CF6-80C2

Workscope Planning Guide

GEK 117580 WSPG

Date: March 2014

Revision: 20

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.
 CF6-80C2
GE Aviation Workscope Planning Guide

Contents
SECTION SUBJECT Page

1. Introduction…………………………………………………………….. 1-1

1.0. Introduction……………………………………………………………….. 1-1

1.1. Technical Information Statement……………………………….………. 1-1
1.2. Objectives……………………………..………………………………….. 1-1
1.3. Engine Applications……………………………………………………… 1-3
1.4. Extended Range Operations…………………………………….……… 1-3
1.5. “Soft-Time” Threshold Maintenance Discussion……………………… 1-4
1.6. Modular Thresholds……………………………………….……………... 1-5
1.7. Engine Accessories Soft Time Recommendations…………………... 1-6
1.8. Level of Work…………………………………………………….……….. 1-6
1.9. Inspection Limits/Level of Disassembly……………………….……….. 1-7
1.10. Engine Assembly Workscope……………………………….………….. 1-8
1.11. Assembled Engine Workscope………………………………….……… 1-9
1.12. Individual Engine Workscope………………………………….………... 1-9

2. Consolidated Inspection and Servicing

Recommendations……………………………………………………… 2-1
……………

2.0. Purpose…………………………………………………………………… 2-1

2.1. Schedule Maintenance Checks………………………………………… 2-1
2.2. Abbreviations……………………………………………………………... 2-2
2.3. Appendix A……………………………………………….……………….. 2-14

3. Modular Thresholds……………………………………………………. 3-1

3.0. Modular Thresholds…………….……………………………….……….. 3-1

3.1. Fan Stage 1 Rotor………….………………….………………….……… 3-2
3.2. Fan Booster Rotor……………….…………….…………………….…… 3-2
3.3. Fan Stator……………………………………………………………….… 3-2
3.4. HPC Module…………………………………………………….………… 3-3
3.5. CRF Module……………………...……………………………….………. 3-3
3.6. Combustor Module…………………………..………………….……….. 3-4
3.7. HPT Stage 1 Nozzle………………………………………………….….. 3-4
3.8. HPT Stage 2 Nozzle …………….………………………………….…… 3-5
3.9. HPT Rotor…………………………………..……………………….……. 3-5
3.10. LPT Module………………………………………………………….……. 3-5
3.11. Accessory Drives Module………….……………………………….…… 3-6
3.12. Configurations…………………..………….……………………….……. 3-6
3.13. Controls and Accessories……………….………………………………. 3-6

GE Proprietary Information 0-1 Workscope Planning Guide

Subject to restrictions on the cover or first page
 CF6-80C2
GE Aviation Workscope Planning Guide

SECTION SUBJECT Page

4. Performance Effects by Module…..……………...………………… 4-1

4.0. Module Performance Effects………………………………....…….….. 4-2

4.1. Performance Effects for Fan Module Airfoils Clearances and
Surface Conditions……………………………………………………… 4-2
4.2. Performance Effects for HPC Module Airfoils Clearances and
Surface Conditions……………………………….……………………… 4-3
4.3. Performance Effects for CDP and 4R Vent Seal Clearances…….… 4-4
4.4. Performance Effects for HPT Stage 1 Nozzle Assembly………….... 4-5
4.5. Performance Effects for HPT Clearances…………………………..… 4-7
4.6. Performance Effects for HPT Configuration 2 (R88DT Rotor)
Forward Seal Clearances………..…………………………………….. 4-10
4.7. Performance Effects for LPT Module…………………………………. 4-11

5. Assembled Engine…………….………………………………………. 5-1

5.0. Assembled Engine Cross Section………….………………………….. 5-2

5.1. Engine Performance Restoration Contributors………….………….... 5-2
5.2. Assembled Engine Special Workscope - General……….…………... 5-4

6. Fan/Booster Module…….………………………………………..…… 6-1

6.0. Fan/Booster Module Assembly…….………………………………….. 6-2

6.1. Performance Effects for Fan/Booster Module…….………………….. 6-12
6.2. Fan/Booster Module Minimum Workscope…………………………… 6-12
6.3. Fan Module Minimum Workscope Tasks…………………...………… 6-14
6.4. Fan Module Performance Workscope - Discussion.……...………… 6-15
6.5. Fan/Booster Module Full Overhaul Workscope……….……………… 6-16
6.6. Fan Module Full Overhaul Workscope Tasks………………………… 6-19
6.7. Critical Items, Reliability and Key Product Improvements, and
Best Practices - Fan Frame Assembly………………………………… 6-21
6.8. Critical Items, Reliability and Key Product Improvements, and
Best Practices - Fan Stator Assembly……………………………….... 6-34
6.9. Critical Items, Reliability and Key Product Improvements, and
Best Practices - Fan Rotor Assembly………………………………… 6-38

