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AOT_7146029_00111. txt
ALL OPERATORS TELEX - ALL OPERATORS TELEX SUBJECT: A300-600 GE CF6-80C2 - ATA 71 - Inspection and replacement of forward engine mount cast yoke OUR REF: AOT A300-71A6029 dated 30 March 2010
1. AIRCRAFT AFFECTED All A300-600 CF6-80C2 powered aircraft
2. REFERENCED DOCUMENTATION
2.1 ESPM task 20-55-00 Cleaning (AIRBUS)
2.2 AMM task 24-00-00 PB301 General servicing
2.3 AMM task 71-13-00 PB301 Cowl doors - Servicing
2.4 AMM task 71-21-00 PB401 Engine forward mount - Removal/Installation
2.5 CMMm 71-21-01 Forward mount assembly
2.6 GENERAL ELECTRIC Service Bulletin No. CF6-80C2 72-0222
2.7 AMM task 71-00-00 PB401 General - Removal/Installation
3. REASON
3.1 FACTS In the frame of the Extended Service Goal (ESG) activities on GE CF6 engine mounts, it has been demonstrated that one location on the CF6- 80C2 forward engine mounts does not meet the ESG objective (45000 There are 3 types of yokes in service: skinny cast yoke, strengthenec cast yoke and forged yoke versions. The torged yoke mount was designed to increase fatigue life of the system. The manufacturing process was changed to increase fatigue life of the yoke.
Post-certification analysis to support ESG shows that the skinny cast yoke does not meet this objective.
Analysis requires that the skinny cast yokes (P/N 9383M43G08 or 9383M43G09 or 9383M43G10 or 9383M43G11) must be replaced within 7000FC after inspection.
3.2 CONSEQUENCES Yoke failure could adversely affect the structural integrity of the forward engine mount.
3.3 AIM The aim of this AOT is to perform a one time detailed inspection of the forward engine mount yokes of GE CF6-80C2 powered aircraft and to replace by a forged yoke with improved fatigue life if skinny cast yoke installed.
In case of replacement of the skinny cast yoke, the GE CF6-80C2 Service Bulletin 72-0222 is to be completed if not already accomplished.
4. SHORT TERM ACTION
4.1 PLANNING AND MANPOWER
4.1.1 PLANNING For each engine, do a General Visual Inspection (GVI) for the P/N of Page 1
AOT_71A6029_00[1]. txt 9383M43G08 or 9383M43G09 or 9383M43G10 or 9383M43G11)'400FC after the forward engine mount yoke and, if found skinny (i.e. P/N do a Detailed Inspection (DET) as per paragraph 4.2 within the next this AOT issuance date.
within 7000FC from Detailed Inspection, replace the skinny cast yoke by a forged one as per §4.2.4.
4.1.2 MANPOWER From 5 to 283 man-hours and from 2.5 to 46.5 elapsed time hours are required, depending on findings.
4.2 DESCRIPTION Apply the following instructions for both engines.
4.2.1 General warning WARNING: MAKE SURE THAT YOU OBEY ALL THE WARNINGS AND ALL THE CAUTIONS INCLUDED IN THE REFERENCED PROCEDURES.
CAUTION: ALWAYS OBEY THE PRECAUTIONS THAT FOLLOW TO KEEP ELECTRICAL
WIRING IN A SATISFACTORY CONDITION (ELECTRICALLY AND MECHANICALLY SERVICEABLE). WHEN YOU DO MAINTENANCE WORK, REPAIRS OR MODIFICATIONS,
ALWAYS KEEP ELECTRICAL WIRING, COMPONENTS AND THE WORK AREA AS CLEAN AS POSSIBLE.
TO DO THIS:
PUT PROTECTION, SUCH AS PLASTIC SHEETING, CLOTHS, ETC; AS NECESSARY ON WIRING AND COMPONENTS.
REGULARLY REMOVE ALL SHAVINGS, UNWANTED MATERIAL AND OTHER CONTAMINATION.
