General Electric SB 72-A0060: Revision R05

CF34-8E Service Bulletins (SBs) SB 72-A0060 R05 ENGINE - Fan Rotor Assembly (72-00-21) - Inspection of Fan Blades Date Printed:

2016/12/19 GE PROPRIETARY INFORMATION - Not to be used, disclosed to others or reproduced without the express written consent of GE. Technical data is considered ITAR and/or EAR controlled;

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Page 1 of 8 CF34-8E ALERT SERVICE BULLETIN - 72- A0060 R05 Revised:06/15/2016 SB 72-A0060 R05 ENGINE - FAN ROTOR ASSEMBLY (72-00-21) -

INSPECTION OF FAN BLADES Issued:

01/16/2007

GE PROPRIETARY INFORMATION The information contained in this document is 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.

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.

Copyright (2016) General Electric Company, U.S.A.

TRANSMITTAL INFORMATION REVISION 5 TO SERVICE BULLETIN 72-0060 Revision 5 is issued to update paragraphs 1., , 2.,PLANNING INFORMATION , 3., , and to addMATERIAL INFORMATION ACCOMPLISHMENT INSTRUCTIONS paragraphs 4., and 5., .APPENDIX A APPENDIX B Revision 4 was issued October 29, 2013. Revision 3 was issued April 09, 2012. Revision 2 was issued August 18, 2011. Revision 1 was issued February 19, 2010. The original was issued January 16, 2007. Revision bars in the left margin identify changes.

1. PLANNING INFORMATION A. Effectivity * * * CF34-8E2, -8E2A1, -8E5, -8E5A1, -8E5A2, -8E6, -8E6A1 This Service Bulletin is applicable to all CF34-8E engines.

B. Description This Service Bulletin recommends an inspection initiation point of the fan blade pinholes via ECI, a program for inspecting fan blade pinholes at recommended intervals, a termination point of the inspection, and a requirement to rework the fan blades.

C. Compliance Category 2

CF34-8E Service Bulletins (SBs) SB 72-A0060 R05 ENGINE - Fan Rotor Assembly (72-00-21) - Inspection of Fan Blades Date Printed:

2016/12/19 GE PROPRIETARY INFORMATION - Not to be used, disclosed to others or reproduced without the express written consent of GE. Technical data is considered ITAR and/or EAR controlled;

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Page 2 of 8

(1) GE recommends that you begin with this inspection plan when the fan blades accumulate the operating cycles since new (CSN) as follows:

Engine Model Group Engine Thrust Rating Initial Inspection (Part Cycles) Reduced Inspection (Part Cycles) Initial Inspection Threshold Initial Inspection Interval Reduced Inspection Threshold Reduced Inspection Interval Group 1 CF34-8E2 25,000 3,000 N/A N/A Group 2 CF34-8E2A1, CF34-8E5, CF34-8E5A1, CF34-8E6, CF34-8E6A1 19,500 3,000 25,000 1,500 Group 3 CF34-8E5A2 19,000 3,000 25,000 1,500

(2) GE recommends subsequent re-inspection of the affected fan blades in compliance with this Service Bulletin as follows:

(a) At 41,000 part cycles, the fan blades are no longer serviceable and the inspection plan terminates.

(b) At 41,000 part cycles, repair the fan blades per CF34-8E S/B or72-0115 remove the fan blades and replace with serviceable fan blades.

Example:

For fan blades installed on CF34-8E5 that reached 19,500 part CSN, you would do an ECI. Then, repeat the ECI at 22,500, 25,000, 26,500, 28,000, 29,500, 31,000, 32,500, 34,000, 35,500, 37,000, 38,500, and 40,000 part cycles.

NOTE:Notice that once the fan blades reach 25,000 part CSN, the ECI interval is reduced from 3,000 to 1,500 part cycles.

At 41,000 part CSN, the fan blades would have to be reworked per CF34-8E S/B or replaced with new serviceable fan blades of the same part72-0115 number.