7. High Pressure Compressor Module……….…………………. 7-1

7.0. High Pressure Compressor Rotor Cross Section……….…………… 7-2

7.1. HPC Module Minimum Workscope….………………………………... 7-10
7.2. HPC Module Minimum Workscope Tasks……..……………………... 7-11
7.3. HPC Module Performance Workscope………….…….………………. 7-12
7.4. HPC Module Performance Workscope Tasks.…….…….…………… 7-13
7.5. HPC Module Full Overhaul Workscope……………………….………. 7-14

GE Proprietary Information 0-2 Workscope Planning Guide

Subject to restrictions on the cover or first page
 CF6-80C2
GE Aviation Workscope Planning Guide

SECTION SUBJECT Page

7. High Pressure Compressor Module (Cont.)………………………. 7-1

7.6. HPC Module Full Overhaul Workscope Task and Subtask………… 7-16
7.7. Critical Items, Reliability and Key Product Improvements,
and Best Practices - High Pressure Compressor Rotor Assembly.… 7-18
7.8. Critical Items, Reliability and Key Product Improvements,
and Best Practices - High Pressure Compressor Stator Assembly.... 7-37

8. CRF Module……………………………………………………………… 8-1

8.0. CRF Module Cross Section………….…………………………….……. 8-2

8.1. CRF Module Cross Section……………………….……………….……. 8-7
8.2. CRF Module Minimum Workscope Tasks……………….…..….….….. 8-8
8.3. CRF Module Performance Workscope…………………..……….……. 8-8
8.4. CRF Module Performance Workscope Tasks.……………………....... 8-10
8.5. CRF Module Full Overhaul Workscope ……...…………………….….. 8-10
8.6. CRF Module Full Overhaul Workscope Tasks………………………… 8-12
8.7. Critical Items, Reliability and Key Product Improvements, and
Best Practices - CRF Module. ………………….………………….…... 8-13

9. Combustor Module…………………………………………………….. 9-1

9.0. Combustor Module Cross Section……………………….………...…... 9-2

9.1. Combustor Module Minimum Workscope Tasks....…….…………..… 9-6
9.2. Combustor Module Overhaul Workscope Tasks……….………..….... 9-6
9.3. Combustor Module Critical Items, Reliability and Key Product
Improvements, and Best Practices ………………….…………….…… 9-7

10. HPT Module…………………………………………………………..….. 10-1

10.0. HPT Module - HPT Stage 1 Nozzle Assembly…….……………...…... 10-2

10.1. Configuration 1 and Configuration 2 Rotors - HPT Module
Assembly…………………………………………………………………... 10-6
10.2. Configuration 1 and Configuration 2 Rotors - HPT Module
Assembly……………………………………………………………….….. 10-9
10.3. HPT Module Performance Effects……………………..……….….….... 10-10
10.4. HPT Module Workscopes………………...……………………………… 10-10
10.5. Critical Items, Reliability and Key Product Improvements, and Best
Practices - HPT Rotor Assembly - Configuration 1 (Inco 718 Rotors). 10-24
10.6. Critical Items, Reliability and Key Product Improvements, and Best
Practices - HPT Rotor Assembly - Configuration 2 (R88DT Rotors)… 10-40
10.7. HPT Rotor Hardware - Handling Best Practices………………………. 10-49
10.8. Critical Items, Reliability and Key Product Improvements, and Best
Practices - HPT Stage 1 Nozzle Assembly…………………………….. 10-52
10.9. Critical Items, Reliability and Key Product Improvements, and Best
Practices - HPT Stage 2 Nozzle Assembly……………………….…… 10-54

GE Proprietary Information 0-3 Workscope Planning Guide

Subject to restrictions on the cover or first page
 CF6-80C2
GE Aviation Workscope Planning Guide

