E6-13437. Airworthiness Directives; General Electric Company (GE) CF6-80 Series Turbofan Engines

AGENCY:

Federal Aviation Administration (FAA), Department of Transportation (DOT).

ACTION:

Final rule; request for comments.

SUMMARY:

The FAA is superseding an existing airworthiness directive (AD) for GE CF6-80 series turbofan engines with certain stage 1 high-pressure turbine (HPT) rotor disks. That AD currently requires an initial inspection as a qualification for the mandatory rework procedures for certain disks, and repetitive inspections only for certain disks for which the rework procedures were not required. That action also requires reworking certain disks before further flight, and removes certain CF6-80E1 series disks from service. This AD requires the same actions but shortens the compliance schedule for HPT disks that have not been previously inspected using AD 2004-04-07, which this AD supersedes. This AD results from a recent report of an uncontained failure of a stage 1 HPT disk. We are issuing this AD to detect and prevent cracks in the bottoms of the dovetail slots that could propagate to failure of the disk and cause an uncontained engine failure.

DATES:

Effective September 5, 2006. The Director of the Federal Register approved the incorporation by reference of certain publications listed in the regulations as of September 5, 2006. The Director of the Federal Register previously approved the incorporation by reference of certain other publications listed in the regulations as of March 12, 2004 (69 FR 8801, February 26, 2004).

We must receive any comments on this AD by October 17, 2006.

ADDRESSES:

Use one of the following addresses to submit comments on this ad:

• By mail: Federal Aviation Administration (FAA), New England Region, Office of the Regional Counsel, Attention: Rules Docket No. 2004-NE-05-AD, 12 New England Executive Park, Burlington, MA 01803.
• By fax: [phone].
• By e-mail: [e-mail].

Contact General Electric Company via Lockheed Martin Technology Services, 10525 Chester Road, Suite C, Cincinnati, Ohio 45215, telephone [phone], fax [phone], for the service information identified in this AD.

You may examine the AD docket, by appointment, at the FAA, New England Region, Office of the Regional Counsel, 12 New England Executive Park, Burlington, MA. You may examine the service information, by appointment, at the FAA, New England Region, Office of the Regional Counsel, 12 New England Executive Park, Burlington, MA.

FOR FURTHER INFORMATION CONTACT:

James Lawrence, Aerospace Engineer, Engine Certification Office, FAA, Engine and Propeller Directorate, 12 New England Executive Park, Burlington, MA 01803; telephone: [phone], fax: [phone].

SUPPLEMENTARY INFORMATION:

On February 13, 2004, we issued AD 2004-04-07, Amendment 39-13488 (69 FR 38; February 26, 2004). That AD requires an initial inspection as a qualification for the mandatory rework procedures for certain disks, and repetitive inspections only for certain disks for which the rework procedures were not required. That action also requires reworking certain disks before further flight. That AD was the result of the manufacturer's investigation and development of a rework procedure to chamfer the aft breakedge of the dovetail slot bottom to reduce stresses. That condition, if not corrected, could result in cracks in the bottoms of the dovetail slots that could propagate to failure of the disk and cause an uncontained engine failure.

Actions Since AD 2004-04-07 Was Issued

Since AD 2004-04-07 was issued, a CF6-80A turbofan engine, installed on a Boeing 767 airplane, experienced an uncontained stage 1 HPT disk failure on June 2, 2006. The disk failure resulted in a fire and significant damage to the airplane. The event occurred during an on-ground maintenance operation.

Relevant Service Information

We reviewed and approved the technical contents of the following GE Service Bulletins (SBs) and Alert Service Bulletin (ASB) that describe procedures for removing, inspecting, and reworking certain stage 1 HPT rotor disks:

• SB No. CF6-80E1 S/B 72-0251, dated January 22, 2004;
• SB No. CF6-80A S/B 72-0779, Revision 1, dated January 22, 2004;
• SB No. CF6-80A S/B 72-0788, Revision 3, dated July 20, 2006;
• SB No. CF6-80A S/B 72-0822, dated July 20, 2006;
• ASB No. CF6-80C2 S/B 72-A1026, Revision 2, dated January 22, 2004;
• SB No. CF6-80C2 S/B 72-1089, Revision 3, dated July 20, 2006;
• SB No. CF6-80C2 S/B 72-1217, dated July 20, 2006.

