
Fuel

11th Stg

Leak
Plug

Error
40
GE Proprietary Information September 2012
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CF6-80C2 Conference
Moscow, Russia
October 2012

Reliability Rates by Airplane Type

GE Proprietary Information – The information contained in this document is General Electric Company (GE) proprietary information and is disclosed
in confidence. It is the property of GE and shall not be used, disclosed to others or reproduced without the express written consent of GE, including, but
without limitation, it is not to be used in the creation, manufacture, development, or derivation of any repairs, modifications, spare parts, designs, or
configuration changes or to obtain FAA or any other government or regulatory approval to 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 document shall appear in any such reproduction in whole or in part. The information contained
in this document may also be controlled by the U.S. export control laws. Unauthorized export or re-export is prohibited.
 A300-600 Rates 0.016
Take-Off Abort Rate

CF6-80C2A1/A3/A5/A5F/A8 0.014
A300-600 Total IFSD Rate
A300-600 Basic IFSD Rate
0.012
0.010
0.008
0.006
0.004
0.002
0.000

Dec-04

Jun-05

Dec-05

Jun-06

Dec-06

Jun-07

Dec-07

Jun-08

Dec-08

Jun-09

Dec-09

Jun-10

Dec-10
In-Flight Shutdown Rate Shop Visit Rate
0.016 0.160
A300-600 Total IFSD Rate A300-600 Total TOA Rate
0.014 A300-600 Basic IFSD Rate 0.140 A300-600 Basic TOA Rate
0.012 0.120
0.010 0.100
0.008 0.080
0.006 0.060
0.004 0.040
0.002 0.020
0.000 0.000
Dec-04

Jun-05

Dec-05

Jun-06

Dec-06

Jun-07

Dec-07

Jun-08

Dec-08

Jun-09

Dec-09

Jun-10

Dec-10

Dec-04

Jun-05

Dec-05

Jun-06

Dec-06

Jun-07

Dec-07

Jun-08

Dec-08

Jun-09

Dec-09

Jun-10

Dec-10
42
GE Proprietary Information September 2012
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 A310 Rates 0.160
Take-Off Abort Rate
A310 Total TOA Rate
CF6-80C2A2/A8 0.140
0.120
A310 Basic TOA Rate

0.100
0.080
0.060
0.040
0.020
0.000

Dec-04

Jun-05

Dec-05

Jun-06

Dec-06

Jun-07

Dec-07

Jun-08

Dec-08

Jun-09

Dec-09

Jun-10

Dec-10
In-Flight Shutdown Shop Visit Rate
0.016
Rate 0.2
0.014 A310 Total IFSD Rate
A310 Basic IFSD Rate 0.16 A310 Total Shop Visit Rate
0.012 A310 Basic Shop Visit Rate
0.010 0.12
0.008
0.006 0.08
0.004
0.04
0.002
0.000 0
Dec-04

Jun-05

Dec-05

Jun-06

Dec-06

Jun-07

Dec-07

Jun-08

Dec-08

Jun-09

Dec-09

Jun-10

Dec-10
Dec-04

Jun-05

Dec-05

Jun-06

Dec-06

Jun-07

Dec-07

Jun-08

Dec-08

Jun-09

Dec-09

Jun-10

Dec-10

43
GE Proprietary Information September 2012
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 B747-400 Rates 0.140
Take-Off Abort Rate

CF6-80C2B1F/B5F 0.120
B747-400 Total TOA Rate
B747-400 Basic TOA Rate
0.100
0.080
0.060
0.040
0.020
0.000

Dec-04

Jun-05

Dec-05

Jun-06

Dec-06

Jun-07

Dec-07

Jun-08

Dec-08

Jun-09

Dec-09

Jun-10

Dec-10
In-Flight Shutdown Rate Shop Visit Rate
0.016 0.200
B747-400 Total IFSD Rate B747-400 Total Shop Visit Rate
0.014 B747-400 Basic Shop Visit Rate
B747-400 Basic IFSD Rate 0.160
0.012
0.010 0.120
0.008
0.080
0.006
0.004 0.040
0.002
0.000
0.000
Dec-04

Jun-05

Dec-05

Jun-06

Dec-06

Jun-07

Dec-07

Jun-08

Dec-08

Jun-09

Dec-09

Jun-10

Dec-10
Dec-04

Jun-05

Dec-05

Jun-06

Dec-06

Jun-07

Dec-07

Jun-08

Dec-08

Jun-09

Dec-09

Jun-10

Dec-10

44
GE Proprietary Information September 2012
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 B767-200/300 Rates 0.200
Take-Off Abort Rate

CF6-80C2B2/B4/B6 PMC 0.160 B767 PMC Total TOA Rate

B767 PMC Basic TOA Rate
0.120

0.080

0.040

0.000

Dec-04

Jun-05

Dec-05

Jun-06

Dec-06

Jun-07

Dec-07

Jun-08

Dec-08

Jun-09

Dec-09

Jun-10

Dec-10
In-Flight Shutdown Rate Shop Visit Rate
0.016 0.200
B767 PMC Total IFSD Rate
0.014 B767 PMC Total Shop Visit Rate
B767 PMC Basic IFSD Rate 0.160
0.012 B767 PMC Basic Shop Visit Rate
0.010 0.120
0.008
0.006 0.080
0.004
0.040
0.002
0.000 0.000
Dec-04

Jun-05

Dec-05

Jun-06

Dec-06

Jun-07

Dec-07

Jun-08

Dec-08

Jun-09

Dec-09

Jun-10

Dec-10

Dec-04

Jun-05

Dec-05

Jun-06

Dec-06

Jun-07

Dec-07

Jun-08

Dec-08

Jun-09

Dec-09

Jun-10

Dec-10
45
GE Proprietary Information September 2012
Subject to restrictions on the cover or first page GE Aviation
 B767-200/300/400 Rates Take-Off Abort Rate
CF6-80C2B2/B4/B6/B7/B8 FADEC 0.14
B767 FADEC Total TOA Rate
0.12 B767 FADEC Basic TOA Rate
0.1
0.08
0.06
0.04
0.02
0

Jun-05

Jun-06

Jun-07

Jun-08

Jun-09

Jun-10
Dec-04

Dec-05

Dec-06

Dec-07

Dec-08

Dec-09

Dec-10
In-Flight Shutdown Rate
Shop Visit Rate
0.016 0.2
B767 FADEC Total IFSD Rate B767 FADEC Total Shop Visit Rate
0.014 B767 FADEC Basic Shop Visit Rate
B767 FADEC Basic IFSD Rate 0.16
0.012
0.01 0.12
0.008
0.006 0.08
0.004
0.04
0.002
0 0
Dec-04

Jun-05

Dec-05

Jun-06

Dec-06

Jun-07

Dec-07

Jun-08

Dec-08

Jun-09

Dec-09

Jun-10

Dec-10

Dec-04

Jun-05

Dec-05

Jun-06

Dec-06

Jun-07

Dec-07

Jun-08

Dec-08

Jun-09

Dec-09

Jun-10

Dec-10
46
GE Proprietary Information September 2012
Subject to restrictions on the cover or first page GE Aviation
 MD11 Rates 0.140
Take-Off Abort Rate

MD11 Total TOA Rate

CF6-80C2D1F 0.120 MD11 Basic TOA Rate

0.100

0.080

0.060

0.040

0.020

0.000

Jun-05

Jun-06

Jun-07

Jun-08

Jun-09

Jun-10
Dec-04

Dec-05

Dec-06

Dec-07

Dec-08

Dec-09

Dec-10
In-Flight Shutdown Rate Shop Visit Rate
0.018 0.200
MD11 Total Shop Visit Rate
0.016 MD11 Basic Shop Visit Rate
0.014 0.160
0.012
0.120
0.010
0.008
0.080
0.006
0.004
0.040
0.002 MD11 Total IFSD Rate
MD11 Basic IFSD Rate
0.000 0.000
Jun-05