(3) GE recommends that you do this Service Bulletin on the fan blades listed in paragraph 1.A., at or as close as conveniently possible toEffectivity the recommended inspection limits without exceeding the recommended inspection limits.

NOTE:If the fan blades have cycles accumulated on one or more CF34 models and/or have an unknown accumulated number of part cycles, refer to paragraph 4., .APPENDIX A NOTE:This Service Bulletin can be accomplished on wing or in shop.

This Service Bulletin is offered to improve the reliability or performance of your GE product, or to help prevent the occurrence of the event or condition described in this Service Bulletin. If the operator elects not to participate in the bulletin, that decision will be taken into consideration by GE in evaluating future product performance issues that may arise in the operator's fleet.

D. Concurrent Requirements None.

E. Reason

(1) Objective:

(a) To recommend an initial inspection requirement for fan blade pinholes.

(b) To introduce an ECI and a program for inspecting fan blade pinholes at recommended intervals.

(c) To recommend re-inspection at specified intervals until rework procedures are completed for the affected fan blades.

(d) To introduce a termination point of the inspection plan and recommend rework of the fan blades per CF34-8E S/B .72-0115

(e) To advise operators to maintain time since new (TSN) and CSN data of

CF34-8E Service Bulletins (SBs) SB 72-A0060 R05 ENGINE - Fan Rotor Assembly (72-00-21) - Inspection of Fan Blades Date Printed:

2016/12/19 GE PROPRIETARY INFORMATION - Not to be used, disclosed to others or reproduced without the express written consent of GE. Technical data is considered ITAR and/or EAR controlled;

transfer of this data to a Non-US Person, without USG authorization, is strictly prohibited.

Page 3 of 8 their fan blades.

(f) To advise operators that GE has developed a rework procedure for the fan blades. Refer to CF34-8E S/B .72-0115

(2) Condition:

Operation of fan blades beyond recommended limits could result in cracks through one-half of a fan blade tang. These cracks could cause excessive fan vibrations and heavy fan blade rubs which could lead to separation of the fan blade.

(3) Cause:

During operation beyond 25,000 or 19,500 part cycles based on thrust groupings in paragraph 1.C., , the stresses in the fan bladeCompliance pinholes could result in crack initiation at pinhole surfaces, and continuation through one-half of a fan blade tang.

(4) Improvement:

A reoccurring ECI plan has been initiated to inspect all the fan blades up to 41,000 part cycles to reduce the probability of the cracks propagating to failure. At 41,000 part cycles the fan blades must be reworked or removed from service. Refer to CF34-8E S/B .72-0115

(5) Substantiation:

Analysis and component testing have indicated that the minimum fan blade low cycle fatigue (LCF) capability is less than the published aircraft life. The ECI initiation point is based on crack initiation. It is set below the minimum fan blade LCF capability. The ECI interval is based on crack propagation. The reinspection interval is below the predicted minimum crack propagation rate.

F. Approval This Service Bulletin has been reviewed by the FAA and the repair(s) and modification(s) herein comply with the applicable Federal Aviation Regulations and are FAA APPROVED for installation in the model(s) listed in this Service Bulletin.

G. Manpower For planning purposes, the following times apply:

*The approximate time required to remove and install a fan blade set is 4 man-hours.

*The approximate time required to accomplish an ECI of an uninstalled fan blade set in accordance with the recommendations in this Service Bulletin is 4 man-hours.

NOTE:The approximate time required to accomplish an ECI of a single uninstalled fan blade is 1 man-hour.

*The approximate time required to strip and re-coat the heat cured lubricant on an uninstalled fan blade set is 24 man-hours.