FAA's Determination and Requirements of This AD

The unsafe condition described previously is likely to exist or develop on other GE CF6-80 series turbofan engines of the same type design. This AD requires rework of the dovetail slot bottom of certain stage 1 rotor disks. The disks must pass an inspection to qualify for the rework. This AD also requires removal from service of certain disks for which the rework procedures were not previously required. This AD also tightens the compliance schedule for HPT disks that have not been previously inspected using AD 2004-04-07. Operators must use the compliance schedule carried forward from AD 2004-04-07 or the new compliance schedule below, whichever occurs first:

• For stage 1 HPT rotor disks with 9,000 or more cycles-since-new (CSN) on the effective date of this AD, within 250 cycles-in-service (CIS) after the effective date of this AD, or by March 31, 2007, whichever occurs first.
• For stage 1 HPT rotor disks with 6,900 or more but fewer than 9,000 CSN on the effective date of this AD, within 500 CIS after the effective date of this AD, or before accumulating 9,250 CSN, or by December 31, 2007, whichever occurs first.
• For stage 1 HPT rotor disk with fewer than 6,900 CSN on the effective date of this AD, before accumulating 7,400 CSN, or by December 31, 2008, whichever occurs first.

This AD also removes from service certain CF6-80E1 series disks. You must use the service information described previously to perform the actions required by this AD.

FAA's Determination of the Effective Date

Since an unsafe condition exists that requires the immediate adoption of this AD, we have found that notice and opportunity for public comment before issuing this AD are impracticable, and that good cause exists for making this amendment effective in less than 30 days.

Comments Invited

This AD is a final rule that involves requirements affecting flight safety and was not preceded by notice and an opportunity for public comment; however, we invite you to submit any written relevant data, views, or arguments regarding this AD. Send your comments to an address listed under ADDRESSES. Include “AD Docket No. 2004-NE-05-D” in the subject line of your comments. If you want us to acknowledge receipt of your mailed comments, send us a self-addressed, stamped postcard with the docket number written on it; we will date-stamp your postcard and mail it back to you. We specifically invite comments on the overall regulatory, economic, environmental, and energy aspects of the rule that might suggest a need to modify it. If a person contacts us verbally, and that contact relates to a substantive part of this AD, we will summarize the contact and place the summary in the docket. We will consider all comments received by the closing date and may amend the AD in light of those comments.

Examining the AD Docket

You may examine the AD Docket (including any comments and service information), by appointment, between 8 a.m. and 4:30 p.m., Monday through Friday, except Federal holidays. See ADDRESSES for the location.

Authority for This Rulemaking

Title 49 of the United States Code specifies the FAA's authority to issue rules on aviation safety. Subtitle I, section 106, describes the authority of the FAA Administrator. Subtitle VII, Aviation Programs, describes in more detail the scope of the Agency's authority.

We are issuing this rulemaking under the authority described in subtitle VII, part A, subpart III, section 44701, “General requirements.” Under that section, Congress charges the FAA with promoting safe flight of civil aircraft in air commerce by prescribing regulations for practices, methods, and procedures the Administrator finds necessary for safety in air commerce. This regulation is within the scope of that authority because it addresses an unsafe condition that is likely to exist or develop on products identified in this rulemaking action.

Regulatory Findings

We have determined that this AD will not have federalism implications under Executive Order 13132. This AD will not have a substantial direct effect on the States, on the relationship between the National Government and the States, or on the distribution of power and responsibilities among the various levels of government.

For the reasons discussed above, I certify that the regulation:

1. Is not a “significant regulatory action” under Executive Order 12866;

2. Is not a “significant rule” under the DOT Regulatory Policies and Procedures (44 FR 11034, February 26, 1979); and

3. Will not have a significant economic impact, positive or negative, on a substantial number of small entities under the criteria of the Regulatory Flexibility Act.

We prepared a summary of the costs to comply with this AD and placed it in the AD Docket. You may get a copy of this summary by sending a request to us at the address listed under ADDRESSES. Include “AD Docket No. 2004-NE-05-AD” in your request.

