AD 2006-16-06

You are responsible for having the actions required by this AD performed within the compliance times specified unless the actions have already been done.

At the next piece-part exposure, for stage 1 HPT rotor disks, P/N 9362M58G09, with serial numbers (SNs) listed in Table 2 of this AD, do the following, unless already done using superseded AD 2004-04-07:

(1) Visually inspect the rotor disks for the presence of a chamfer on the aft breakedges of the dovetail slot bottoms. Use paragraph 3.A. of GE Service Bulletin (SB) No. CF6-80A S/B 72-0822, dated July 20, 2006, to do the inspection.

(2) For disks that have the chamfered breakedges, re-mark, fluorescent penetrant inspect (FPI), and eddy current inspect (ECI) the rotor disk. Use paragraph 3.A.(1) of the Accomplishment Instructions of GE SB No. CF6-80A S/B 72-0822, dated July 20, 2006, to re-mark and inspect the rotor disk and remove from service as necessary.

(3) For disks that do not have the chamfered breakedges, remove the disk from service. Use paragraph 3.A(2) of the Accomplishment Instructions of GE SB No. CF6-80A S/B 72-0822, dated July 20, 2006.

For stage 1 HPT rotor disks, P/Ns 9234M67G22, G24, G25, G26, 9367M45G04, G09, 9362M58G02, G06, G07, and 9362M58G09 with SNs not listed in Table 2 of this AD, inspect, rework, and re-mark the disks using paragraphs 3.A.(1) through 3.A.(2) of Accomplishment Instructions of GE SB No. CF6-80A S/B 72-0788, Revision 3, dated July 20, 2006, at the following, unless already done using superseded AD 2004-04-07:

(1) For both new and used stage 1 HPT rotor disks not installed in engines, inspect, rework, re-mark, and remove from service as necessary before further flight.

(2) For stage 1 HPT rotor disks that have been inspected using any version of GE SB No. CF6-80A S/B 72-0779, inspect, rework, re-mark, and remove from service as necessary at the next Engine Shop Visit (ESV) using the compliance times in the following Table 3:

(3) For stage 1 HPT rotor disks which have not been inspected using any version of GE SB No. CF6-80A S/B 72-0779, inspect, rework, re-mark, and remove from service as necessary using the following Table 4 or Table 4A compliance times, whichever occurs first:

For stage 1 HPT rotor disks, P/N 9367M45G02, remove the disk from service at the following times:

(1) For stage 1 HPT rotor disks not installed in engines, remove from service before further flight.

(2) For stage 1 HPT rotor disks that have been inspected before the effective date of this AD using any version of GE SB No. CF6-80A S/B 72-0779, and had more than zero CSN at the time of that inspection, remove from service at next ESV.

(3) For stage 1 HPT rotor disks that have not been inspected, or were only inspected with zero CSN before the effective date of this AD using any version of GE SB No. CF6-80A S/B 72-0779, remove from service using the following Table 5 or Table 5A compliance times, whichever occurs first:

(i) At the next piece-part exposure, for stage 1 HPT rotor disks, P/N 1531M84G10, with SNs listed in Table 6 (Group 1) of this AD, do the following, unless already done using superseded AD 2004-04-07:

(1) Visually inspect the rotor disks for the presence of a chamfer on the aft breakedges of the dovetail slot bottoms. Use paragraph 3.A. of GE SB No. CF6-80C2 S/B 72-1217, dated July 20, 2006, to do the inspection.

(2) For disks that have the chamfered breakedges, re-mark, FPI, and ECI the rotor disk. Use paragraph 3.A.(1) of the Accomplishment Instructions of GE SB No. CF6-80C2 S/B 72-1217, dated July 20, 2006, to re-mark and inspect the rotor disk, and remove from service as necessary.

(3) For disks that do not have the chamfered breakedges, remove the disk from service. Use paragraph 3.A.(4) of the Accomplishment Instructions of GE SB No. CF6-80C2 S/B 72-1217, dated July 20, 2006.

For stage 1 HPT rotor disks, P/N 1531M84G10, with SNs listed in Table 6A of this AD, with chamfered breakedges, (Group 2):

(1) With more than 6,900 CSN, perform paragraphs (j)(3) through (j)(5) as applicable, at the next ESV, but within 500 CIS after the effective date of this AD, unless already done using superseded AD 2004-04-07.

(2) With 6,900 CSN or fewer, perform paragraphs (j)(3) through (j)(5) as applicable, at the next ESV, but before accumulating 7,400 CSN, unless already done using superseded AD 2004-04-07.

(3) Visually inspect the rotor disks for the presence of a chamfer on the aft breakedges of the dovetail slot bottoms. Use paragraph 3.A. of GE SB No. CF6-80C2 S/B 72-1217, dated July 20, 2006, to do the inspection.

(4) For disks that have the chamfered breakedges, re-mark, FPI, and ECI the rotor disk. Use paragraph 3.A.(2) of the Accomplishment Instructions of GE SB No. CF6-80C2 S/B 72-1217, dated July 20, 2006, to re-mark and inspect the rotor disk, and remove from service as necessary.

(5) For disks that do not have the chamfered breakedges, remove the disk from service. Use paragraph 3.A.(4) of the Accomplishment Instructions of GE SB No. CF6-80C2 S/B 72-1217, dated July 20, 2006.