H. Weight and Balance Weight and balance are not changed.

I. References (Use the latest version of these documents) GEK 112031, CF34-8E Engine Manual (EM) GEK 9250, Commercial Engine Standard Practices Manual (SPM) CF34-8E-AL S/B , ENGINE - Fan Rotor Assembly (72-21-00) -72-0115 Introduction of Fan Blade Bushing Repair CF34-8C-AL S/B , ENGINE - Fan Rotor Assembly (72-00-21) -72-0137 Inspection of Fan Blades J. Publications Affected GEK 112031, CF34-8E Engine Manual (EM) K. Interchangeability If a fan blade is replaced in accordance with this Service Bulletin, the replacement fan blade will be physically and

CF34-8E Service Bulletins (SBs) SB 72-A0060 R05 ENGINE - Fan Rotor Assembly (72-00-21) - Inspection of Fan Blades Date Printed:

2016/12/19 GE PROPRIETARY INFORMATION - Not to be used, disclosed to others or reproduced without the express written consent of GE. Technical data is considered ITAR and/or EAR controlled;

transfer of this data to a Non-US Person, without USG authorization, is strictly prohibited.

Page 4 of 8 functionally interchangeable with the fan blade it replaces.

L. Software Accomplishment Summary Not applicable.

2. MATERIAL INFORMATION A. Material - Price and Availability

(1) Parts necessary to do this Service Bulletin:

None.

(2) Other spare parts:

(a) If fan blades need to be replaced due to inspection results, refer to the table below.

Part Number Qty/ Eng Part Name Unit ($) Price Pkg Qty Lead Time Days 4114T15P02 (AR) Fan Blade 12,000.00 (2) 30 NOTE:Prices are provided for planning purposes and are subject to change.

(3) Consumables:

None.

B. Industry Support Information

(1) Materials required to accomplish this Service Bulletin are listed in paragraph 2.A.(2), .Other Spare Parts

(2) Material and labor cost estimates may be obtained from any GE Aircraft Engines authorized service or overhaul facility upon request. Material and labor costs are the responsibility of the operator.

C. Configuration Chart None.

D. Parts Disposition If you do not have GE ECI certification, return the fan blades to one of these GE certified ECI sources:

GE Aircraft Engines Maintenance Center Strother Field Arkansas City, KS 67005 +1 620-442-3600 U.S.A.

OR Standard Aero 33 Allen Dyne Road Winnipeg, Manitoba Canada R3H 1A1 +1 204-789-1800 OR Lufthansa Technik AERO Alzey GmbH Rudolf -Diesel-Strasse 10 55232 Alzey, Germany +49 6731-497-0 OR MTU Maintenance Berlin-Brandenburg GmbH Dr. Ernst-Zimmermann-Strae 2 14974 Ludwigsfelde, Germany +49 3378-824-0 OR IHI Mizuho Plant 229 Tonogaya Mizuho-Machi Nishi Tama-Gun Tokyo, Japan

CF34-8E Service Bulletins (SBs) SB 72-A0060 R05 ENGINE - Fan Rotor Assembly (72-00-21) - Inspection of Fan Blades Date Printed:

2016/12/19 GE PROPRIETARY INFORMATION - Not to be used, disclosed to others or reproduced without the express written consent of GE. Technical data is considered ITAR and/or EAR controlled;

transfer of this data to a Non-US Person, without USG authorization, is strictly prohibited.

Page 5 of 8 190-1212 +81 42-568-7371/7103 E. Tooling - Price and Availability NOTE:For approved eddy current instruments, probe rotors and other tooling, refer to GEK 112031, 72-09-05, INSPECTION 001.

Tool Number Description GE-FQAP-3XX*+ 300 Series Inspection Kit GE-FQAP-446 Fan Blade Pin Hole Inspection Kit J058077G01+ Guide Fixture -- Cables and Adapters -- Eddy Current Instrument -- High Speed Probe Rotor *Includes J050884G01 guide fixture (which is for the CF34-3 fan blades; this may be omitted at request), two probes, and a calibration standard. The kit depends of the eddy current instrument being used.

+Locally manufactured probe alignment tooling can be used as alternative to the recommended tooling.