List of Subjects in 14 CFR Part 39

• Air transportation
• Aircraft
• Aviation safety
• Incorporation by reference
• Safety

Adoption of the Amendment

Accordingly, under the authority delegated to me by the Administrator, the Federal Aviation Administration amends part 39 of the Federal Aviation Regulations (14 CFR part 39) as follows:

PART 39—AIRWORTHINESS DIRECTIVES

1. The authority citation for part 39 continues to read as follows:

Authority: 49 U.S.C. 106(g), 40113, 44701.

§ 39.13

[Amended]

2. The FAA amends § 39.13 by removing Amendment 39-13488 ( 69 FR 8801; February 26, 2004), and by adding a new airworthiness directive, Amendment 39-14706, to read as follows:

2006-16-06 General Electric Company: Amendment 39-14706. Docket No. 2004-NE-05-AD.

Effective Date

(a) This airworthiness directive (AD) becomes effective September 5, 2006.

Affected ADs

(b) This AD supersedes AD 2004-04-07 (69 FR 8801; February 26, 2004).

Applicability

(c) This AD applies to the General Electric Company (GE) CF6-80 turbofan engine models listed in the following Table 1:

Table 1.—Applicability Models, Part Numbers, Airplanes

Models	Stage 1 high pressure turbine (HPT) rotor disk part numbers (P/Ns)	Engines installed on but not limited to
CF6-80A, CF6-80A1, CF6-80A2, CF6-80A3	9234M67G22/G24/G25/G26, 9362M58G02/G06/G07/G09, 9367M45G02/G04/G09	Airbus A310 and Boeing 767 airplanes.
CF6-80C2A1, CF6-80C2A2, CF6-80C2A3, CF6-80C2A5, CF6-80C2A8, CF6-80C2A5F, CF6-80C2B1, CF6-80C2B2, CF6-80C2B4, CF6-80C2B6, CF6-80C2B1F, CF6-80C2B2F, CF6-80C2B4F, CF6-80C2B5F, CF6-80C2B6F, CF6-80C2B6FA, CF6-80C2B7F, CF6-80C2D1F	1862M23G01, 9392M23G10/G12/G21, 1531M84G02/G06/G08/G10/G12	Airbus A300, A310, Boeing 747, 767, and McDonnell Douglas MD11 airplanes.
CF6-80E1A2, CF6-80E1A4	1639M41P04	Airbus A330 airplanes.

These engines are installed on, but not limited to, the airplanes listed in Table 1 of this AD.

Unsafe Condition

(d) This AD results from a recent report of an uncontained failure of a stage 1 HPT disk. The actions specified in this AD are intended to detect and prevent cracks in the bottoms of the dovetail slots that could propagate to failure of the disk and cause an uncontained engine failure.

Compliance

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

CF6-80A, -80A1, -80A2, and -80A3 Engines

Stage 1 HPT Rotor Disks, P/N 9362M58G09, With Chamfered Breakedges

(f) At the next piece-part exposure, 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:

GWN03RD7

GWN03TKG

GWN03TKH

GWN03TKJ

GWN03W3M

GWN03W3N

GWN03W3R

GWN042J3

GWN04FW2

GWN04FW3

GWN04FW4

GWN04FW5

GWN04H0M

GWN04HRA

GWN04HRD

GWN04HRE

GWN04HRF

GWN04HRG

GWN04HRH

GWN04K8N

GWN04M9J

GWN04M9K

GWN04M9L

GWN04M9M

GWN04M9R

GWN04M9T

GWN04M9W

(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.

Stage 1 HPT Rotor Disks, P/Ns 9234M67G22, G24, G25, G26, 9367M45G04, G09, 9362M58G02, G06, G07, and 9362M58G09 with SNs not listed in Table 2 of this AD

(g) For stage 1 HPT rotor disks, P/Ns 9234M67G22, G24, G25, G26, 9367M45G04, G09, 9362M58G02, G06, G07, and 9362M58G09 with SNs not listed in Table 2 of this AD, inspect, rework, and 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:

Table 3.—Compliance Times for Inspection and Rework of CF6-80A Series Stage 1 HPT Rotor Disks, P/Ns 9234M67G22, G24, G25, G26, 9367M45G04, G09, 9362M58G02, G06, G07, and 9362M58G09 With SNs Not Listed in Table 2 of This AD—Previously Inspected

