SB 78-5120

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Middle River Aircraft Systems

CF6-80E1 SERVICE BULLETIN

EXHAUST - Fan Reverser – Improved Precooler Inlet Fairing Assembly and Cover Assembly

29 November 2012 CF6-80E1 S/B 78-5120Page 1 of 19

MRAS PROPRIETARY INFORMATION

The information contained in this document is Middle River Aircraft Systems proprietary information andis disclosed in confidence. It is the property of Middle River Aircraft Systems and shall not be used,disclosed to others or reproduced without the express written consent of Middle River Aircraft Systems,including, but without limitation, it is not to be used in the creation, manufacture, development, orderivation of any repairs, modifications, spare parts, designs, or configuration changes or to obtain FAAor any other government or regulatory approval to do so. If consent is given for reproduction in whole orin part, this notice and the notice set forth on each page of this document shall appear in any suchreproduction in whole or in part.

This technical data is considered EAR controlled pursuant to 15 CFR Parts 730-774 respectively.Transfer of this data by any means to a Non-US Person, whether in the United States or abroad, without

the proper U.S. Government authorization (e.g., License, exemption, NLR, etc.), is strictly prohibited.

All technical documentation and information contained herein, with respect to assembly and disassembly,cleaning, inspection methods and limits, repair methods and limits, operational limits, life limits and thelike, have been developed and approved for use with fan reversers and parts that have beenmanufactured and/or approved by Middle River Aircraft Systems and that have been maintained inaccordance with Middle River Aircraft Systems technical documentation and recommendations. MiddleRiver Aircraft Systems has no contractual or legal obligation for, nor knowledge of, non-MRAS-approvedparts and repairs. Accordingly, this document is not intended to apply to non-MRAS-approved parts andrepairs.

Copyright (2012) Middle River Aircraft Systems, MRA Systems Inc. – A Subsidiary of GE

1. PLANNING INFORMATION

A. Effectivity

CF6-80E1A2, A3, A4, A4/B

(1) Precooler Inlet Fairing Assemblies Part Number (PN) 491B1341008-009 and Precooler InletCover Assemblies PN 491B1341004-009 & -019 installed on CF6-80E1 fan reversersmounted on A330 airplanes or stocked as spares are affected.

(2) Precooler Inlet Fairing Assemblies PN 491B1341010-009 and Precooler Inlet Cover Assemblies PN 491B1341009-009 will be introduced in production for the CF6-80E1 fanreversers listed below:

(A330) R553/554-024 and up, R555/556-445 and up

B. Concurrent Requirements

None

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29 November 2012 CF6-80E1 S/B 78-5120Page 2

MRAS PROPRIETARY INFORMATION – Subject to the restrictions on the first page.

1. C. Description

The Precooler Inlet Fairing Assembly and the Precooler Inlet Cover Assembly on CF6-80E1 FanReverser Core Cowls are cracking in service. There have been sixteen confirmed reports ofcracking since 2005. Cracks appear to be initiated by wear-through of fairing fastener holesfollowed by cracking of the fairing and the cover.

Improved Precooler Inlet Fairing Assembly and Improved Precooler Inlet Cover Assembly havebeen designed to prevent or reduce cracking. Installation of dimpled washers under fastenerheads for the fairing assembly will reduce bearing stresses and prevent fasteners from wearingthrough the fairing surface.

This Service Bulletin provides instructions to replace the Precooler Inlet Fairing Assembly and thePrecooler Inlet Cover Assembly.

This Service Bulletin can be accomplished on-wing or in the shop.

D. Compliance

Category 4

Do when the precooler inlet is exposed and can be accessed for maintenance without effect onrevenue service.

E. Reason

Objective:

To install Improved Precooler Inlet Fairing Assemblies and Improved Precooler Inlet Cover Assemblies on CF6-80E1 Fan Reversers

Condition:

The Precooler Inlet Fairing Assembly and the Precooler Inlet Cover Assembly on CF6-80E1Fan Reverser Core Cowls are cracking in service.

Cause:

Cracks appear to be initiated by wear-through of fairing fastener holes followed by cracking ofthe fairing and cover. Observations of the structures suggest high frequency vibrations as thesource of damage.

Improvement:

Improved Precooler Inlet Fairing Assembly and Improved Precooler Inlet Cover Assembly havebeen designed to prevent or reduce cracking. Installation of dimpled washers under fastenerheads for the fairing assembly will reduce bearing stresses and prevent fasteners from wearingthrough the fairing surface.