For stage 1 HPT rotor disks, P/N 1531M84G12, with SNs listed in Table 6B of this AD, with chamfered breakedges:

(1) With more than 6,900 CSN, perform paragraph (k)(3) at the next ESV, but not to exceed 500 cycles after the effective date of this AD.

(2) With 6,900 CSN or fewer, perform paragraph (k)(3) at the next ESV, but before accumulating 7,400 CSN.

(3) FPI and ECI the rotor disk. Use paragraph 3.A.(3) of the Accomplishment Instructions of GE SB No. CF6-80C2 S/B 72-1217, dated July 20, 2006, to re-mark and inspect the rotor disk, and remove from service as necessary.

For stage 1 HPT rotor disks, P/Ns 9392M23G10, G12, G21, 1531M84G02, G06, G08, and 1531M84G10 with SNs not listed in Table 6 and Table 6A of this AD, inspect, rework, and re-mark the disks using paragraphs 3.A.(1) through 3.A.(2) of Accomplishment Instructions of GE SB No. CF6-80C2 S/B 72-1089, Revision 3, dated July 20, 2006, at the following, unless already done using superseded AD 2004-04-07:

(1) For both new and used stage 1 HPT rotor disks not installed in engines, inspect, rework, re-mark, and remove from service as necessary before further flight.

(2) For stage 1 HPT rotor disks that have been inspected before March 12, 2004 (effective date of superseded AD 2004-04-07) using GE ASB No. CF6-80C2 S/B 72-A1024, Revision 1, dated November 3, 2000, or any version of GE ASB No. CF6-80C2 S/B 72-A1026, inspect, rework, re-mark, and remove from service as necessary using the compliance times in the following Table 7:

(3) For stage 1 HPT rotor disks that have not been inspected before March 12, 2004 (effective date of superseded AD 2004-04-07) using GE ASB No. CF6-80C2 S/B 72-A1024, Revision 1, dated November 3, 2000, or any version of GE ASB No. CF6-80C2 S/B 72-A1026, inspect, rework, re-mark, and remove from service as necessary using the following Table 8 or Table 8A compliance times, whichever occurs first:

For stage 1 HPT rotor disk, P/N 1862M23G01, remove the disk from service at the following times:

(1) For stage 1 HPT rotor disks not installed in engines, remove from service as necessary before further flight.

(2) For stage 1 HPT rotor disks that have been inspected before March 12, 2004 (effective date of superseded AD 2004-04-07), using any version of GE ASB No. CF6-80C2 S/B 72-A1026, and had more than zero CSN at the time of that inspection, remove from service at next ESV.

(3) For stage 1 HPT rotor disks that have not been inspected, or were only inspected with zero CSN before March 12, 2004 (effective date of superseded AD 2004-04-07), using any version of GE ASB No. CF6-80C2 S/B 72-A1026, remove from service using the following Table 9 or Table 9A compliance times, whichever occurs first:

For stage 1 HPT rotor disks, P/N 1639M41P04, remove the rotor disks from service using paragraphs 3.A.(1) through 3.A.(2) of Accomplishment Instructions of GE SB No. CF6-80E1 S/B 72-0251, dated January 22, 2004, at the following times:

(1) For stage 1 HPT rotor disks currently in service, remove the disk using the compliance times in the following Table 10 or Table 10A compliance times, whichever occurs first:

(2) After March 12, 2004 (effective date of superseded AD 2004-04-07), do not install any stage 1 HPT rotor disk, P/N 1639M41P04, into any engine.

For the purpose of this AD, the following definitions apply:

(1) An engine shop visit (ESV) is when the engine is removed from an aircraft for maintenance and a major engine flange is disassembled. For stage 1 HPT rotor disks that have been inspected using any version of GE SB No. CF6-80A SB 72-0779 or any version of GE ASB No. CF6-80C2 ASB 72-A1026 or GE SB No. CF6-80C2 SB 72-A1024, Revision 1, dated November 3, 2000 or are listed in Table 6A or Table 6B, the following actions, either separately or in combination with each other, are not considered ESVs for the purpose of this AD:

(i) The removal of the upper compressor stator case solely for airfoil maintenance.

(ii) The module level inspection of the high-pressure compressor rotor 3-9 spool.

(iii) The replacement of stage 5 high-pressure compressor variable stator vane bushings or lever arms.

(2) Piece-part exposure is when according to the manufacturer's engine manual or other FAA-approved engine manual the stage 1 HPT rotor disk is considered completely disassembled.

Within five calendar days of the inspection, report the results of inspections that equal or exceed the reject criteria to: Engine Certification Office, FAA, Engine and Propeller Directorate, 12 New England Executive Park, Burlington, MA 01803; telephone (781) 238-7176; fax (781) 238-7199. Reporting requirements have been approved by the Office of Management and Budget and assigned OMB control number 2120-0056. Be sure to include the following information:

(1) Engine model in which the stage 1 HPT rotor disk was installed.

(2) Part Number.

(3) Serial Number.

(4) Part CSN.

(5) Part CSLI.

(6) Date and location where inspection was done.

(q) We request that you record the inspection information and results on GE Form 1653-1, entitled CF6-80A/80C Stage 1 HPT Disk Dovetail Slot Bottom Inspection. This form is available in any version of GE SB CF6-80A S/B 72-0779, or GE ASB CF6-80C2 S/B 72-A1026. We also request that a copy of the data be sent to GE Airline Support Engineering, General Electric Aircraft Engines, Customer Support Center, 1 Neumann Way, Mail Drop RM285, Cincinnati, OH 45215.