Stage 1 HPT rotor disk cycles-since-last-inspection (CSLI) on March 12, 2004 (effective date of superseded AD 2004-04-07)	Compliance time for inspection and rework
(i) More than 1,500 CSLI	At the next ESV after March 12, 2004 (effective date of superseded AD 2004-04-07), but not to exceed 4,500 CSLI.
(ii) 1,500 CSLI or fewer	At the next ESV after March 12, 2004 (effective date of superseded AD 2004-04-07), but not to exceed 3,500 CSLI.

(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:

Table 4.—Compliance Times for Inspection and Rework of CF6-80A Series Stage 1 HPT Rotor Disks, P/Ns 9234M67G22, G24, G25, G26, 9367M45G04, G09, 9362M58G02, G06, G07, and 9362M58G09 With SNs Not Listed in Table 2 of This AD—Not Previously Inspected

Stage 1 HPT rotor disk cycles-since-new (CSN) on the effective date of this AD	Compliance time for inspection and rework
(i) 9,000 or more CSN	Within 250 cycles-in-service (CIS) after the effective date of this AD, or by March 31, 2007, whichever occurs first.
(ii) 6,900 or more but fewer than 9,000 CSN	Within 500 CIS after the effective date of this AD, but before accumulating 9,250 CSN, or by December 31, 2007, whichever occurs first.
(iii) Fewer than 6,900 CSN	Before accumulating 7,400 CSN, or by December 31, 2008, whichever occurs first.

Table 4A.—Compliance Times for Inspection and Rework of CF6-80A Series Stage 1 HPT Rotor Disks, P/Ns 9234M67G22, G24, G25, G26, 9367M45G04, G09, 9362M58G02, G06, G07, and 9362M58G09 With SNs Not Listed in Table 2 of This AD—Not Previously Inspected

Stage 1 HPT rotor disk CSN on March 12, 2004 (effective date of superseded AD 2004-04-07)	Compliance time for inspection and rework
(i) 10,000 or more CSN	At the next ESV or within 1,000 CIS after March 12, 2004 (effective date of superseded AD 2004-04-07), whichever occurs first.
(ii) 5,000 or more CSN but fewer than 10,000 CSN	At the next ESV or within 2,400 CIS after March 12, 2004 (effective date of superseded AD 2004-04-07), whichever occurs first, but before accumulating 11,000 CSN.
(iii) Fewer than 5,000 CSN	At the next ESV or within 3,500 CIS after March 12, 2004 (effective date of superseded AD 2004-04-07), whichever occurs first, but before accumulating 7,400 CSN.

Stage 1 HPT Rotor Disks, P/N 9367M45G02

(h) For stage 1 HPT rotor disks, P/N 9367M45G02, 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:

Table 5.—Compliance Times for Removal of CF6-80A Series Stage 1 HPT Rotor Disks, P/N 9367M45G02—Not Previously Inspected

Stage 1 HPT rotor disk CSN on the effective date of this AD	Compliance time for removal
(i) 9,000 or more CSN	Within 250 CIS after the effective date of this AD, or by March 31, 2007, whichever occurs first.
(ii) 6,900 or more but fewer than 9,000 CSN	Within 500 CIS after the effective date of this AD, but before accumulating 9,250 CSN, or by December 31, 2007, whichever occurs first.
(iii) Fewer than 6,900 CSN	Before accumulating 7,400 CSN, or by December 31, 2008, whichever occurs first.

Table 5A.—Compliance Times for Removal of CF6-80A Series Stage 1 HPT Rotor Disks, P/N 9367M45G02—Not Previously Inspected

Stage 1 HPT rotor disk CSN on March 12, 2004 (effective date of superseded AD 2004-04-07)	Compliance time for removal
(i) 10,000 or more CSN	At the next ESV or within 1,000 CIS after March 12, 2004 (effective date of superseded AD 2004-04-07), whichever occurs first.
(ii) 5,000 or more CSN but fewer than 10,000 CSN	At the next ESV or within 2,400 CIS after March 12, 2004 (effective date of superseded AD 2004-04-07), whichever occurs first, but before accumulating 11,000 CSN.
(iii) Fewer than 5,000 CSN	At the next ESV or within 3,500 CIS after March 12, 2004 (effective date of superseded AD 2004-04-07), whichever occurs first, but before accumulating 7,400 CSN.