THESE PRECAUTIONS WILL DECREASE THE RISK OF CONTAMINATION AND DAMAGE TO THE ELECTRICAL WIRING INSTALLATION.
IN CASE OF CONTAMINATION REFER TO ESPM TASK REF 2.1.
4.2.2 Inspection for the P/N of the forward engine mount yoke
4.2.2.a. Preparation Make sure that the aircraft is electrically grounded (refer to AMM task ref 2.2) .
Put the access platform(s) in position.
Open the fan cowl doors 435AL and 436AR for engine 1 and 445AL and +46AR for engine 2 (refer to AMM task ref 2.3).
Open the thrust reverser cowl doors 451AL and 452AR for engine 1 anc 461AL and 462AR for engine 2 (refer to AMM task ref 2.3).
4.2.2.b. Procedure Do a General Visual Inspection (GVI) for the P/N of the forward engine mount yoke (refer to Appendix 01 Figure 1 and Figure 2).
If P/N 9383M43G08 or 9383M43G09 or 9383M43G10 or 9383M43G11 is not installed, complete the inspection report (Appendix 02). No further action is necessary.
If P/N 9383M43G08 or 9383M43G09 or 9383M43G10 or 9383M43G11 is installed, do a Detailed Inspection (DET) for full rupture in the forward engine mount skinny cast yoke as per §4.2.3.
4.2.2.c. Close-up Make sure that the work areas are clean and clear of tools and other Page 2
AOT_71A6029_00[1]. txt items of equipment.
446AR for engine 2 (refer to AMM task ref 2.3)'452AR for engine 1 and Close the fan cowl doors 435AL and 436AR for engine 1 and 445AL and Close the thrust reverser cowl doors 451AL and Restore the system and the airfar to un tas oper ting condition. 461AL and 462AR for
4.2.3 Inspection of the Forward Engine Mount skinny Cast Yoke
4.2.3.a. Preparation Make sure that the aircraft is electrically grounded (refer to AMM task ref 2.2).
Put the access platform(s) in position.
Open the fan cowl doors 435AL and 436AR for engine 1 and 445AL and 446AR for engine 2 (refer to AMM task ref 2.3).
Open the thrust reverser cowl doors 451AL and 452AR for engine 1 and 461AL and 462AR for engine 2 (refer to AMM task ref 2.3).
4.2.3.b. Procedure Refer to Appendix 01 Figure 1 and Figure 2 and Appendix 04.
Do a Detailed Inspection (DET) of the forward engine mount skinny cast yoke in the specified area shown on Appendix 01 Figure 2.
- If the skinny cast yoke is found fully ruptured, contact Airbus at the following address for investigation and special workscope. In addition, the forward mount assembly must be removed and replaced before next flight:
Laure Dupland, SEEE3 Customer Services Phone: +33 (0) 5 61 18 20 24 Fax: +33 (0) 5 61 93 36 14 Mailto: laure.dupland@airbus.com
- If the skinny cast yoke is not ruptured, attach a Movement Traceability Sheet (MTS) to the skinny cast yoke (Cf. Appendix 03).
The skinny cast yoke must be replaced by a torged yoke (P/N 1806M79G01) as per §4.2.4 before havinq accumulated 7000FC since the MTS creation.
If a rupture is found on a skinny cast yoke within 7000FC, Airbus at the following address for investigation and special workscope. In addition, the forward mount assembly must be removed and replaced before next flight:
Laure Dup and, SEEE3 customer Services Phone: +33 (0)5 61 18 20 24 Fax: +33 (0)5 61 93 36 14 Mailto: laure.dupland@airbus.com
4.2.3.c. Close-up Make sure that the work areas are clean and clear of tools and other items of equipment.
Close the fan cowl doors 435AL and 436AR for engine 1 and 445AL and 446AR for engine 2 (refer to AMM task ref 2.3).