Jun-06

Jun-07

Jun-08

Jun-09

Jun-10
Dec-04

Dec-05

Dec-06

Dec-07

Dec-08

Dec-09

Dec-10

Jun-05

Jun-06

Jun-07

Jun-08

Jun-09

Jun-10
Dec-04

Dec-05

Dec-06

Dec-07

Dec-08

Dec-09

Dec-10
47
GE Proprietary Information September 2012
Subject to restrictions on the cover or first page GE Aviation
CF6-80C2 Conference
Moscow, Russia
October 2012

Critical Items
GE Proprietary Information – The information contained in this document is General Electric Company (GE) proprietary information and is disclosed
in confidence. It is the property of GE and shall not be used, disclosed to others or reproduced without the express written consent of GE, including, but
without limitation, it is not to be used in the creation, manufacture, development, or derivation of any repairs, modifications, spare parts, designs, or
configuration changes or to obtain FAA or any other government or regulatory approval to 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 document shall appear in any such reproduction in whole or in part. The information contained
in this document may also be controlled by the U.S. export control laws. Unauthorized export or re-export is prohibited.
Critical Items List
CF6-80C2 Critical Items List consists of 3 levels of high
priority actions:
• Priority A – Safety or Airworthiness Directive related
– Control plans or corrective actions for issues that are deemed safety
items by GE’s safety board and/or items that are mandated by the FAA
or other agency
• Priority B – Top reliability related
– Control plans or corrective actions for issues that are top causes of
fleet unreliability
• Priority C – Key Product Improvements and Historical items
(still applicable)
– Key product improvements (recently released)
– Control plans or corrective actions for historical issues that were top
causes of fleet unreliability (mostly complete in the fleet but some
engines may still not be in compliance)
GE recommends that you review records for each of your
engines to ensure critical items have been implemented
49
GE Proprietary Information September 2012
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CF6-80C2 Fleet Scorecard – Fleet Critical Items Priority A
Safety or Airworthiness Directive related
Action Metric(s) SB
No. Critical Item Documents Action Description
Status Affected Category
SB 72-1089 Mandatory rework of disk dovetail breakedge (AD 2006-16-06) 2
1 HPT S1 Disk Dovetail Available Safety
SB 72-1217 Disk Inspection for Slot Edge Anomalies and Re-identification 2
Airworthiness Rework LPT case to install debris deflectors at stg 5 for improved
2 LPT Case Debris Deflectors Available SB 72-1171 4
Directive containment capability (AD 2008-21-11)
SB 73-0326R1 Inspection and clamp replacement program (AD 2009-05-02) 2
3 Fuel Manifold P-Clamp Chafing Available SB 73-0365 Safety Application of PTFE tape under loop clamps 3
SB 73-0371 New design fuel manifold - terminates AD inspection requirement 5
Fuel Manifold Supply Tube to Fuel New snap ring for improved fuel manifold supply tube in case of manifold
4 Available SB 73-0337 Safety 3
Nozzle Retaining Clip break - prevent undercowl fuel leak and possible fire (AD 2007-11-20 )
HPC S11-14 Seal Wire Groove Airworthiness
5 Available SB 72-1052 Inspect and repair seal wire grooves of affected spools (AD 2005-17-05) 2
Repair Directive
Airworthiness
6 3R Packing Available SB 72-A1385 Replace nonconforming packings (AD 2012-03-12) 2
Directive
7 HPC 10-14 Spool Available SB 72-A1122 IFSD/UER Spool inspection (shop level and module level) (AD 2009–07–03) 3
Cast Forward Mount Platform or SB 72-1206 Replace 13 affected platforms within 500 cycles or 6 months (AD 2007-05-14) 2
8 Available Safety
Yoke With Weld Repairs SB 72-1207 Replace 59 affected yokes at next shop visit (AD 2007-05-14) 3
FADEC software version 8.2.R for B747/B767 with enhanced flameout
SB 73-0375
Engine Inclement Weather prevention for high and middle altitudes. (AMOC for AD 2007-12-07 )
Flameout and Boeing FADEC FMV Airworthiness FADEC software version 8.3.K for MD-11 with enhanced flameout prevention
9 Available SB 73-0351 3
Fault Accommodation Logic Directive for high and middle altitudes. (AD 2007–22–07)
Improvement FADEC software version 8.4.F for A300 with enhanced flameout prevention
SB 73-0352
for high and middle altitudes. (AD 2007-21-06)
A300-78-6024 Airbus Service Bulletins to add thrust reverser actuation system locks as a
A300/A310 Thrust Reverser
10 Available A300-78-6025 Safety third line of defense against inadvertent thrust reverser deployment (DGAC N/A
Actuation System Locks
A310-78-2023 AD F-2004-165)
Thrust Reverser Actuator
Replacement of actuator 3/8 inch rod ends and other inspections to prevent
11 Inspection and Rod End Available SB 78-A1162 Safety 2
rod end breakage and potential partial transcowl liberation (AD 2009-21-07)
Replacement
Inspection (AD 2002-25-08) N/A
12 HPC 3-9 Spool Available SB 72-0937 Safety
Spool replacement with improved design 7
13 LPT Overspeed Protection Available SB 72-1152 Safety Repair cutback of LPT nozzle 5
SB 72-0952 On-wing inspection (AD 2004-22-07) 2
14 HPT Stage 2 Nozzle Guide Vanes Available IFSD/UER/TOW
SB 72-1291 Redesigned (TechCF6) Nozzles 7
SB 78-1068
MD11 Thrust Reverser Half SB 78-1077
15 Available High Cost Event Service Bulletins for improved thrust reverser latches. (AD 2006-06-08) 2
Liberation SB 78-1078
SB 78-1088
Thrust Reverser Improved Flex Improved flex-shaft to improve reliability (747 and 767 applications only -
16 Available SB 78-1168R1 Reliability 2
Shaft Boeing cover SB 747-78A2185 and SB 767-78A0100) (AD Pending)
Improved front panel design to address potential uncommanded engine
17 ECU Front Panel Improvement Available SB 72-0386 IFSD 2
shutdown due to electrical interference (AD 2012-04-05)
IDG Oil Cooler Fuel Tube Flange Improved bracket design to integrate the function of both the IDG bracket
18 Available SB 73-0242 IFSD 3
Spray Shield and spray shield into one part. (AD Pending)