CF6-80C2 Series Engines

Stage 1 HPT Rotor Disks, P/N 1531M84G10, With Chamfered Breakedges, Group 1

(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:

GWN03111

GWN03114

GWN031N2

GWN031N3

GWN031N4

GWN031N5

GWN031N6

GWN031N7

GWN031N8

GWN031N9

GWN031NA

GWN031NC

GWN032G1

GWN032G2

GWN032G3

GWN032G4

GWN032G5

GWN032G6

GWN032G7

GWN032G8

GWN032G9

GWN032GE

GWN0335P

GWN0335R

GWN033C5

GWN034KR

GWN034KT

GWN03501

GWN0350M

GWN0350N

GWN0350P

GWN0350R

GWN0350T

GWN0350W

GWN035M5

GWN035M6

GWN035M7

GWN035M8

GWN035M9

GWN035MA

GWN035MC

GWN035MD

GWN035TH

GWN035TJ

GWN035TK

GWN035TL

GWN035TM

GWN03699

GWN0369A

GWN0369C

GWN0369D

GWN0369E

GWN0369G

GWN0369H

GWN0369J

GWN036JG

GWN036JH

GWN036JJ

GWN036JK

GWN036JL

GWN036JM

GWN036JN

GWN03752

GWN03753

GWN03754

GWN03755

GWN03756

GWN03757

GWN03759

GWN0375A

GWN0375C

GWN0375D

GWN0375E

GWN037H2

GWN03981

GWN03982

GWN03983

GWN03984

GWN03985

GWN03986

GWN03987

GWN03988

GWN03989

GWN0398A

GWN0398C

GWN039PF

GWN039PG

GWN039PH

GWN039PJ

GWN039PK

GWN039PL

GWN039PM

GWN039PN

GWN03A4J

GWN03A4K

GWN03A4L

GWN03A4M

GWN03A4N

GWN03A4P

GWN03A4R

GWN03A4T

GWN03A4W

GWN03C12

GWN03C13

GWN03C14

GWN03CA0

GWN03DC9

GWN03DCA

GWN03DCC

GWN03DCD

GWN03DCE

GWN03DCF

GWN03DCG

GWN03DCH

GWN03DCJ

GWN03DCK

GWN03DCL

GWN03DCM

GWN03DCN

GWN03DCP

GWN03DCR

GWN03DME

GWN03DMF

GWN03ER7

GWN03ER8

GWN03ER9

GWN03ERA

GWN03FTN

GWN03FTP

GWN03FTR

GWN03FTT

GWN03FTW

GWN03FW0

GWN03H56

GWN03H57

GWN03H58

GWN03HTL

GWN03HTM

GWN03HTN

GWN03HTP

GWN03HTR

GWN03HTT

GWN03J8T

GWN03J8W

GWN03J91

GWN03J92

GWN03JNN

GWN03JNP

GWN03K3C

GWN03K3D

GWN03K3F

GWN03K3G

GWN03K3H

GWN03K3K

GWN03K3L

GWN03K3M

GWN03K3N

GWN03K3T

GWN03K3W

GWN03K40

GWN03K7R

GWN03KR1

GWN03KR3

GWN03KR4

GWN03KR6

GWN03KR7

GWN03KR8

GWN03KRC

GWN03L2D

GWN03L2E

GWN03L2F

GWN03LNF

GWN03LNJ

GWN03LNK

GWN03M88

GWN03M8C

GWN03M8E

GWN03M8J

GWN03M8K

GWN03NHN

GWN03NHP

GWN03NHR

GWN03R74

GWN03R76

GWN03R78

GWN03R7E

GWN03R7F

GWN03R9G

GWN03R9H

GWN03R9M

GWN03R9P

GWN03R9T

GWN03RA2

GWN03RA3

GWN03RA5

GWN03RA8

GWN03RPA

GWN03RPC

GWN03RPD

GWN04026

GWN0402A

GWN0402F

GWN0402L

GWN040R5

GWN04189

GWN0418A

GWN0418D

GWN0418E

GWN0418F

GWN0418H

GWN0418J

GWN0418L

GWN0418N

GWN0418R

GWN04366

GWN044DP

GWN0454H

GWN0454M

GWN0454N

GWN045T0

GWN045T2

GWN045T8

GWN045TD

GWN045TG

GWN04722

GWN04729

GWN047LK

GWN048CD

GWN048CF

GWN048CH

GWN048CJ

GWN048CK

GWN049GJ

GWN049M8

GWN049M9

GWN04AER

GWN04ALR

GWN04AM1

GWN04CGJ

GWN04CGN

GWN04CGT

GWN04CGW

GWN04CH3

GWN04CH5

GWN04CH8

GWN04CH9