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1. E. (Continued)

Substantiation:

Substantiation is by comparative analysis and analysis.

F. Approval

This Service Bulletin contains no modification information that revises the approved configurationand therefore does not require FAA approval.

G. Manpower

After you get access to the precooler inlet, allow approximately 2 man-hours (3 man-hours on-wing) to replace the Precooler Inlet Fairing Assembly and the Precooler Inlet Cover Assembly.

Allow approximately 1 man-hour to prepare the SPD Precooler Inlet Cover Assembly and the SPDShim for installation.

H. Weight and Balance

Weight is increased by an estimated 0.55 lbs per fan thrust reverser. Balance is not affected.

I. References

GE Aircraft Engines Commercial Engine Standard Practices Manual, GEK 9250 Airbus A330 Aircraft Maintenance Manual (AMM)CF6-80E1 Fan Reverser Component Maintenance Manual (CMM) MR 99440

For MRAS internal use: ECS 10-00712 Revision 2

J. Publications Affected

CF6-80E1 Fan Reverser Illustrated Parts Catalog (IPC) MR 99379

K. Interchangeability

This design improvement is one-way interchangeable.

Precooler Inlet Fairing Assembly PN 491B1341008-009 is superseded by Precooler Inlet Fairing Assembly PN 491B1341010-009. Precooler Inlet Fairing Assembly PN 491B1341010-009 shallnot be replaced by Precooler Inlet Fairing Assembly PN 491B1341008-009.

Precooler Inlet Cover Assemblies PN 491B1341004-009 and PN 491B1341004-019 aresuperseded by Precooler Inlet Cover Assembly PN 491B1341009-009 or by SPD Precooler InletCover Assembly PN 491B1341009S009. Neither Precooler Inlet Cover Assembly PN491B1341009-009 nor SPD Precooler Inlet Cover Assembly PN 491B1341009S009 shall bereplaced by Precooler Inlet Cover Assembly PN 491B1341004-009 or by Precooler Inlet Cover

Assembly PN 491B1341004-019.

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2. MATERIAL INFORMATION

A. Material – Price and Availability

(1) Parts necessary to do this Service Bulletin:

Part NumberQuantityper Fan

ReverserPart Name

2012Unit Price

($)

PkgQty

LeadTime

(Days)

491B1341009-009 1 Cover Assembly 670.00 1 30OR491B1341009S009 1 Cover Assembly (SPD) 653.00 1 30

491B1341010-009 1 Fairing Assembly 696.00 1 30

491B1341011-001 1 Shim (Filler) 125.00 1 30OR491B1341011S001 Shim (Filler) (SPD) 215.00 1 30

NAS1153E3 5 Screw 2.00 50 30

NAS1169C10 7 Dimpled Washer 0.30 100 30

Obtain the parts listed above from Aviall Services, Inc. Send a Charge Purchase Order (thePurchase Order should include the part numbers listed above and the number of this ServiceBulletin) to:

Aviall Services, Inc2750 Regent BlvdDFW Airport, TX 75261

SITA Address: DALAVXD

Toll Free: 800-284-2558Toll Free Fax: 800-329-2842

International: 972-586-1435International Fax: 972-586-1361

Website: www.aviall.com

AOG: 1-800-AVIALL-1

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2. A. (Continued)

(2) Consumables:

NOTE: Middle River Aircraft Systems does not supply consumables. Refer to GE AircraftEngines Commercial Standard Practices Manual (SPM), GEK 9250, for sources ofsupply.

Code Number Description

C01-007 or equivalent RTV-106 (Red Sealant)

C01-014 or equivalent Sealant, Primer, Adhesive Silicone

C01-073 Temperature Resistant Sealing Compound

(Aero Sealant PR1750)

C03-077 or equivalent Epoxy Resin Primer

B. Industry Support Information

None

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2. C. Configuration Chart

*** CF6-80E1A2, A3, A4, A4/B ***

New Part NumberQty /F/RHalf

Part NameOld Part Number /

IPC LocationQty /F/RHalf

OpCode

Chg /SprtCode

(Production / Field)

491E1340000-079 (X) Core Cowl Assembly(Left Hand)