50
GE Proprietary Information March 2012
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CF6-80C2 Fleet Scorecard – Fleet Critical Items Priority B
Top reliability related
Action Metric(s) SB
No. Critical Item Documents Action Description
Status Affected Category
Fan Forward Inner Liner Brackets - SB 72-1223R1 Improved fan forward inner liner bracket 3
19 Available High Cost Event
Inspection and Replacement SB 72-1374 Inspection of fan forward inner liner bracket (pre-SB 72-1223) 2
20 Maintenance Related Reliability Available Training IFSD Awareness and training, Maintenance Newsletters N/A
CRF Sump Vent Oil Impingement Improved design or rework instructions for CRF sump vent oil impingement
21 Available SB 72-1265 IFSD/UER 5
Tube Rework and Improvements tube to prevent tube cracking and oil loss
EGT Thermocouple Probe On-Wing IFSD/High Cost On-wing resistance check of older EGT probes to avoid tip separation and
22 Available SB 77-0050 2
Inspection Event downstream LPT damage
CESM204 (bearing handling best practices). Enhanced oil filter fault isolation
23 No. 4 Ball Bearing Available CESM 204 IFSD/UER N/A
procedures in AMMs.
Oil Manifold for IGB Horizontal New oil supply manifold with debris screen to prevent oil nozzle blockage and
24 Available SB 72-1230 IFSD/UER 5
Drive Shaft Spline Wear resulting IGB horizontal drive shaft spline wear
SB 79-0086 Improved oil pressure tube system 3
25 Oil Pressure Tube Available IFSD
SB 79-0082 Improved tube support brackets and clamps 3
SB 72-1104 Service Bulletin defining Teflon seal replacement intervals 4
26 IGB Gearshaft Teflon Seal Available SB 72-1186 IFSD/UER Service Bulletin defining welded ring repair replacement of Teflon seal 6
SB 72-1193 Spare part Service Bulletin releasing solid metal gear (production config.) 8
SB 79-001 (High Thermal Stability Oils) 9
SB 72-0001
27 TRF Oil Tube Coking Available IFSD/UER Engine Manual (72-58-01 Repair 01) Tube Cleaning N/A
CESM 09
Trend Monitoring N/A
[Link] Engine manual changes - open seal clearance, strip/inspect seal teeth;
28 HPT Thermal Shield Available IFSD/ATO/TOW N/A
WSPG specified min. seal tooth thickness
72-1288 (S1-
R142) 72-
1296 (S1-N5)
HPT Blade Shank Corrosion 72-1269 (S1- Corrosion coating to prevent corrosion on blade shanks. Available in new
29 Available COO/IFSD/ATO
Coating Repair) 72- Tech CF6 blades and by repair Service Bulletin
1283 (S2)
72-1271 (S2-
Repair)
30 Bleed Flow Sensor (PMC Engines) Available SB 75-0202 IFSD/UER Replace stainless steel bleed flow sensor with new part made of Inconel 3

51
GE Proprietary Information March 2012
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 CF6-80C2 Fleet Scorecard – Fleet Critical Items Priority C
Key Product Improvements and Historical Reliability Items (still applicable)
Action Metric(s) SB
No. Critical Item Documents Action Description
Status Affected Category
31 Thrust Reverser Available SB 78-0146 ATO Improved PRSOV - addresses "REV UNLK" message
Airworthiness Improved design LPT shrouds with improved containment capability (AD 2003-
32 Improved LPT Shrouds Available SB 72-1006 4
Directive 02-07)
SB 72-1081 Improved design stage 5 lever arm system N/A
33 S5 VSV Lever Arms Available IFSD/ATO/TOW
CESM 205 VSV lever arms and bushings maintenance 3
SB 72-1117
On-wing borescope inspection of affected engines. Replacement of S11
34 HPC S11 Vane Rail Wear Available SB 72-1118 IFSD/UER 2/4
vanes with Al-Br coating
SB 72-1125
SB 75-0156
35 Stage 11 Air System Available IFSD Twin pipe design 3
SB 75-0200
Introduced FOD tolerant airfoils for HPC stages 3-5 blades. Maintains
36 HPC Stages 3-5 Blades Available SB 72-1060 IFSD/ATO/UER 3
improved dovetail geometry.
SB 72-1288 Tech CF6 (DSR142) Improved design blades
37 HPT S1 Blades Available TOW/UER 7
SB 72-1296 Tech CF6 (N5) Improved design blades
SB 72-0982 R80 material blade retirement 4
38 HPT Stage 2 Blades Available IFSD/TOW
SB 72-1283 Tech CF6 Blades 7
SB 72-1245 Tech CF6 Vane Erosion Resistant Coating
39 HPC Stages 6 & 10 Vane Erosion Available IFSD/UER 7
Shop Manual Shop Manual inspection (Chapter 72-32-03)
SB 73-0287 Standard (non-dribble flow) fuel nozzles with welded heat shield 3
40 Fuel Nozzle Welded Heat Shield Available IFSD/UER
SB 73-0289 Dribble flow fuel nozzles with welded heat shield 3
SB 75-0167 Redesigned duct support for FADEC engines+F24 4
41 HP Recoup Ducts Available IFSD
SB 75-0168 Redesigned duct support for PMC engines 4
SB 72-1002 Redesigned HP recoup tube clamp stops 5
42 CRF Internal Oil Tubes Available SB 72-753R5 UER/TOW Redesigned oil supply tube 5
SB 72-0933 Redesigned oil supply manifold 5
43 CRF B/C Sump O-Rings Available SB 72-1107 UER/TOW AFLAS material O-rings (more tolerant of high temperatures) 5
HPT S1 Disk Inner Transition Available SB 72-1195 Introduction of baffle ring to prevent erosion 5
44 COO
Radius Erosion Available 72-1313 New HPT S1 disk design 7
Eng manual Engine manual and Aircraft Maintenance manual changes - improved limits
45 Fan Case Corrosion Available COO N/A
and AMMs and repairs

52
GE Proprietary Information March 2012
Subject to restrictions on the cover or first page GE Aviation
CF6-80C2 Critical Items - Summary

Overall, CF6-80C2 fleet reliability is excellent

• Thank you for your good work to make this happen!

To maintain this high level of reliability and

associated improvement in cost of ownership,
critical items should be incorporated

53
GE Proprietary Information March 2012
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CF6-80C2

CF6-80C2 Critical Items

Additional Information
GE Proprietary Information – The information contained in this document is General Electric Company (GE) proprietary information and is disclosed
in confidence. It is the property of GE and shall not be used, disclosed to others or reproduced without the express written consent of GE, including, but
without limitation, it is not to be used in the creation, manufacture, development, or derivation of any repairs, modifications, spare parts, designs, or
configuration changes or to obtain FAA or any other government or regulatory approval to 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 document shall appear in any such reproduction in whole or in part. The information contained
in this document may also be controlled by the U.S. export control laws. Unauthorized export or re-export is prohibited.
CF6-80C2 HPT S1 Disk Dovetail Ref. C.I.
No. 1

Inco 718 Rotors

Disk event in June 2006 Resulted in update to HPT stage 1 disk
field plan Background
Breakedge • Service bulletin 72-1089
- P/Ns 1531M84G10, 9392M23G10,
9392M23G12, 9392M23G21,
1531M84G02, 1531M84G06, and
1531M84G08
Non Chamfered (Breakedge) Disk • Require the machining of a chamfer,
FPI, and eddy current inspection at
Chamfer the aft edge of the 80 dovetail slots
• Incorporate completion dates
• AD 2006-16-06 for new field
program
S/B Field Rework Disk Chamfer (.036-.056”)

55
GE Proprietary Information March 2012
Subject to restrictions on the cover or first page GE Aviation
CF6-80C2 - New HPT 1 Disk Design Ref. C.I.
No. 1

Service Bulletin 72-1313 Inco 718 Rotor Ref. C.I.