GWN04D52

GWN04D54

GWN04D56

GWN04D57

GWN04D58

GWN04D59

GWN04DPW

GWN04E9K

GWN04E9L

GWN04E9M

GWN04EMA

GWN04EMK

GWN04EML

GWN04EMM

GWN04FTL

GWN04FTM

GWN04FTN

(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.

CF6-80C2 Series Engines

Stage 1 HPT Rotor Disks, P/N 1531M84G10, With Chamfered Breakedges, Group 2

(j) 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.

GWN03J90

GWN03K3R

GWN03K6J

GWN03K7T

GWN03KR2

GWN03KR5

GWN03KRA

GWN03KRD

GWN03M89

GWN03M8D

GWN03M8F

GWN03NHT

GWN03R73

GWN03R75

GWN03R77

GWN03R79

GWN03R7A

GWN03R7C

GWN03R7D

GWN03R7G

GWN03R7H

GWN03R9J

GWN03R9K

GWN03R9L

GWN03R9N

GWN03R9R

GWN03R9W

GWN03RA0

GWN03RA1

GWN03RA4

GWN03RA6

GWN03RA7

GWN03RP7

GWN03RP9

GWN03RPE

GWN03RPF

GWN03RPG

GWN04027

GWN04028

GWN04029

GWN0402E

GWN0402G

GWN0402H

GWN0402J

GWN0402K

GWN0402M

GWN0402N

GWN0402P

GWN0418C

GWN0418G

GWN0418K

GWN0418M

GWN0418P

GWN0418T

GWN0418W

GWN04190

GWN04191

GWN0454E

GWN0454F

GWN0454G

GWN0454J

GWN0454K

GWN0454L

GWN045T1

GWN045T3

GWN045T4

GWN045T5

GWN045T6

GWN045T7

GWN045T9

GWN045TA

GWN045TC

GWN045TE

GWN045TF

GWN045TH

GWN046F6

GWN046F7

GWN046F8

GWN04726

GWN047LG

GWN047LH

GWN047LJ

GWN047LL

GWN048CG

GWN048CM

GWN048CN

GWN048CP

GWN048CR

GWN049GH

GWN049GK

GWN049JL

GWN049JM

GWN049M7

GWN04AEP

GWN04AET

GWN04ALT

GWN04ALW

GWN04AM0

GWN04AM2

GWN04AM3

GWN04AM4

GWN04CGL

GWN04CHA

GWN04CHC

GWN04D55

GWN04DR4

GWN04DR9

GWN04DRE

GWN04DRJ

GWN04E9N

GWN04EM5

GWN04F8N

GWN04F8P

GWN04FTJ

(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.

CF6-80C2 Series Engines

Stage 1 HPT Rotor Disks, P/N 1531M84G12, With Chamfered Breakedges

(k) 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.

GWN04CH6

GWN04G5H

GWN04M03

(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.

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

(l) 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:

Table 7.—Compliance Times for Inspection and Rework of CF6-80C2 Series Stage 1 HPT Rotor Disks, P/Ns 9392M23G10, G12, G21, 1531M84G02, G06, G08, and 1531M84G10 With SNs Not Listed in Table 6 and Table 6A of This AD—Previously Inspected

Stage 1 HPT rotor disk cycles-since-last-inspection (CSLI) on March 12, 2004 (effective date of superseded AD 2004-04-07)	Compliance time for inspection and rework
(i) More than 1,500 CSLI	At the next ESV after March 12, 2004 (effective date of superseded AD 2004-04-07), but not to exceed 4,500 CSLI.
(ii) 1,500 CSLI or fewer	At the next ESV after March 12, 2004 (effective date of superseded AD 2004-04-07), but not to exceed 3,500 CSLI.