491E1340000-07978-32-21-1-810

(X) RM - / -

.491B1341009-009

.491B1341009S009

1

ALT

Cover Assembly,Precooler InletSPD Cover Assy

.491B1341004-009

.491B1341004-01978-32-21-30-120

1 ALT RE 1 / A

.491B1341011-001

.491B1341011S0011

ALTShim (Filler)SPD Shim (Filler)

.491B1340000-00778-32-21-30-135

1 RE 1 / A

.491B1341010-009 1 Fairing Assembly,Precooler Inlet

.491B1341008-00978-32-21-30-140

1 RE 1 / A

.NAS1153E3 5 Screw .NAS1153E278-32-21-30-160

5 RE 1 / A

.NAS1169C10 7 Washer, Dimpled, 100° ---------- --- AD 5 / -

Change Code Operation Code1 = One-way interchangeable AD = Add5 = Parts added RE = Replace

RM = RemainsSpare Parts Support Code

A = Old parts will no longer be supplied.

D. Parts Disposition

Discard removed precooler inlet fairing assemblies.Discard removed precooler inlet cover assemblies.Discard removed, unserviceable shims.Discard removed Screws PN NAS1153E2.

E. Tooling

Mechanic’s hand tools including drill, drill bits, drill reamer bits and clampsDrill PressSharp knife or equivalent for cutting aero sealantPlastic knife to scrape away MA-25S insulation

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3. ACCOMPLISHMENT INSTRUCTIONS

A. Job Set-up

WARNING: MAKE CERTAIN THAT CIRCUIT BREAKERS ARE OPEN, SAFETIED, ANDTAGGED BEFORE ATTEMPTING MAINTENANCE PROCEDURES.INADVERTENT ENGINE START OR FAN REVERSER OPERATION COULDRESULT IN DEATH OR SERIOUS INJURY TO PERSONNEL. MAKE CERTAINTHAT THROUGHOUT THE JOB SET-UP, THE AIRCRAFT PNEUMATIC SYSTEMIS NOT PRESSURIZED BY PNEUMATIC GROUND POWER, APU, OR ANOTHERENGINE.

(1) Open, safety, and tag the appropriate circuit breakers per A330 Aircraft Maintenance Manual(AMM) Subtask 78-31-00-865-051.

WARNING 1: IF ANY INSPECTION/MAINTENANCE IS TO BE PERFORMED WITH THETRANSLATING COWL DEPLOYED, REMOVE THE AIR SUPPLY FROM THEFAN REVERSER SYSTEM. WITH THE AIR SUPPLY CONNECTED, PARTIALLOSS OF ELECTRICAL POWER (I.E., LOSS OF ELECTRICAL POWER TO THEDPV WITH THE PRSOV ENERGIZED) COULD CAUSE THE TRANSLATINGCOWL TO STOW. INADVERTENT STOW COULD RESULT IN DEATH ORSERIOUS INJURY TO PERSONNEL.

WARNING 2: CLEAR THE AREA AROUND THE FAN REVERSER OF PERSONNEL ANDEQUIPMENT TO PREVENT INJURY OR DAMAGE IN CASE OFUNCOMMANDED FAN REVERSER OPERATION.

(2) Refer to Figure 1. Get access to the Precooler Inlet Cover Assembly (Item 120) and the

Precooler Inlet Fairing Assembly (Item 140).

B. Remove the Precooler Inlet Cover Assembly.

(1) Refer to Figure 1. Using a sharp knife or equivalent, cut the aero sealant around the edge ofthe Precooler Inlet Cover Assembly (Item 120).

(2) Remove the Precooler Inlet Cover Assembly (Item 120) and the Shim (Item 135) by removingthirteen Screws (Item 95) and by removing five Screws (Item 160) as shown in Detail B.Temporarily retain the Precooler Inlet Cover Assembly. Discard the Shim if it isunserviceable; it is the option of the operator to re-use the Shim if it is serviceable. Retainthe thirteen Screws (Item 95). Discard the five Screws (Item 160).

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3. C. Remove the Precooler Inlet Fairing Assembly.

(1) Refer to Figure 1. Using a sharp knife or equivalent, cut the aero sealant around the edge ofthe Precooler Inlet Fairing Assembly (Item 140).

(2) Refer to Detail B. Remove the two Screws (Item 95) that attach the Precooler Inlet Fairing Assembly (Item 140). Retain both screws.