No. 41

Disk redesign program initiated

after June 2006 event
• Eliminate the high stress in
dovetail slot bottom
• Increase resistance to potential
damage in the slot bottom region
• Chapter 5 life limits 15K for all
thrust levels
Not subject to AD 2006-16-06
Enhanced Durability

56
GE Proprietary Information March 2012
Subject to restrictions on the cover or first page GE Aviation
CF6-80C2 LPT Case Debris Deflectors Ref. C.I.
No. 2

AD 2008-21-11… Service Bulletins 72-1170 or 72-1171

Addresses S5 LPT blade plane LPT case breach caused

by blade fragmentation
• Rub-through / “machine” through mechanism
– New design with a rework for the field LPT cases:
» SB 72-1170 (December 2004) released the new
production LPT case with integral debris stops
» SB 72-1171 (May 2005) released the field rework
definition to add “bolt in” debris stops
24 bolted in debris
Doubler welded stops to prevent
on LPT case fragment entrapment

57
GE Proprietary Information March 2012
Subject to restrictions on the cover or first page GE Aviation
Fuel Manifold Clamp Chafing Ref. C.I.
No. 3
AD 2009-05-02 … CF6-80C2 - Service Bulletin 73-0326 R4
CF6-80E1 – Service Bulletin 73-0061 R4
Inspect fuel manifold and replace clamps
• Clamps that appear to be serviceable with
visual inspection can contain contaminants
which accelerate tube wear
• SB affects both drained and drainless
HOLE
systems
• Taped fuel manifolds also require inspection
until it demonstrates effectiveness

Repeat fuel manifold inspections includes clamp replacement

58
GE Proprietary Information March 2012
Subject to restrictions on the cover or first page GE Aviation
Fuel Manifold Supply Tube Shroud Retaining Clip Ref. C.I.
No. 4

AD 2007-11-20 … CF6-80C2 - Service Bulletin 73-0337

CF6-80E1 – Service Bulletin 73-0075
Incorporation of snap ring improves
retention of fuel manifold feeder tube in
O-ring fitting event of a severed tube
• Plug load on o-ring fitting can exceed
retention capability of the retainer ring
• Results in loss of fuel containment
• 2 fire events caused by this problem
• Retainer ring replaced with snap ring
• Snap ring installation is not
recommended while the fuel manifold is
Liberated Retaining Ring installed on the engine
• AD 2007-11-20 requires incorporation of
the snap ring at next shop visit for
drainless manifolds
59
GE Proprietary Information March 2012
Subject to restrictions on the cover or first page GE Aviation
HPC S11-14 Seal Wire Groove Repair Ref. C.I.
No. 5
AD 2005-17-05… S/B 72-1052 (80C2) and S/B 72-0232 (80E)

Seal wires installed in stages 6-14 S11-14 Spool Seal Wire Grooves
• Installed in grooves in outer diameter of
dovetail slots
• Two grooves per stage, one forward, one
aft of dovetail slot
• Intended to reduce air backflow under
blade platforms
Typical Seal Wire Wear
AD requires repair to eliminate wear
notches
• Affects S11-14 spool/shafts with
circumferential cut repairs
GE recommends HPCR seal wires be
left out at engine overhaul

60
GE Proprietary Information March 2012
Subject to restrictions on the cover or first page GE Aviation
CF6-80C2 3R Packing (Gasko Seal) Ref. C.I.
No. 6
Service Bulletin 72-A1385 (Category 2)
No 3R packing between fan frame and 3R Stationary oil seal
• Multiple holes in packing meter pressurization and bore cooling air from booster
Fifty (50) nonconforming parts shipped as spare parts
• 5 holes were manufactured undersized… reduces
cooling flow to rotor bores
• Increased thermal stress in HPC & LPT LLP 3R
• Prolonged operation with nonconforming Packing
packing lowers Ch 5 life of certain parts: Undersize
d Holes
– LPT Stage 3 Disk PN 9373M53P05 Locations
– LPT Stage 4 Disk PN 9373M54P03
– All Stage 10-14/Stage 11-14 HPC Spools
Control program and corrective action
per SB 72-A1385 (end date 31-Jan-2017)
• If engine has LPT S3 disk PN 9373M53P05,
replace nonconforming 3R packing at next
shop visit, not to exceed 2,550 cycles
• Replace nonconforming 3R packing at next
shop visit not to exceed 5,500 cycles
• Alternatively, nonconforming seal can be confirmed by borescope inspection (but
requires removal of one flowpath fairing to gain access)
61
GE Proprietary Information March 2012
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HPC Module, Rotor: 10-14 Spool Shaft Inspection Ref. C.I.
No. 7
AD 2009–07–03 … Service Bulletin 72-A1122 (80C2)
Service Bulletin 72-A0258 (80E1)
Circumferential cracking of S14 disk web
• Cracks initiated by vibration induced by inertia weld
• Part numbers 1703M49G02, 1703M49G03 and 1509M71G10
• 740 spool shafts affected , last build 2002
• Cracking results in very high N2 vibration
Inspect affected spools at first (next) engine shop visit
Inertia Weld Location
CF6 10-14 HPC Spool
Cross-Section
(1703M49)

Crack Locations in Stage 14 Web

62
GE Proprietary Information March 2012
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CF6-80C2 Cast Forward Mount Platform or Yoke With
Weld Repairs Ref. C.I.
No. 8
AD 2007-05-14 … Service Bulletins 72-1206 and 72-1207
Removal of Yokes/Platforms
Yoke • New-make welds in structurally critical
areas. Cracks may originate from weld
• Not all hardware affected, see SBs for
specific serial numbers
• Platforms: 1292M13G06/1846M24G04
1301M28G08/1459M70G07
• Yokes: 9383M43G14/9383M43G16
• AD 2007-05-14 issue 5 Mar 2007
• Hardware replacement program in place
Platform

63
GE Proprietary Information March 2012
Subject to restrictions on the cover or first page GE Aviation
 Ref. C.I.
CF6-80C2 Inclement Weather Flameout No. 9

AD’s on VBV schedule changes issued on recent FADEC software

Service Bulletins
B767/B747 8.2.R SB SB 73-0375R1 issued Dec ‘09
• FAA AD 2007-12-07 effective July 11, ’07 for 8.2.Q1
• AMOC to AD 2007-12-07 issued Jan ’10 to allow 8.2.R to be installed
A300 CF6-80C2A5F 8.4.F SB 73-0352 issued Feb, ’07
• FAA-NE AD 2007-21-06, effective Nov 15, ’07 (>30% complied)
MD-11 CF6-80C2D1F SB 73-0351 8.3.K issued Apr, ’07
• FAA-NE AD 2007-22-07, effective Nov 28, ’07
A330 CF6-80E1 SB 73-0091 E.1.O issued May ‘07
• EASA AD 2007-0215 … terminating action for bleed procedure
• FAA AD 2007-17-01, effective Aug 29, ’07 (100% complied Jan ’08)

64
GE Proprietary Information March 2012
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CF6-80C2 A300/A310 Thrust Reverser Actuation
System Locks Ref. C.I.
DGAC Airworthiness Directive F-2004-165 No. 10

CF6-80C2 Thrust Reverser New Locking Actuator Assembly

TLOD* Modification
 Replacement of the lower end
actuator with one that includes
integral locking locking
actuator and gearbox
assembly
 Addition of pneumatic supply
tube from the Y- check valve
 New electrical harness from
pylon junction box to reverser
 Modification of the Hold Open
Rod bracket
* TLOD - Third Line of Defense
for the A/C to guard against an Locking Actuator and Gearbox Assembly (LAGA)
inadvertent deployment (IAD) 3272636 or 3272638
65
GE Proprietary Information March 2012
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CF6-80C2 Thrust Reverser Actuator Ref. C.I.
No. 11
NO ACTION
REQUIRED
Inspection and Rod End Replacement PER SB
78A1162
Service Bulletin 78A1162 and AD 2009-21-07
Purge the fleet of older
3/8” dia KBE-59 rod ends
and replace them on-wing
with improved M81935/1-
6 rod ends 3/8” dia 7/16” dia
threads threads