Close the thrust reverser cowl doors 451AL and 452AR for engine 1 and 461AL and 462AR for engine 2 (refer to AMM task ref 2.3).
Remove the access platform (s).
AOT_71A6029_00[1]. txt Restore the systems and the aircraft to normal operating condition.
4.2.4 Replacement of skinny cast yoke by a forged one
4.2.4.a. Preparation Make sure that the aircraft is electrically grounded (refer to AMM task ref 2.2) .
put the access platforcesure as specified in the removal/installation Do the preparation procedure of the forward engine mount (refer to AMM task ref 2.4).
4.2.4.b. Procedure Remove the skinny cast yoke (refer to AMM task ref 2.4 and CMMm ref
2.5) and install a forged one P/N 1806M79G01 (refer to AMM task ref
2.4 and CMMm ref 2.5).
If GE VSB 72-0222 has not been already accomplished, modity the forward engine mount system (see ret 2.6).
4.2.4.c Test Install the power plant (refer to AMM task ref 2.7).
o the test procedure as specitied after the installation of the power plant (refer to AMM task ref 2.7).
4.2.4.d Close-up Remove the access platform(s).
4.3 MATERIAL INFORMATION
4.3.1 Material - Price and availability following address of from any other aproved sturest at the
GENERAL ELECTRIC Manager, Customer Account Support GE Engine Services Distribution, L.L.C.
Product Support Operation One Neumann way Room 115 Cincinnati, OH 45215-1998 USA http://customer.geae.com Procurement terms for the equipment must be negotiated with the equipment supplier.
The quantity of yokes to order depends on the result of the inspection.
4.3.2 Tooling accomplish this AOT, it is necessary to use the tools listed in the AMM task ref 2.4.
4.4 NOTE From this AOT issuance, a skinny cast yoke (P/N 9383M43G08 or Page 4
AOT_71A6029_00[1]. txt 9383M43G09 or 9383M43G10 or 9383M43G11) can be re-installed on CF6- 80C2 A300-600 equipped aircraft only if a MTS (Movement Traceability Sheet) is attached and if it has accumulated less than 7000FC since the MTS creation.
caution note will be introduced in the AMM to avoid re-installation of a skinny cast yoke without MTS.
5. FLOW CHART For readability purpose, a flow chart has been compiled accordingly (see Appendix 04).
6. AOT APPROVAL The technical content of this AOT has been approved under the authority of EASA design organization approval number EASA 21J.031.
7. REPORTING/ACKNOWLEDGMENT Operators are requested to acknowledge receipt of this AOT within 48 hours after receipt to:
E-mail: richard.lascours@alrbus.com Fax: +33/ (0) 5 61 93 32 73 This acknowledgement can be made through the Airbus RCSM when available.
Questions about the technical content of this AOT are to be addressed MS. Laure DUPLAND, SEEE3 TEL: +33 / (0) 5 61 18 20 24 FAX: +33 / (0) 5 61 93 36 14 E-Mail: laure.dupland@airbus.com Best regards, E. VAN AELST VICE PRESIDENT A300 PROGRAMME
CUSTOMER SERVICES DIRECTORATE If you receive this message via e-mail/internet, we draw your attention to the fact that it may be monitored and/or intercepted.
Further, whilst Airbus has taken reasonable measures to ensure the integrity of this message and its contents, no warranty, whether © A haress of an us wor 2 or euest that it be rena stered is given that the contents hereof conform to the by fax or telex.
Appendix 01 - AOT 71A6029 - Figures Z 460 Z450 ..
WD
ENGINE MOUNT YOKE NOTE: INSPECTION AREA Figure 1: Forward Engine Mount Yoke
PN TO BE CHECKED
AREA TO BE
INSPECTED Figure 2: Area to be inspected
Appendix 02 - AOT 71A6029 - Inspection Report
INSPECTION REPORT AOT No.: A300-71A6029 DATE OF INSPECTION:
A/C MSN: INSPECTION METHOD:
FLIGHT CYCLES: GENERAL VISUAL INSPECTION FOR P/N
• DET FOR FULL RUPTURE FLIGHT HOURS:
ENGINE 1 (LH)
YES NO SKINNY CAST YOKE (P/N 9383M43G08 OR 9383M43G09 OR 9383M43G10 OR 9383M43G11) INSTALLED?