NOTE:Inspection kits with the reference number of GE-FQAP-XXX and guide fixture can be obtained from:J058077G01 GE Inspection Technologies Attn.: NDE Kit Coordinator 50 Industrial Park Road Lewistown, PA 17044 U.S.A.

Email: ndttooling@ge.com Fax: 513-552-1386

3. ACCOMPLISHMENT INSTRUCTIONS A. General NOTE:Maintenance facilities where the inspections will be performed must be approved by GE. Maintenance facilities that are approved to perform the ECI for the CF34-3 fan blade pinholes are considered approved sources to perform the ECI for the CF34-8 fan blade pinholes, although the CF34-8 guide fixture J058077G01 might need to be procured.

NOTE:To become a GE certified ECI source, contact GE Fleet Support at:

Phone: (513) 552-3272 OR E-mail: aviation.fleetsupport@ge.com NOTE:To become a GE certified ECI source you must have a certified level II eddy current inspector and must purchase the ECI equipment.

NOTE:If you do not have GE ECI certification, refer to paragraph 2.D., Parts .Disposition B. Removal Remove the fan blades. Refer to GEK 112031, 72-00-21, Removal.

NOTE:Mark the fan blades relative to the 0-mark. This is important to make sure that the fan blades are reinstalled in the same order to minimize balance issues after completing this procedure.

C. Inspection of Fan Blades

(1) Do an inspection of the fan blades pin holes. Refer to GEK 112031, 72-09-05, INSPECTION 001, step 3.C.

D. Deleted E. Installation Install the fan blades. Refer to GEK 112031, 72-00-21, Installation.

CF34-8E Service Bulletins (SBs) SB 72-A0060 R05 ENGINE - Fan Rotor Assembly (72-00-21) - Inspection of Fan Blades Date Printed:

2016/12/19 GE PROPRIETARY INFORMATION - Not to be used, disclosed to others or reproduced without the express written consent of GE. Technical data is considered ITAR and/or EAR controlled;

transfer of this data to a Non-US Person, without USG authorization, is strictly prohibited.

Page 6 of 8 NOTE:Install the fan blades with the No. 1 fan blade at the 0-mark to make sure that they are installed in the same clocking locations as when they were removed.

F. Testing Do an on-wing test. Refer to GEK 112031, 72-00-00, Testing 001, Figure 1314 for required testing.

4. APPENDIX A - Fan Blades used on multiple models or with unknown accumulated cycles NOTE:If you have a situation which is not defined below, please contact your Customer Service Manager.

A. If the number of part cycles accumulated on one or more CF34-8 models/configurations is accurately known and documented, the initial inspection limit for a part used in more than one CF34-8 model/configuration can be calculated by pro-rating the cycles consumed. Calculate the fraction of cycles used for a part installed in a given CF34-8 model/configuration, then calculate the remaining part CSN for the part installed in a different CF34-8 model/configuration, as follows:

(1) Calculate the fraction of life used for a part installed in initial CF34-8 model/configuration as follows:

Fraction of life used = Cycles accumulated on CF34-8 model 1LCF limit for CF34-8 model 1

(2) Use this fraction and calculate the remaining CSN on the part if installed in another different CF34-8 model (model 2) as follows:

Cycles remaining for CF34-8 model 2 = [ 1.0 Fraction of life used (from above) ] X LCF limit forCF34-8 model 2

(3) Determine the Inspection Interval (for fan blades which the part cycles are known) Once the inspection plan has begun, for a part used in more than one CF34-8 models/configurations the re-inspection interval is determined as follows:

(a) If the part has not changed models/configurations since the last inspection, follow the re-inspection interval listed below:

1 For parts that operate on group 1 engines listed in 1.C., , re-inspect every 3,000 part cycles.Compliance 2 For parts that operate on group 2 and group 3 engines listed in

1.C., , re-inspect every 1,500 part cycles.Compliance

(b) If the part is changing models/configurations immediately, inspect the part, then follow the re-inspection interval as follows:

1 For parts that will operate on group 1 engines, re-inspect every 3,000 part cycles.

2 For parts that will operate on group 2 and group 3 engines, re-inspect every 1,500 part cycles.

B. For fan blades where the part CSN is unknown, it is recommended that the operator assume that the part CSN is equal to the CSN on the highest-time engine in the operator's fleet. Base the recommendation for inspection on that CSN. This applies only if the operator has not purchased any fan blades with unknown part CSN that may have been owned by a previous operator.