The SB recommends that

operators eventually
upgrade adjustable length
end actuators to 7/16” dia Initial:
ON WING REPLACEMENT
rod ends within 11,000 FC 3/8” dia WITHIN 500 FC
Follow on:
• This can be incorporated SHOP UPGRADE to 7/16”
on attrition during dia WITHIN 11,000 FC
normal shop visits of end
actuators or thrust reversers If feasible, operators could install 7/16” adjustable or fixed
length actuators within 500 FC to preclude follow on action
66
GE Proprietary Information March 2012
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HPC Module, Rotor: 3-9 Spool AD Inspection Ref. C.I.
No. 12
AD 2002-25-08 – CF6-80C2 SBs 72-A0812, 72-A0848, 72-A0937
CF6-80E1 SBs 72-A0135, 72-A0126, 72-A0137
Ultrasonic and eddy current inspection for melt conditions and
dwell fatigue,1998, revised in 2003
CF6-80C2 Affects older (pre-1995) material
Total Engines 13" & 9/10" Billet Spools

4000

3500 Repeat inspection intervals get

smaller as part CSN increases
Number of Spools

3000

2500

2000
• 2000 CSLI for spools over 8000 CSN
• Will limit engine time on wing
1500

1000

500

0
Spools subject to 10,500 CSN re-use
2/95

1/96

4/96

3/97

2/98

1/99

4/99

3/00

2/01

1/02

4/02

3/03

2/04

1/05

4/05

3/06

2/07

1/08

Quarter / Year
limit
Adding notes to EM 05-11-02 identifying affected spools
New 5-piece spools not affected
• SB 72-0937 (80C2), 72-0144 (80E1)
Replace old material spools at ESV if over 8000 CSN 67
GE Proprietary Information March 2012
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CF6-80C2 LPT Overspeed Protection Ref. C.I.
No. 13
Category 5 Service Bulletin 72-1152 (November 2004)
If fan midshaft would separate, design intent is for axial
translation of LPT rotor to clash with LPT stator
• Clashing would break airfoils and act as a “brake” to slow rotor to
avoid free-running rotor and possible overspeed Unmodified Part
Analysis determined S4/S5 LPT nozzles inner
platform could provide “false bearing”
• Possible delay in clashing and
fragmentation of the blades
• Unloaded free rotor could continue Cut off inner
to run to overspeed band lip

GE Safety Board directed corrective redesign

cutback of LPT S4/S5 nozzle inner platform
• RD 934-234-S2 or later
– Set incorporation is required
Modified Part
68
GE Proprietary Information March 2012
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CF6-80C2/E1 HPT Stage 2 Nozzle Ref. C.I.
No. 14
AD 2004-22-07 – CF6-80C2 SBs 72-0952

For R80 Phase 1 HPT Stage 2 Nozzle :

 Repetitive BSI per SB 72-0952 and AD 2004-22-07
Phase 2 design not subject to
repetitive inspection per
Airworthiness Directive
 CF6-80C2 SB 72-0978 (R80)or
SB 72-1099 (N5)
 CF6-80E1 SB 72-0244 (N5)
 Phase 2 airfoil replacement
repair for either R80 or N5
– CF6-80C2 SB 72-1169

69
GE Proprietary Information March 2012
Subject to restrictions on the cover or first page GE Aviation
 CF6-80C2 HPT Stage 2 Nozzle

Ref. C.I.
Tech CF6 - HPT Stage 2 Nozzle (80C2/80E1) No. 14
CF6-80C2 SB 72-1291 and –80E1 SB 72-0385
INCREASE TRAIL REDUCE LEAD
VANE SUCTION- VANE SUCTION- Custom cooling air inserts
SIDE COOLING SIDE COOLING
• Custom cooling insert improves part durability,
scrap rate and lifecycle cost with no impact to
performance.
INCREASE TRAIL
• Reduced thermal stresses in nozzle segment by
VANE PRESSURE- improved distribution of cooling air
SIDE COOLING REDUCE LEAD
VANE PRESSURE- • Directly addresses top scrap rate driver for the
SIDE COOLING Phase 2 HPT nozzle
• Can be incorporated at FAB repair or new
make, SB 72-1286
• Successful endurance testing completed 2004
and 2006
• Piece-part interchangeable with current design

70
GE Proprietary Information March 2012
Subject to restrictions on the cover or first page GE Aviation
CF6-80C2/MD-11 Thrust Reverser Half Liberation Ref. C.I.
No. 15
AD 2006-06-08 … MD-11 Aircraft

Recommends mandatory incorporation of

78-1068R2 OR 78-1077R1 with compliance
time “at next normally scheduled
maintenance period or within 1,200 flight
hours time-in-service (TIS) after the
effective date of AD, whichever occurs
first.”
Recommends mandatory incorporation of
78-1088R5 AND 78-1078R1 with
compliance time “at the next normally
scheduled maintenance period or within
6,000 flight hours TIS after the effective
date of AD, whichever occurs first.”
This AD is intended to prevent liberation of
thrust reverser hardware at landing, which
can result in runway debris and a possible
hazard to other aircraft

71
GE Proprietary Information March 2012
Subject to restrictions on the cover or first page GE Aviation
CF6-80C2 747/767 Thrust Reverser Flex Shaft Ref. C.I.
No. 16
Service Bulletin 78-1168R2 (Category 2)
Previous flex shaft design prone to overload
failure
 High impact speeds during thrust
reverser actuation exceeds design
capability
 Compromises thrust reverser third Flex Shaft
line of defense
Improved flex shaft design
improved durability
 Manufacturer change Flex Failed Flex Shaft
 Core material change and Shaft
diameter increase
 Flex shaft braid winding change
 End fitting change TRAS
 Attachment of end fitting to core Lock
change
78-1168R2 released April 2011 with Upper End
installation record/ torque inspection data Actuator
sheets added.
• Torque inspection required every 1000
hours
• Send data sheets to MRAS Wire End Fitting
Wound
GE Proprietary Information Core 72
September 09
Subject to restrictions on the cover or first page GE Aviation
 Ref. C.I.
CF6-80C2 ECU Front Panel Improvement No. 17

SB 73-0386 & 73-0395 – Introduced Front Panel Assembly rework

Event fault reports and QAR/DFDR data point to ignition
excitation occurring at the time of the IFSD or GSD
• Cycle of the ignition system resulted in electrical noise within
the ECU due to ignition system relay contact bounce

SB73-0386 Issued to rework the ECU hardware containing the

latest PSS & FPA assemblies
• ECU P/N’s involved: 2121M38P01/P02, 2121M41P01/P02
• Jumper wire added across low side of the ECU ignition relays
• Ferrite bead added to high side of the ECU ignition relays
• Ignition relay noise is suppressed, so CPU faults no longer set
FAA Issued AD 2012-04-05 to mandate introduction of
reworked PN with the latest improvements.
SB 73-0396 issued to apply the same rework as in SB 73-0386
to ECU’s containing the latest FPA assemblies that addressed
ECU removals due to single channel EEC C1 EICAS message
• ECU PN’s 1471M63P42, 1519M89P32, 1820M33P15
73
GE Title or job number
10/2/2012
 Ref. C.I.
CF6-80C2 IDG Oil Cooler No. 18

Fuel Tube Flange Spray Shield

SB 73-0242 – Improve maintainability of flange joint
•Spray Shield •Spray Shield

•FLANGE •FLANGE
•IDG BRACKET

Three reports of incorrectly installed

•TOP VIEW
spray shields at the IDG Cooler •Incorrect assembly – •Correct assembly
bracket since 2006 improper seating of bolts

 Inspect seal for damage  Make sure tube flange is not hung-up
• Two fires – 2006 & 2012  Clean flange surface to ensure no
on the ferrule shoulder

debris and proper seating  Torque bolts in diagonal pattern to

ensure proper seating
• One fuel leak – 2012  Ensure proper positioning of
 Use proper torque on bolts per AMM
components

SB 73-0242 introduced in 1996

• Integrates the function of both •IDG oil
•cooler bracket
•IDG oil
•cooler bracket
the IDG bracket and spray
shield into one part
•IDG oil
• Changed to a Cat 3 after the •cooler
2006 event •IDG oil
•cooler •Spray shield
•Spray shield
•Spray shield incorrectly installed under •Spray shield correctly installed over IDG bracket
IDG bracket