SECTION SUBJECT Page

11. LPT Module…………………………………………………………….. 11-1

11.0. LPT Module……………………………………………...……..………… 11-2

11.1. Performance Effects for LPT Module ………………….…...………… 11-10
11.2. LPT Module Minimum Workscope ………………………..…………... 11-10
11.3. LPT Module Minimum Workscope Tasks….…………………..……… 11-12
11.4. LPT Module Full Overhaul Workscope………..…………...…………. 11-14
11.5. LPT Module Full Overhaul Tasks……………………………………… 11-16
11.6. Critical Items, Reliability and Key Product Improvements, and Best
Practices - LPT Stator Assembly……………………………….……… 11-17
11.7. Critical Items, Reliability and Key Product Improvements, and Best
Practices - LPT Rotor Assembly……………………………..………… 11-28
11.8. Critical Items, Reliability and Key Product Improvements, and Best
Practices - Turbine Rear Frame (TRF) Assembly……………………. 11-31

12. Accessory Drives Module…………………………………………… 12-1

12.0. Accessory Drives Module.…...……………………………………….... 12-2

12.1. Accessory Drives Module Minimum Workscope…………..….……… 12-8
12.2. Accessory Drives Module Performance Workscope.…..……………. 12-9
12.3. Accessory Drives Module Full Overhaul Workscope………………… 12-10
12.4. Critical Items, Reliability and Key Product Improvements, and Best
Practices - Accessory Drives Module…………………………………. 12-11

13. Configurations Module………………………………………………. 13-1

13.0. Configurations Module Assembly……...……………………..……….. 13-2

13.1. Configurations Minimum Workscope…………………..……………… 13-3
13.2. Configurations Module Full Overhaul Workscope…….……………… 13-6
13.3. Critical Items, Reliability and Key Product Improvements, and
Best Practices - Configurations Module………………………………. 13-6

14. Controls and Accessories Module………………………………… 14-1

14.0. Engine Controls and Accessories Soft Time Discussion………..….. 14-2

14.1. Engine Controls and Accessories List and Soft Time*
Recommendations………………………………………………...…….. 14-3
14.2. Controls and Accessories Minimum Workscope……………………... 14-5
14.3. Controls and Accessories Full Overhaul Workscope………………... 14-7
14.4. Controls and Accessories Module-Critical Items, Reliability and Key
Product Improvements, and Best Practices………………………….. 14-11

GE Proprietary Information 0-4 Workscope Planning Guide

Subject to restrictions on the cover or first page
 CF6-80C2
GE Aviation Workscope Planning Guide

SECTION 1

INTRODUCTION

1.0. Introduction.

Maintenance recommendations in this guide are intended to complement the “on-

condition” maintenance concept of the CF6 engine family. In general,
maintenance is only required when a limit defined by an instruction for continued
airworthiness, such as the AMM, engine manual, or airworthiness directive, is
reached or exceeded. However, experience has shown that proactive
maintenance is necessary to maintain optimal reliability and cost of ownership.
The only hard-time limits are for certain part life limits published in Chapter
05-10-00 of the Engine Manual, or those mandated by specific airworthiness
directives issued by the FAA.

1.1. Technical Information Statement.

This document contains references to the CF6-80C2 Engine Manual, Aircraft

Maintenance Manuals, Service Bulletins, Component Maintenance Manuals,
Commercial Engine Service Memorandums, component and assembly part
numbers and other GE documentation. All technical documentation and
information contained in this document and the referenced documents, with
respect to assembly and disassembly, cleaning, inspection methods and limits,
repair methods and limits, operational limits, life limits and the like, have been
developed and approved for use with engines and parts that have been
manufactured and/or approved by GE and that have been maintained in
accordance with GE technical documentation and recommendations. GE has no
contractual or legal obligation for, nor knowledge of, non-GE-approved parts and
repairs. Accordingly, this document is not intended to apply to non-GE-approved
parts and repairs.

1.2. Objectives.

The objectives of the information contained within this guide are to communicate
the extent of work to enable the user of the guide to achieve their engine
durability, performance and maintenance cost goals while maintaining high
standards of engine reliability.

The recommendations contained herein are based on an average engine in the

fleet. However, there are many variable factors that can affect the specific
workscope definition for a given operator or engine.

GE Proprietary Information 1-1 Workscope Planning Guide

Subject to restrictions on the cover or first page
 CF6-80C2
GE Aviation Workscope Planning Guide

Below is a list of examples of such factors that must be considered, but not
limited to:

• Specific durability, performance and maintenance cost goals.