(3) Refer to Detail C. Use a plastic knife to scrape gently MA-25S insulation from the six Nuts(Item 180). Remove the Precooler Inlet Fairing Assembly (Item 140) by removing six Bolts(Item 165, six Washers (Item 170), six Washers (Item 175) and six Nuts (Item 180). Discardthe Precooler Inlet Fairing Assembly. Retain the bolts, washers and nuts.

D. Determine if Improved Precooler Inlet Cover Assembly PN 491B1341009-009 can be installed.

(1) Refer to Figure 2. To determine if Improved Precooler Inlet Cover Assembly PN491B1341009-009 can be installed, check the hole pattern along the long edge of theImproved Precooler Inlet Cover Assembly with the hole pattern along the long edge of thetemporarily retained Precooler Inlet Cover Assembly PN 491B1341004-009/-019.

(a) If the hole patterns match, discard removed Precooler Inlet Cover Assembly PN491B1341004-009/-019, and proceed to Section 3.F. to install Improved Precooler InletCover Assembly PN 491B1341009-009 and the Improved Precooler Inlet Fairing

Assembly.

(b) If the hole patterns do not match, it will be necessary to install SPD Improved PrecoolerInlet Cover Assembly PN 491B1341009S009. Proceed to Section 3.E. to prepare theSPD Improved Precooler Inlet Cover Assembly for installation.

E. Prepare SPD Improved Precooler Inlet Cover Assembly and SPD Shim for installation.

(1) Prepare SPD Improved Precooler Inlet Cover Assembly for installation.

(a) Make a template of the nine hole locations along the long edge of the outer surface of theremoved Precooler Inlet Cover Assembly PN 491B1341004-009/-019. The template willbe used to transfer the nine hole locations to the SPD Improved Precooler Inlet Cover

Assembly.

(b) Clamp the template to the long edge of the outer surface of the SPD Improved PrecoolerInlet Cover Assembly PN 491B1341009S009 so that the nine template holes are locatedon the SPD Improved Precooler Inlet Cover Assembly to match the hole locations onremoved Precooler Inlet Cover Assembly PN 491B1341004-009/-019.

(c) Back drilling from the template, spot drill the SPD Improved Precooler Inlet Cover Assembly using a #8 drill to mark the nine hole locations.

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3. E. (1) (Continued)

(d) Remove the template from the SPD Improved Precooler Inlet Cover Assembly and finishdrill the 0.199-inch diameter holes through the SPD Improved Precooler Inlet Cover

Assembly using a #8 drill. Open the 0.199-inch diameter holes to 0.218 to 0.224-inchdiameter using a #2 drill. (A drill press is recommended. A drill reamer bit isrecommended for drilling the 0.218 to 0.224-inch diameter holes.)

(e) On the outer surface of the SPD Improved Precooler Inlet Cover Assembly, countersinkthe nine holes 0.376 to 0.385 inch X 100°. Deburr the holes. Apply a coat of epoxy resinprimer (C03-005) to the nine newly drilled holes.

NOTE: The inner surface of the SPD Improved Precooler Inlet Cover Assembly has fivenut plates installed.

(f) Discard the removed Precooler Inlet Cover Assembly PN 491B1341004-009/-019.

NOTE: If the Shim removed in Step 3.B.(2) is serviceable, and if the operator chooses to re-useit, preparation of the SPD Shim is not necessary.

(2) Prepare SPD Shim for installation.

(a) Refer to Figure 3 for an illustration of the SPD Shim.

(b) Clamp the SPD Shim to the inner surface of the long edge of the newly drilled SPDImproved Precooler Inlet Cover Assembly PN 491B1341009S009 so that the nine newlydrilled holes are located on the center line of the SPD Shim. Position the SPD Shim sothat the outermost holes along the long edge of the newly drilled SPD Improved

Precooler Inlet Cover Assembly are the same distance from each end of the SPD Shim.

(c) Back drilling from the newly drilled SPD Improved Precooler Inlet Cover Assembly, spotdrill the SPD Shim using a #8 drill to mark the nine hole locations on the SPD Shim.

(d) Remove the SPD Shim from the newly drilled SPD Improved Precooler Inlet Cover Assembly. Finish drill the 0.199-inch diameter holes through the SPD Shim using a #8drill. Open the 0.199-inch diameter holes to 0.218 to 0.224-inch diameter using a #2 drill.(A drill press is recommended. A drill reamer bit is recommended for drilling the 0.218 to0.224-inch diameter holes.)