SKINNY CAST YOKE FOUND FULLY RUPTURED?
ENGINE 2 (RH)
YES NO SKINNY CAST YOKE (P/N 9383M43G08 OR 9383M43G09 OR 9383M43G10 OR 9383M43G11) INSTALLED?
SKINNY CAST YOKE FOUND FULLY RUPTURED?
The results of the inspection must be forwarded to Airbus department SEEE3:
Laure Dupland, SEEE Customer Services Phone: +33 (0)5 61 18 20 24 Fax: +33 (0)5 61 93 36 14 Mailto: laure.dupland@airbus.com
Serial Number of the detail ENDORSEMENT All information stated in the MTS have to be validated/endorsed by the relevant quality organisation Page: 1/1 POS Position of the detail part (ENG1 or ENG2) • Issue date: 04-Mar-2005 Time: 12:09 CSN Cycles since new of the aircraft the detail part is fitted to COMPONENT MOVEMENT TRACEABILITY SHEET PART's S/N AIRCRAFT TSN MSN WV Aircraft Weight variant Time since new of the aircraft the detail part Manufacturer is fitted to Serial Number of the aircraft the detail part is fitted to Model Model of the aircraft the detail part is fitted to ASSY CSO TSO Time since overhaul of the assembly the detail part is fitted Serial Cycles since Number of overhaul of the assembly the assembly the detail the detail part is fitted part is fitted REMARKS Reference date (status/issue date/time and page number) P/N Part Number of the assembly the detail part is fitted to CSI Cycles since MTS creation of the detail COMPONENT DESCRIPTION: part PART TSI 0/00 Time since MTS creation of the detail Nomenclature of the detail DATE P/N Off Reason Reason for removal (repair, overhaul...) Part Number of the detail part Date when the detail part is removed from the aircraft All relevant remarks on the part/aircraft have to be introduced here. Appendix 03 - AOT 71A6029 - MTS explanation part Date when the detail part is fitted on the aircraft or date of MTS creation
ENDORSEMENT Page: 1/1
• POS Issue date: 04-Mar-2005 Time: 12:09 CSN COMPONENT MOVEMENT TRACEABILITY SHEET PART's S/N AIRCRAFT TSN MSN W Model CSO
ASSY TSO REMARKS S/N P/N CSI COMPONENT DESCRIPTION: PART TSI 0:00 P/N DATE Off Reason Appendix 03 - AOT 71A6029 - MTS On
CONTACT AIRBUS AND REPLACE THE FORWARD MOUNT ASSEMBLY BEFORE NEXT FLIGHT YES DO A DETAILED INSPECTION (DET) OF THE SKINNY CAST YOKE FOR FULL RUPTURE CAST YOKE FULLY RUPTURED?
CREATE AND ATTACH A MTS (APPENDIX 03) SEND TO AIRBUS INSPECTION REPORT (APPENDIX 02) REPLACE THE FORWARD ENGINE MOUNT YOKE BY A FORGED YOKE (P/N 1806M79G01) WITHIN 7000FC AND ACCOMPLISH GE SB 72- 0222 IF NOT ALREADY ACCOMPLISHED DO A GENERAL VISUAL INSPECTION OF THE ENGINE FRONT MOUNT YOKE TO IDENTIFY THE P/N WITHIN 400FC SKINNY CAST YOKE (P/N 9383M43G08 or 9383M43G09 or 9383M43G10 or 9383M43G11) INSTALLED?
Appendix 04 - AOT 71A6029 - Flow Chart NO SEND TO AIRBUS INSPECTION REPORT (APPENDIX 02) NO FURTHER ACTION