(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:

Table 8.—Compliance Times for Inspection and Rework of CF6-80C2 Series Stage 1 HPT Rotor Disks, P/Ns 9392M23G10, G12, G21, 1531M84G02, G06, G08, and 1531M84G10 With SNs Not Listed in Table 6 and Table 6A of This AD—Not Previously Inspected

Stage 1 HPT rotor disk cycles-since-new (CSN) on the effective date of this AD	Compliance time for inspection and rework
(i) 9,000 or more CSN	Within 250 CIS after the effective date of this AD, or by March 31, 2007, whichever occurs first.
(ii) 6,900 or more but fewer than 9,000 CSN	Within 500 CIS after the effective date of this AD, but before accumulating 9,250 CSN, or by December 31, 2007, whichever occurs first.
(iii) Fewer than 6,900 CSN	Before accumulating 7,400 CSN, or by December 31, 2008, whichever occurs first.

Table 8A.—Compliance Times for Inspection and Rework of CF6-80C2 Series Stage 1 HPT Rotor Disks, P/Ns 9392M23G10, G12, G21, 1531M84G02, G06, G08, and 1531M84G10 With SNs Not Listed in Table 6 and Table 6A of This AD—Not Previously Inspected

Stage 1 HPT rotor disk CSN on March 12, 2004 (effective date of superseded AD 2004-04-07)	Compliance time for inspection and rework
(i) 10,000 or more CSN	At the next ESV or within 1,000 CIS after March 12, 2004 (effective date of superseded AD 2004-04-07), whichever occurs first.
(ii) 5,000 or more CSN but fewer than 10,000 CSN	At the next ESV or within 2,400 CIS after March 12, 2004 (effective date of superseded AD 2004-04-07), but before accumulating 11,000 CSN.
(iii) Fewer than 5,000 CSN	At the next ESV or within 3,500 CIS after March 12, 2004 (effective date of superseded AD 2004-04-07), whichever occurs first, but before accumulating 7,400 CSN.

Stage 1 HPT Rotor Disks, P/N 1862M23G01

(m) 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:

 Table 9.—Compliance Times for Removal of CF6-80C2 Series Stage 1 HPT Rotor Disks, P/N 1862M23G01—Not Previously Inspected

Stage 1 HPT rotor disk CSN on the effective date of this AD	Compliance time for removal
(i) 9,000 or more CSN	Within 250 CIS after the effective date of this AD, or by March 31, 2007, whichever occurs first.
(ii) 6,900 or more but fewer than 9,000 CSN	Within 500 CIS after the effective date of this AD, but before accumulating 9,250 CSN, or by December 31, 2007, whichever occurs first.
(iii) Fewer than 6,900 CSN	Before accumulating 7,400 CSN, or by December 31, 2008, whichever occurs first.

 Table 9A.—Compliance Times for Removal of CF6-80C2 Series Stage 1 HPT Rotor Disks, P/N 1862M23G01—Not Previously Inspected

Stage 1 HPT rotor disk CSN on March 12, 2004 (effective date of superseded AD 2004-04-07)	Compliance time for removal
(i) 10,000 or more CSN	At the next ESV or within 1,000 CIS after March 12, 2004 (effective date of superseded AD 2004-04-07), whichever occurs first.
(ii) 5,000 or more CSN but fewer than 10,000 CSN	At the next ESV or within 2,400 CIS after March 12, 2004 (effective date of superseded AD 2004-04-07), whichever occurs first, but before accumulating 11,000 CSN.
(iii) Fewer than 5,000 CSN	At the next ESV or within 3,500 CIS after March 12, 2004 (effective date of superseded AD 2004-04-07), whichever occurs first, but before accumulating 7,400 CSN.