74
GE Title or job number
10/2/2012
CF6-80C2 Fan Forward Inner Liner Bracket Ref. C.I.
No. 19

SB 72-1223 R2 – Improved Brackets

SB 72-1374 – On-Wing Inspection of Pre SB 72-1223 Brackets
Forward inner liner support bracket can
crack in operation
• Several events of bracket separation and
liner liberation
• Has caused significant thrust reverser
transcowl damage
New design improves bracket durability
• Introduced by SB 72-1223
• SB category revised to Cat 3 in SB 72-1223 R2
after increase in significant liberation events
On-wing inspection program introduced
to reduce chance of liner liberation
• Bracket inspection introduced by SB 72-1374
Cracked Bracket Transcowl Damage (Cat 2)… 400 cycle repetitive interval
(Secondary) • Only applies to pre-SB 72-1223 brackets
75
GE Proprietary Information March 2012
Subject to restrictions on the cover or first page GE Aviation
Maintenance Related Reliability
Ref. C.I.
No. 20

Maintenance Newsletters

GE has published a series of Maintenance Newsletters

• Issued with Fleet Highlights
• Topics selected based on fleet reliability data
Maintenance Newsletters inform maintainers of best
practices to avoid maintenance errors
• Training aid with suggested ways to prevent errors
Newsletters are available for your use
• Some customers use these letters in training or as
maintenance bulletins
• If you need a PowerPoint version, please let us know
76
GE Proprietary Information March 2012
Subject to restrictions on the cover or first page GE Aviation
 GE Transportation
Ref. C.I.
Maintenance Training Newsletter
CF6-80C2 & 80E Flanged Tube
No. 20

Newsletter Issue C F680C21005 • O ctober 2005

Installation
Example Loose Bolts and damaged seals…
High Speed Take-Off Abort
During t ake-off pri or to rotati on a CF6 -80C2 en gine had a loss of thrust. The cre w a borted the
take-off and three t ires were dam aged du ring deceler ation . Investigati on r evealed a fue l le ak at
the flang e jo int of the fue l d ischarge t ube between the fuel pump and main eng ine c ontrol. The
Engine location: Right hand side,
flange attachin g bo lts were found with l ow t orque. The bo lts were re-torq ued but the fue l le ak
Acces sory Gearbox
remained. The fu el tu be g asket seal was inspected and foun d to have damage to t he o -ring
portion of the seal. This eve nt resulted in a 37 hr fl ight delay. The tubi ng a nd fl ange construction
is the same for the CF6-8 0C2 and CF6 -80E1 engi nes.

Preventing these Errors Seal

Close-up
 When c hang ing accessories both ends Correct
of tubin g shou ld be l oose
Instal lation
 Slight differences in accessory Coupling
alignme nt will lead to t ubin g Flange
Tube
alignme nt differences.
 Ensure all bo lts pass throu gh th e
gasket holes befo re thre adin g i nto the Tu b e Fe rru l e
accessory housing. Training N ewsletter
Accessory Housing is published by GE Transportation
 No brackets shou ld b e loc ated
Customer Training Services.
between tube fl ange and accessory
housing. Leaks wi ll occ ur.
Flange Copyright, 2005
Instal lation with
 Finger ti ghten all bo lts first. Close-up General Electric Company
incorrect Flange
seating Product Support Engineering
 Evenly tighte n b oth en ds of tu be while 1-877-GEAE-CSC
ensuring fl ange remai ns centered on
Flange geae .csc@[Link] m
tube en d. Use cross-pattern seque nce
not
when t ighten ing & app lying torqu e. centered
For procedure steps or further information,
 Do not use tubi ng attach p oints to Reference EM Task 72-00-05 or contact your
force ali gnment of accessories an d GE Field Rep or CSC (1-877-GEAE-CSC) or
tubing. geae .csc@[Link] m.

 Damage to g asket seal mater ial

can result.
Inspect inserts and GE PROPRIETARY INFORMATION
 Damage to accessory inserts gasket seal
can result. material The information contained in thisdocument is GE
proprie tary information and is disclo sed in confidence. It
 Tube flan ge may not ce nter Brackets is the property of GE and shallnot be used,disclosed to
around tube end. on tube others or reproduced without the express written
side of consent of GE, inclu din g, but without limit ation, it isnot
 Check torq ues after fi nal assembly. flange to be used in the creatio n, manufacture, development,
Post-maintena nce le ak checks do not or derivation of any repair s, modificatio ns, spare parts,
always detect loose c onnecti ons. designs, or configuratio n changes or to obtain FAA or
any other government or regulatory approval to 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
document shall appear in any such reproduction in
whole or in part. The info rmation contained in this 77
GE Proprietary Information document may also be controlle d bythe [Link]
control laws. Unauthorized export or re -export is
March 2012
Subject to restrictions on the cover or first page prohibit ed. GE Aviation
This document is for training purposes only.
Maintenance newsletters – complete list
Ref. C.I.
No. 20
• CF6-80C2 Oil Pressure Sensing Tube Installation
• CF6-80E1 Tolerance Take-Up Unit & Stage 14 Tubes Installation
• CF6-80C2/-80E1 Flanged Tube Installation
• CF6-80C2/-80E1 FADEC Fuel Filter Pressure Differential Switch Installation
• CF6-80C2/-80E1 Oil Tank Cap Installation
• CF6-80C2/-80E1 Accessory Gearbox Drive Pad Cover Installation
• CF6-80C2/-80E1 HPT Stage 1 Nozzle Borescope Plug Installation
•
•
CF6-80C2/-80E1 Self-Locking Nuts Torque Check for Re-use
CF6-80C2/-80E1 Electrical System Cable Connector Maintenance
All Maintenance
• CF6-80C2/-80E1 Accessory Gearbox Carbon Seal Installation Newsletters are
• CF6-80C2 EGT Probe Maintenance
• CF6-80C2/-80E1 LRU Drive Shaft O-Ring Installation available on the GE
•
•
CF6-80C2/-80E1 VSV Actuator Rod End Installation
CF6-80E1 7th Stage Differential Pressure Switch
Customer Web Center
• CF6-80C2 IDG Oil Cooler Fuel Tube Flange Spray Shield (CWC) or from the GE
• CF6-80C2/-80E1 V-Band Clamp Coupling Assembly
• CF6-80C2/-80E1 4-Bolt Flange Fastener Condition Aviation Operations
•
•
CF6-80C2/-80E1 Tube System Clamps
CF6-80E1 Fuel Pump Strainer
Center
• CF6-80C2/-80E1 Abnormal Engine Operation Following Water Wash ([Link]@[Link])
• CF6-80C2/-80E1 Starter Oil Servicing
• CF6-80C2 Best Practices to Avoid FOD through VBV Doors
• CF6 All Fluid Line B-Nut Fittings Best Practices
• CF6-80C2 Fan Trim Balance
• CF6-80C2 FADEC Questions & Answers
• CF6-80C2/-80E1 Thrust Reverser Maintenance
• CF6-80C2 MFP Fuel Supply and Return Tubes
78
GE Proprietary Information March 2012
Subject to restrictions on the cover or first page GE Aviation
CRF Sump Vent Oil Impingement Tube Ref. C.I.
No. 21