(1) Determine the Inspection Interval (for fan blades which the part cycles are unknown) If the part cycles are unknown and the assumed number of cycles is greater than the inspection start point, immediately inspect the part, then follow the re-inspection interval as follows:

(a) For parts that will operate on group 1 engines, re-inspect every 3,000 part cycles.

(b) For parts that will operate on group 2 and group 3 engines, re-inspect every 1,500 part cycles.

C. For fan blades that have been purchased with the part CSN unknown and could have been owned by a previous operator, it is recommended that the operator

CF34-8E Service Bulletins (SBs) SB 72-A0060 R05 ENGINE - Fan Rotor Assembly (72-00-21) - Inspection of Fan Blades Date Printed:

2016/12/19 GE PROPRIETARY INFORMATION - Not to be used, disclosed to others or reproduced without the express written consent of GE. Technical data is considered ITAR and/or EAR controlled;

transfer of this data to a Non-US Person, without USG authorization, is strictly prohibited.

Page 7 of 8 assume that the part CSN is equal to the CSN on the highest-time engine in the fleets. Base the recommendation for inspection on that CSN. Operators should work with their assigned Customer Support Manager to obtain this highest-time engine information.

(1) Determine the Inspection Interval (for fan blades which the part cycles are unknown) If the part cycles are unknown and the assumed number of part cycles is greater than the inspection start point, immediately inspect the part, then follow the re-inspection interval as follows:

(a) For parts that will operate on group 1 engines, re-inspect every 3,000 part cycles.

(b) For parts that will operate on group 2 and group 3 engines, re-inspect every 1,500 part cycles.

D. For fan blades that have been purchased with part CSN unknown, the initial purchase date of the fan blade is known, and the fan blade has not been installed on any other operator, the operator can use the maximum usage rate of their fleet to estimate the part CSN.

(1) Determine the Inspection Interval (for fan blades which the part cycles are unknown) If the part cycles are unknown and the assumed number of part cycles is greater than the inspection start point, immediately inspect the part, then follow the re-inspection interval as follows:

(a) For parts that will operate on group 1 engines, re-inspect every 3,000 part cycles.

(b) For parts that will operate on group 2 and group 3 engines, re-inspect every 1,500 part cycles.

NOTE:The fan blade is a common part for CF34-8C and CF34-8E engines. If the fan blade is being moved between CF34-8C and CF34-8E fleets, the mixed fleet methodology described in this Service Bulletin is still applicable. Please refer to the equivalent CF34-8C-AL S/B for the inspection threshold,72-0137 re-inspection interval, and reduced inspection intervals (if applicable) by thrust.

5. APPENDIX B - Examples of Prorated Calculations for Mixed Model Fan Blades Examples Where Part CSN and Model History is Accurately Known and Documented Example 1 - Low Thrust to High Thrust Model Switch Before Inspection Starting Point A set of fan blades operates on a CF34-8E2 for 10,000 cycles and then switches to a CF34-8E5. The prorated initiation point is calculated as follows:

Fraction of life used = Cycles accumulated on CF34-8E2/LCF limit for the CF34-8E2 = 10,000/25,000 = 0.4 Cycles remaining for CF34-8E5= 1 - Fraction of life used X LCF limit for CF34-8E5 = (1-0.4)X19,500= 11,700 cycles Therefore, the inspection would begin in 11,700 cycles (or at 21,700 part CSN). The inspection would occur every 1,500 part cycles. The fan blades should be reworked at 41,000 part CSN or sooner.