• Specific reliability targets.

• Time since and build standard from previous shop visit.

• Remaining LLP stub life.

• Part repair history.

• Anticipated severity level of operation:

- Thrust rating.

- Engine derate usage.

- Flight leg.

- Temperature climate, sandy environment, cold and / or snowy

environment, others.

• Line maintenance burden.

Therefore, it is important to note that this document is intended to only be a baseline

guide for consideration of key factors when defining a workscope. It is not intended to be
an all inclusive workscope specification.

Most CF6-80C2 overhaul providers recommend customized workscope definition or

specifications. Customized workscopes can be based on the specific operator’s, or
engine owner’s factors mentioned above, as well as the overhaul provider’s prior data
and experience. GE supports the customized workscope approach. GE recommends
that operators, or engine owners, work with their overhaul providers to define the
specific workscope, which best fits their goals and objectives.

GE Proprietary Information 1-2 Workscope Planning Guide

Subject to restrictions on the cover or first page
 CF6-80C2
GE Aviation Workscope Planning Guide

1.3. Engine Applications.

Nameplate Thrust, lb
Maximum PMC or Final Certification
Aircraft Model Rating Take-Off
Continous FADEC Engine Aircraft
A300-601 CF6-80C2A1 57,860 @ 86°F 53,390 @ 77°F PMC Jun. '85 Sep. '85
A310-200 (142T*) Apr. '86
CF6-80C2A2 52,460 @ 111°F 48,080 @ 77°F PMC Dec. '85
A310-300 (157T*) Mar. '86
A300-600 CF6-80C2A3 58,950 @ 86°F 54,790 @ 77°F PMC Dec. '86 Jan. '87
A300-600R CF6-80C2A5 60,100 @ 86°F 56,210 @ 77°F PMC Oct. '87 Mar. '88
A300-600F CF6-80C2A5F 60,100 @ 86°F 56,210 @ 77°F FADEC 1 + Oct. '93 Mar. '94
A310-300 (164T*) Mar. '91
CF6-80C2A8 57,860 @ 95°F 48,080 @ 77°F PMC Feb. '91
A300-600 AST Jul. '95
747-200 CF6-80C2B1 55,980 @ 86°F 49,550 @ 77°F PMC Jan. ‘87 Jan. ‘88
747-300 CF6-80C2B1 55,980 @ 86°F 49,550 @ 77°F PMC Oct. '87 Feb. '88
767-200ER (340K) CF6-80C2B2 51,950 @ 90°F 49,020 @ 86°F PMC Apr. '87 May '87
767-200ER (380K) CF6-80C2B4 57,180 @ 90°F 52,370 @ 77°F PMC Oct. '87 Sep. '87
767-300ER (407K) CF6-80C2B6 60,030 @ 86°F 56,100 @ 77°F PMC Sep. '87 Nov. '87
747-400 CF6-80C2B1F 57,160 @ 90°F 49,810 @ 77°F FADEC 1 Mar. '88 May '89
767-300ER (340K) CF6-80C2B2F 52,010 @ 90°F 49,140 @ 86°F FADEC 1 Sep. '88 Mar. '89
767-300ER (380K) CF6-80C2B4F 57,280 @ 90°F 52,470 @ 77°F FADEC 1 Sep. '88 Aug. '91
747-400 CF6-80C2B5F 60,030 @ 86°F 49,810 @ 77°F FADEC 1 May '97 Dec. '97
767-300ER (407K) CF6-80C2B6F 60,030 @ 86°F 56,170 @ 77°F FADEC 1 Sep. '88 Mar. '89
767-AWACS CF6-80C2B6FA 60,030 @ 86°F 56,170 @ 77°F FADEC 1 Sep. '95 Mar. '98
767-300ER (412K) CF6-80C2B7F 60,030 @ 86°F 56,170 @ 77°F FADEC 1 Oct. '93 Mar. '94
767-400ER CF6-80C2B8F 60,030 @ 86°F 56,170 @ 77°F FADEC 1 Mar. '99 Jul. '00
MD-11 CF6-80C2D1F 60,690 @ 86°F 56,730 @ 77°F FADEC 1 Dec. '88 Feb. '91
C-5 CF6-80C2L1F 51,250 @ 95°F 44,100 @ 95°F FADEC 3 Aug. '04 N/A
C-X CF6-80C2K1F 59,740 @ 86°F 43,400 @ 77°F FADEC 3 Feb. '06 N/A
* Metric Tons

NOTE: The takeoff and flat-rated temperatures are at standard day conditions. The
differences between the engine models can consist of different hardware
requirements, different control requirements, and different testing requirements.