CF6-80C2 SB 72-1265 Category 5 April 2007

CF6-80E1 SB 72-0367 Category 5 June 2007
Impingement tube cracks result in
Caution oversized dovetails blade High Oil Consumption
shims required
• 14 confirmed UER’s
• 5 confirmed In Flight Shut Downs
Redesign removes stress
concentration
• Removes the foil and tack welds from tube
• Removes the heat shield
CRF impingement tube recommended
repair at first exposure
Production Introduction Engines:
CF6-80C2: ESN 706-876
CF6-80E1: ESN 811-443
Impingement tube reliability is increased when
stress concentrations are removed
GE Proprietary Information
79
March 2012
Subject to restrictions on the cover or first page GE Aviation
CF6-80C2 EGT Thermocouple Probe On-Wing Ref. C.I.
No. 22
Inspection
CF6-80C2 Cat 2 SB 77-0050 Revision 4

Probe tip liberation has led to significant secondary

damage to the LPT including airfoil separation
On-wing resistance check inspection repeated every
500 cycles or concurrently with HPT borescope
inspection
Begin at EGT probe age threshold of 2800 CSN
Applies to P/N 9373M91P03/P05 and also
1696M81P10/P12/P16
• P/N 1696M81 probes are alternate supplier introduced
in 1996 (same support design as P/N 9373M91 probes)
Shop inspection no longer terminates inspection
* 80E1 only has later standard EGT probes
80
GE Proprietary Information March 2012
Subject to restrictions on the cover or first page GE Aviation
No. 4 Ball Bearing – CESM 204 Ref. C.I.
No. 23

4B bearing is highest loaded bearing

• Core thrust bearing operating at N2 speed
• Made from M50 NIL (vs. just M50)
• M50 NIL material for improved fatigue life
• More sensitive to hard particle type damage
• Surface defects significantly affect the bearing life
• Requires the stringent inspection / handling etc. criteria

Most fleetwide failures occurred shortly after shop visit

• Contamination likely introduced at the shop visit

CESM 204 revision 1 issued Jan 2002

• Provides best practice recommendations that will help extend the
serviceable life of bearings and help prevent costly operational events due
to bearing failures
- Bearing Inspection - Bearing Refurbishment
- Bearing Cleaning - Bearing Handling
- Bearing Assembly - Bearing Preservation
- Engine Transportation - More
81
GE Proprietary Information March 2012
Subject to restrictions on the cover or first page GE Aviation
IGB Horizontal Gearshaft Spline Wear Ref. C.I.
No. 24

Service Bulletins 72-1230 (-80C2) and 72-0333 (-80E1)

Worn splines IGB gear shaft spline wear leads to

decoupling of gearbox from core
• IFSD, ATB, UER can result
Clogged oil nozzles are the leading
cause of IGB spline wear
• BSI of nozzle and backlash check
Introduced a screen in the nozzle
• Prevents contamination of oil jets at
#3R and IGB spline lube nozzle

New nozzle improves reliability of

the gearshaft splines
New oil nozzle
82
GE Proprietary Information March 2012
Subject to restrictions on the cover or first page GE Aviation
Oil Pressure Pressure Tube System Ref. C.I.
No. 25

CF6-80C2 SB 79-0086 Cracks of oil pressure sensor tube

• Causes in-flight shutdowns or flight diversions due to oil
loss
Crack • Most of the events occurred after some maintenance
locations activity
Baseline

• All reports involved missing or broken manifold support

clamps
• 31 since 2001
New design improves stress margin
• System vibration response outside stimulus range
• Improves maintainability
– Tubes separated to ease assembly and component
replacement
Integral – Integral tabs assure proper support and helps prevent
tabs forgotten clamp
Redesign

Initial oil spine tube quality escape is resolved

Improved bracket rework definition
forthcoming in revision 1 expected in April
New system is less like to have missing clamps

83
GE Proprietary Information March 2012
Subject to restrictions on the cover or first page GE Aviation
IGB Gearshaft PTFE Seal Debonding Ref. C.I.
No. 26
Service Bulletins 72-1186 & 72-1193 (-80C2)
72-0313 & 72-0324 (-80E1)

Piece of seal found in Inlet gearbox (IGB) gear shaft PTFE (Teflon®)
pump inlet from TGB seal adhesion loss (debond) can result in oil
hiding and oil leakage
• IFSD, ATB, UER can result
Two Service Bulletins
• Repetitive replacement of the PTFE seal
• Rework of IGB horizontal gearshafts

New design removes PTFE and

ID of gear shaft with replaces with nickel graphite
damaged seal Old design – must replace PTFE per
recommended interval
Inspecting the gearshafts via the limits in the service bulletin or
reworking/replacing seals significantly reduces chance for disbond
84
GE Proprietary Information March 2012
Subject to restrictions on the cover or first page GE Aviation
TRF Oil Tube Coking TRF Tubes
Ref. C.I.
No. 27
No. 6 Oil Nozzle
No. 6 Sump

CF6-80C2 and 80E1 CESM 09

TRF tubes are in close

proximity to the struts Oil Scavenge
• Results in rapid heat
transfer to the tubes
CESM 09 Issued for
CF6-80C2 & -80E1 Oil Supply
• Oil servicing recommendations
2x .046
dia.

– Changing or mixing of brands Detached coke

particles obstruct oil
– Use of HTS oils recommended jets

– Inspection recommendations
• Operational recommendations
– Idle a minimum of 3 minutes prior to shutdown 1x .035

– Tube cleaning recommendations

dia.

– Oil pressure trending recommended Cross section through nozzle

85
GE Proprietary Information March 2012
Subject to restrictions on the cover or first page GE Aviation
CF6-80C2 Thermal Shield Ref. C.I.
No. 28

Thermal shield cracking continues in field

• Scrap stage 1 and stage 2 HPT disks if thermal
shield crack remains axial
• Extensive HPT airfoil and LPT damage if crack
turns circumferential and part of thermal shield is
liberated (chunk-out)
• To date, all occurrences were on older parts
subjected to hard rubs during test cell break-in run
Recommendations
Perform eddy current inspections define in
engine shop manual at piece part opportunity
• FPI alone may not find all cracks
Retire high cycle thermal shields
• Especially those manufactured with tight
clearances (pre-1997) … thermal shield serial
numbers that begin with “BTA”

86
GE Proprietary Information March 2012
Subject to restrictions on the cover or first page GE Aviation
HPT Blade Corrosion Coating
Stage 1 Tech CF6 Blades… Service Bulletin 72-1288 (R142)
Ref. C.I.
Service Bulletin 72-1296 (N5) No. 29
Stage 1 Coating Repair… Service Bulletin 72-1269
Stage 2 Tech CF6 Blades… Service Bulletin 72-1283
Stage 2 Coating Repair… Service Bulletin 72-1271

S1/S2 HPT blade corrosion

coatings
S1 HPT S2 HPT • Reduces shank corrosion with no
Blade Blade impact to performance
• Prevents potential blade shank
separation due to cracking from
corrosion pits
• Reduces blade scrap rates…
lowers overall lifecycle cost
• Piece-part interchangeable with
current design
Coated area of parts
87
GE Proprietary Information March 2012
Subject to restrictions on the cover or first page GE Aviation
CF6-80C2 Bleed Flow Sensor (PMC Engines) Ref. C.I.
No. 30
Service Bulletin 75-0202 (Category 3)

G01 Sensor housings cracking in high cycle

fatigue (HCF) mode
• Cause Fire Warnings, IFSD & Engine
overheat message
Contributing factors determined to be
V-band clamp over-torque and duct
misalignment leading to clamp yielding
Corrective Action:
• Material change from 300 series
stainless steel to INCO 718
– Originally released as Cat 8, SB 72-1044
May 2001
– Cat 3 , SB 75-0202 issued July 2006
• Introduction of V-Band coupling standard practices
88
GE Proprietary Information March 2012
Subject to restrictions on the cover or first page GE Aviation
CF6-80C2 Improved LPT Shrouds Ref. C.I.
No. 32

AD 2003-02-07… Service Bulletin S2-1006

LPT shrouds per SB 72-1006 provide the required
improvement (stages 2, 3, and 4):
• Address any future unknown / special causes of blade
fragment liberation
• Address the variation in compliance to the prime root
cause programs
• Airworthiness Directive (AD) 2003-02-07 was effective on
the 3rd March 2003:
– Mandates the incorporation of the LPT shrouds having
the improved containment capability at next piece part
exposure but no later than the 31st July 2010
– Stages 1 and 5 are not affected.