(e) Deburr the holes in the SPD Shim. Apply a coat of epoxy resin primer (C03-005) to thenine newly drilled holes.

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3. F. Install the Improved Precooler Inlet Fairing Assembly and the Improved Precooler Inlet Cover Assembly

(1) Inspect all retained fastening hardware for serviceability before re-installing on the fanreverser. Replace unserviceable fastening hardware.

(2) Refer to Figure 1, Detail C. Install the Improved Precooler Inlet Fairing Assembly (Item 140)using the retained six Bolts (Item 165), six Washers (Item 170), six Washers (Item 175) andsix Nuts (Item 180). Do not tighten the nuts at this time.

(3) Refer to View B and Detail B. Do a trial fit of the Improved Precooler Inlet Cover Assembly(Item 120) on the Improved Precooler Inlet Fairing Assembly (Item 140). Adjust the twoassemblies for optimum alignment of fastener holes. Hold the Improved Precooler InletFairing Assembly in place and remove the Improved Precooler Inlet Cover Assembly.

(4) Refer to Detail B. Install the two retained Screws (Item 95) and two new Dimpled Washers(Item 163) to attach the Precooler Inlet Fairing Assembly (Item 140). Tighten both Screws(Item 95) to 24-27 lb-in. (2,7-3,1 N.m).

(5) Refer to Detail C. Tighten the six Nuts (Item 180) to 24-27 lb-in. (2,7-3,1 N.m).

(6) Repair MA-25S insulation coating damaged as a result of fastener removal per CF6-80E1Fan Reverser Component Maintenance Manual MR 99440 78-32-02 Repair 022 Section 7.

(7) Refer to Figure 1, Detail B. Install the Improved Precooler Inlet Cover Assembly (Item 120)and new or re-used Shim (Item 135) using the retained thirteen Screws (Item 95). Nextinstall five new Screws (Item 160) and five new Dimpled Washers (Item 163). Tighten thethirteen Screws (Item 95) and five Screws (Item 160) to 24-27 lb-in. (2,7-3,1 N.m).

(8) Apply Aero Sealant PR1750 (C01-073) to the edges and gaps of the Improved PrecoolerInlet Fairing Assembly and to the edges and gaps of the Improved Precooler Inlet Cover

Assembly as shown in Figure 4.

G. Job Close-up

(1) Make certain the working area is clean and clear of tools and miscellaneous items ofequipment.

(2) Remove safety clips and tags and close previously opened circuit breakers.

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MR70669-01-A

Replacement of Precooler Inlet Cover Assembly and Fairing AssemblyFigure 1, Sheet 1 of 5

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MR70670-02-A


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MR70671-01-A


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MR71018-01-A


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MR71019-00-A


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Legend for Figure 1

ItemNo.

Part Name Part Number Quantity SB 78-5120 Accomplishment

Instructions / Notes

10 Core Cowl Bondment Assembly

491B1342000-059 1 Remains

90 Precooler Inlet 491B1341000-009 1 Remains

95 Screw NAS1102E3-12 15 Remove, retain and re-use.

120 Precooler Inlet Cover Assembly

491B1341004-009 or

491B1341004-019(Removed)

491B1341009-009 or491B1341009S009(Installed)

1

Remove and discard.

Install.(S009 is a SPD.)

135 Shim (Filler)

491B1340000-007(Removed)

491B1341011-001 or491B1341011S001(Installed)

1

Remove and discard.

Install.(S001 is a SPD.)

140 Precooler Inlet Fairing Assembly

491B1341008-009

(Removed)

491B1341010-009(Installed)

1

Remove and discard.

Install.

160 Screw

NAS1153E2(Removed)

NAS1153E3(Installed)

5

Remove and discard.

Install.

163 Washer, Dimpled NAS1169C10 7 New for designimprovement. Install.

165 Bolt MS20033-3 6 Remove, retain and re-use.

170 Washer AN960C10L 6 Remove, retain and re-use.

175 Washer AN960C10 6 Remove, retain and re-use.

180 Nut MS21043-3 6 Remove, retain and re-use.

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MR71020-00-A

Precooler Inlet Cover AssembliesFigure 2

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MR71021-00-A

Shims (Fillers) for Precooler Inlet Cover AssembliesFigure 3

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MR71022-00-A

Application of Aero Sealant PR-1750 (C01-073)Figure 4

Documents

SB 78-5120