Example 2 - High Thrust to Low Thrust Model Switch Before Inspection Starting Point A set of fan blades operates on a CF34-8E5 for 10,000 cycles and then switches to a CF34-8E2. The prorated initiation point is calculated as follows:

Fraction of life used = Cycles accumulated on CF34-8E5/LCF limit for the CF34-8E5 = 10,000/19,500 = 0.52 Cycles remaining for CF34-8E2 = 1 - Fraction of life used X LCF limit for CF34-8E2 = (1- 0.52)X25,000 = 12,000 cycles Therefore, the inspection would begin in 12,179 cycles (or at 22,179 part CSN). The inspection would occur every 3,000 part cycles. The fan blades should be reworked at 41,000 part CSN or sooner.

CF34-8E Service Bulletins (SBs) SB 72-A0060 R05 ENGINE - Fan Rotor Assembly (72-00-21) - Inspection of Fan Blades Date Printed:

2016/12/19 GE PROPRIETARY INFORMATION - Not to be used, disclosed to others or reproduced without the express written consent of GE. Technical data is considered ITAR and/or EAR controlled;

transfer of this data to a Non-US Person, without USG authorization, is strictly prohibited.

Page 8 of 8 Example 3 - Low Thrust to High Thrust Model Switch After Inspection Starting Point A set of fan blades operates on a CF34-8E2 for 30,000 cycles and then switches to a CF34-8E5. Since the inspection has already occurred, there is no need to calculate the inspection starting point.

The fan blades should be inspected before returning the engine to service and continue to occur every 1,500 cycles. The fan blades should be reworked at 41,000 part CSN or sooner.

Example 4 - High Thrust to Low Thrust Model Switch After Inspection Starting Point A set of fan blades operates on a CF34-8E5 for 30,000 cycles and then switches to a CF34-8E2. Since the inspection has already occurred, there is no need to calculate the inspection starting point.

The fan blades should be inspected before returning the engine to service and continue to occur every 3,000 part cycles. The fan blades should be reworked at 41,000 part CSN or sooner.

Example 5 - Low Thrust to High Thrust Model Switch After Inspection Starting Point A set of fan blades operates on a CF34-8E5 for 30,000 cycles and then switches to a CF34-8E2. Since the inspection has already occurred, there is no need to calculate the inspection starting point.

The fan blades should be inspected before returning the engine to service and continue to occur every 3,000 part cycles. The fan blades should be reworked at 41,000 part CSN or sooner.

Part Cycles Accumulated are Known, but not by Model Examples Example 6 - Mixed Fleet You have a fleet of CF34-8E2 and CF34-8E5 engines. Fan blades have been switched between the two fleets and the quantity of cycles accumulated on the individual fan blades by model is not known. Some of the fleet has passed the inspection point (19,500 part cycles). Treat the two fleets as CF34-8E5. Start the inspection at 19,500 part cycles and do an inspection of the part every 3,000 part cycles until 25,000 part cycles. Then do an inspection of the part every 1,500 part cycles until 41,000 part cycles where the fan blades are reworked.

Example 7 - Mixed Fleet before inspection point You have a fleet of CF34-8E2 and CF34-8E5 engines. Fan blades have been switched between the two fleets and the quantity of cycles accumulated on the individual fan blades by model is not known. None of the fleet has passed the inspection point and processes are in place to prevent mixing go forward. For the CF34-8E5 start the inspection at 19,500 part cycles and do an inspection of the part every 3,000 part cycles until 25,000 part cycles. Then do an inspection of the part every 1,500 part cycles until 41,000 part cycles where the fan blades are reworked. For the CF34-8E2 start the inspection at 19,500 part cycles and do an inspection of the part every 3,000 part cycles until 41,000 part cycles where the fan blades are reworked.

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