CF6-80E1A2, A4 Engines

Stage 1 HPT Rotor Disks, P/N 1639M41P04

(n) 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:

 Table 10.—Compliance Times for Removal of CF6-80E1 Stage 1 HPT Rotor Disks, P/N 1639M41P04

Stage 1 HPT rotor disk CSN on the effective date of this AD	Compliance Time For Removal
(i) 9,000 or more CSN	Within 250 CIS after the effective date of this AD, or by March 31, 2007, whichever occurs first.
(ii) 6,900 or more but fewer than 9,000 CSN	Within 500 CIS after the effective date of this AD, but before accumulating 9,250 CSN, or by December 31, 2007, whichever occurs first.
(iii) Fewer than 6,900 CSN	Before accumulating 7,400 CSN, or by December 31, 2008, whichever occurs first.

 Table 10A.—Compliance Times for Removal of CF6-80E1 Stage 1 HPT Rotor Disks, P/N 1639M41P04

Stage 1 HPT rotor disk CSN on the March 12, 2004 ( effective date of superseded AD 2004-04-07)	Compliance time for removal
(i) More than 10,000 CSN	At the next ESV or within 600 CIS after March 12, 2004 (effective date of superseded AD 2004-04-07), whichever occurs first.
(ii) More than 5,000 CSN but fewer than or equal to 10,000 CSN	At the next ESV or within 2,500 CIS after March 12, 2004 (effective date of superseded AD 2004-04-07), whichever occurs first, but before accumulating 10,600 CSN.
(iii) Fewer than or equal to 5,000 CSN	At the next ESV or within 3,500 CIS after March 12, 2004 (effective date of superseded AD 2004-04-07), whichever occurs first, but before accumulating 7,500 CSN.

(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.

Definitions

(o) 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.

Reporting Requirements

(p) 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 [phone]; fax [phone]. 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.

Alternative Methods of Compliance

(r) The manager, Engine Certification Office, has the authority to approve alternative methods of compliance for this AD if requested using the procedures found in 14 CFR 39.19.

Material Incorporated by Reference

(s) You must use the service information specified in Table 11 to perform the actions required by this AD. The Director of the Federal Register previously approved the incorporation by reference of General Electric Service Bulletins No. CF6-80E1 S/B 72-0251, dated January 22, 2004 and No. CF6-80A S/B 72-0779, Revision 1, dated January 22, 2004, and Alert Service Bulletin No. CF6-80C2 S/B 72-A1026, Revision 2, dated January 22, 2004, as of March 12, 2004 (69 FR 8801, February 26, 2004). The Director of the Federal Register approved the incorporation by reference of the other documents listed in Table 11 of this AD in accordance with 5 U.S.C. 552(a) and 1 CFR part 51. You can get a copy from General Electric Company via Lockheed Martin Technology Services, 10525 Chester Road, Suite C, Cincinnati, Ohio 45215, telephone [phone], fax [phone]. You may review copies at the FAA, New England Region, Office of the Regional Counsel, 12 New England Executive Park, Burlington, MA; or at the Office of the Federal Register, 800 North Capitol Street, NW, Suite 700, Washington, DC. Table 11 follows:

Table 11.—Incorporation by Reference

Service Bulletin No.	Page	Revision	Date
GE SB No. CF6-80E1 S/B 72-0251	All	Original	January 22, 2004.
Total Pages: 4
GE SB No. CF6-80A S/B 72-0779	ALL	1	January 22, 2004.
Total Pages: 34
GE SB No. CF6-80A S/B 72-0788	ALL	3	July 20, 2006.
Total Pages: 11
GE ASB No. CF6-80C2 S/B 72-A1026	ALL	2	January 22, 2004.
Total Pages: 38
GE SB No. CF6-80C2 S/B 72-1089	ALL	3	July 20, 2006.
Total Pages: 11
GE SB No. CF6-80C2 S/B 72-1217	ALL	Original	July 20, 2006.
Total Pages: 12
GE SB No. CF6-80A S/B 72-0822	ALL	Original	July 20, 2006.
Total Pages: 10

Related Information

(t) GE ASB No. CF6-80C2 S/B 72-A1024, Revision 1, dated November 3, 2000 also pertains to the subject of this AD.

Issued in Burlington, Massachusetts, on August 10, 2006.

Francis A. Favara,

Manager, Engine and Propeller Directorate, Aircraft Certification Service.