89
GE Proprietary Information March 2012
Subject to restrictions on the cover or first page GE Aviation
 HPC Module, Stator: VSV S5 Long Lever Arm Ref. C.I.
No. 33

CF6-80C2 SB 72-1081; CF6-80E1 SB 72-0237

Lever arm length increase shifts
unison ring aft 0.255. Lever Inco 718

Improved Stage 5 lever arm

Bridge connector flipped 180 with shot peening
to avoid interference with

system ~80% incorporated

offset yoke
SB 72-1074 bushings

System is performing
Rework bridge connector similar significantly better than old
to SB 72-944 required to prevent
interference with arm system
No change to actuator New clevis required. GE recommends replacing
or control system New rig angles
lever arms at SV
Clevis connection moves
New master lever forward 1.8 inches • Issued 2003 with Revision in
Sept. 2007
New VSV System • Leading Indicators program to
review improved reliability
New Stage 5 Lever Arm System is Performing Well
90
GE Proprietary Information March 2012
Subject to restrictions on the cover or first page GE Aviation
 11th Stage Air Tube – FADEC Engines Ref. C.I.
No. 35
CF6-80C - Service Bulletin 75-0156 for Post 75-0060 engines
CF6-80C - Service Bulletin 75-0200 for Pre 75-0060 engines

Ruptured 11th The 11th stage air tubes on

stage duct on
original FADEC
FADEC engines are changed
system to a twin pipe, PMC type
design
• Stress in the original
Twin pipe FADEC system caused tube
(PMC style) ruptures resulting in IFSD
design
• The PMC style design is
more reliable

Twin pipe 11th stage system has eliminated reliability issues

91
GE Proprietary Information March 2012
Subject to restrictions on the cover or first page GE Aviation
HPT Stage 1 Blades
Ref. C.I.
No. 37
Tech CF6HPT Stage 1 Blade
(SB 72-1288 & 72-1296 80C2/72-0388 80E1)
S1 HPT blade cooling improvements
• Reduced S1 Blade scrap rates – reduced
overall lifecycle cost by reducing peak
tip temperatures and improve
resistance to tip distress / cracking
Area of • Performance retention benefits-
change prevents heavy tip oxidation which
leads to increased tip clearance
• Piece-part interchangeable with
previous design
• Cooling technology incorporated on
both DSR142 and N5 material blades
92
GE Proprietary Information March 2012
Subject to restrictions on the cover or first page GE Aviation
HPT Module
Blade corrosion coating Ref. C.I.
Tech CF6-80C2 No. 38

New stage 2 blades: CF6-80C2 SB 72-1283

S2 HPT blade with corrosion coatings

• Reduces shank corrosion with no
impact to performance
• Reduces blade scrap rates… lowers
overall lifecycle cost
• Piece-part interchangeable with
current design

Corrosion Coating
93
GE Proprietary Information March 2012
Subject to restrictions on the cover or first page GE Aviation
Tech CF6 Blade and Vane Erosion
Coatings CF6-80C2
Ref. C.I.
CF6-80C2 SB 72-1242, -1243, -1244* & -1245 No. 39

Erosion coated parts offered:

• Blade stages 1,2,6 thru 14 *
• Vane stages 6 and 10
Offered as an upgrade for operators in
erosive environments
Testing and CFM56 experience indicate
50% increase in erosion life
Existing serviceable parts can have
coatings applied

Erosion Coated Stage 6 Vane Coated parts completely interchangeable

with uncoated

* SB 72-1244 on-hold pending investigation of tip cracks

observed in stages 10, 11, and 14
94
GE Proprietary Information March 2012
Subject to restrictions on the cover or first page GE Aviation
HP Recoup Tube Ref. C.I.
No. 41
CF6-80C – Service Bulletin 75-0167 (FADEC)
CF6-80C – Service Bulletin 75-0168 (PMC)
Cracking and rupture of right side HP recoup
air tube have caused high undercowl
temperatures
• Some resulted in in-flight shutdowns
• Caused by high cycle fatigue
A bracket and retaining strap are added at
the CRF/HPT flange
• This new bracket supports the HP recoup
air tube and eliminates HCF
• The new hardware is easier to install
Category 4 SB – do when part is exposed

95
GE Proprietary Information March 2012
Subject to restrictions on the cover or first page GE Aviation
CRF Module - CRF Oil Supply Manifold
CF6-80C2 SB 72-1278 Category 5 September 2008 Ref. C.I.
No. 42

Metal loop clamp slides off wear

sleeve and wears into tube wall
Oil loss can occur when tube wall
wear is excessive
Typical wear
New design introduces a brazed
on tab to prevent clamp moving
off wear sleeve
Longer wear sleeve accounts for
full clamp movement
At each clamp location 1 clamp is
Production Introduction Engine
replaced with a brazed on tab • CF6-80C2: ESN 706933

Integrated tabs provide better support and prevent

clamps from slipping off wear sleeves
96
GE Proprietary Information March 2012
Subject to restrictions on the cover or first page GE Aviation
CRF Module – AFLAS O-Rings
CF6-80C2 SB 72-1107 Ref. C.I.
No. 43
CF6-80E1 SB 72-0314
Oil wetting is sometimes seen on the CRF
case, external tubes and heat shield at
the 6:00 location
• Problem may be due to “crystallized” O-
rings in the B-sump area
AFLAS material was chosen as best
combination of performance and cost
• Result of CF6-80C2 Field Service Evaluation
(FSE) Program that was conducted to
identify valid O-ring materials that were
more tolerant of high temperatures

97
GE Proprietary Information March 2012
Subject to restrictions on the cover or first page GE Aviation
HPT Stage 1 Disk Inner Transition Radius Erosion Ref. C.I.
No. 44
Current Released Programs - In718 Rotors
CF6-80C2 - Service Bulletin 72-0816

Erosion Background
PTSN: 42769 Hours • SB 72-0816, issue Aug 2005
PCSN: 6682 Cycles
P/N: 1531M84 • One configuration fits field disks and new
S/N: RPMCM155 production components
• Flow baffle can be installed either way
(no “fwd” mark required)
• No effect on life limiting locations of disk
Baffle
• No impact on the chapter 5 disk lives in
installed the engine manual
in disk
• A one run expendable component
• New HPT stage 1 disk design (SB 72-
1313) eliminates inner transition feature
so it is not subject to erosion

98
GE Proprietary Information March 2012
Subject to restrictions on the cover or first page GE Aviation
Fan Case Corrosion Ref. C.I.
No. 45
CF6-80C2 – Service Bulletin 72-1196
Fan Case P/N 1821M34G10/11 is latest design
Increasing reports of corrosion:
• OD where Kevlar cover meets the Al fan case
• ID under forward outer liners and/or doubler
plates
• Some operators have reported more than
others due to corrosion awareness

Recommend taking preventive corrosion

measures at next SV, Green Polyurethane
protection on ID and OD of case

G10/G11 Design Improvements:

• Polyurethane added to ID and OD for
additional protection between forward flange
and Kevlar containment
• Doublers are zinc-chromate coated for
corrosion resistance
99
GE Title or job number
10/2/2012