1.4. Extended Range Operations.

The following document must be complied with by aircraft type for extended
range operations:

B767 Boeing document D6T11604, latest revision.

A300/A310 Airbus Industries document AI/EA 3.000, latest revision.

GE Proprietary Information 1-3 Workscope Planning Guide

Subject to restrictions on the cover or first page
 CF6-80C2
GE Aviation Workscope Planning Guide

1.5. “Soft-Time” Threshold Maintenance Discussion.

Maintenance intervals within this document are typically referred to as “soft-time”

recommendations. A “soft-time” recommendation is generally defined as a
threshold of time and/or cycles since a previous shop visit that a certain
maintenance task was performed. By performing the maintenance task at the
recommended threshold, it would be expected that the subject component(s) will
perform reliably with good performance until the next shop visit or beyond.

“Soft-time” recommendations are different than “hard-time” limits. The “soft-time”

thresholds are not mandatory, but are only intended to provide guidance as
defined above. A “hard-time” limit means that the times or cycles that cannot be
exceeded due to reliability concerns. “Soft-time” thresholds in this guide are
based on average engine experience. Therefore, it is necessary for each operator
to evaluate their own, or similar, experience when defining actual maintenance
thresholds for their particular engines.

Some example scenarios of module management using soft times:

NOTE: These are a small sample of possible scenarios shown for illustration of
the soft time module management.

A. Scenario 1: Operator ‘A’ has an engine in the shop. Operator ‘A’ expects
their engine to remain on wing 3, 000 cycles / 12,000 hours after the
current shop visit. The high pressure compressor (HPC) rotor in the engine
currently has 5,000 cycles / 20,000 hours since it was last overhauled. The
Workscope Planning Guide recommends that the HPC rotor be overhauled
if it has accumulated 6,500 cycles (or 39,000 hours) since last overhaul. In
this scenario, the HPC rotor would usually not need to be overhauled at its
current shop visit based on the recommended threshold, even though it
would be expected to exceed 6,500 cycles prior to its next shop visit.

B. Scenario 2: Operator ‘B’ has an engine in the shop. Operator ‘B’ expects
their engine to stay on wing after the current shop visit for 2,200 cycles /
20,000 hours. The HPC rotor in the engine currently has 4,200 cycles /
38,000 hours since it was last overhauled. In this scenario, the operator
should consider their prior experience when deciding whether overhaul of
the HPC should be performed at the current shop visit. Even though the
HPC has not exceeded the “soft-time” threshold of 39,000 hours, it would
be expected to have 58,000 hours since overhaul by the next shop visit if
reinstalled without overhaul at the current shop visit.

GE Proprietary Information 1-4 Workscope Planning Guide

Subject to restrictions on the cover or first page
 CF6-80C2
GE Aviation Workscope Planning Guide

Depending on hardware conditions from previous shop visits, Operator ‘B’

may choose to perform the overhaul on the current shop visit to avoid
excessive wear on the rotor components, if their prior experience shows
that it is warranted. It is recommended that Operator ‘B’ discuss the best
course of action with their overhaul provider.

C. Scenario 3: Operator ‘C’ has an engine in the shop. Operator ‘C’ expects
their engine to stay on wing for 3,500 cycles / 17,000 hours after the
current shop visit. The HPC rotor in the engine currently has 7,000 cycles /
35,000 hours since it was last overhauled. In this scenario, the HPC rotor
should be overhauled to meet the intent of the “soft-time” recommendation
of 6,500 cycles.

1.6. Modular Thresholds.

Thresholds for individual modules, engine maintenance units (EMUs), and piece-
parts are developed as a means to achieve reliability, performance, and cost of
ownership goals. They can address issues of performance restoration or of
hardware integrity.

Thresholds are not hard-time limits. They are economic time guidelines to be
used when deciding an engine‘s bill of work at shop level. Given the wide
variation in usage of the CF6-80C2, it is not possible to define a single threshold
number. As discussed in Section 1.2., Objectives, of this document, there are
many factors that must be considered when defining the workscope of an engine.
Therefore, workscope thresholds are defined as a range of time. GE recommends
that operators work with their overhaul providers to define specific thresholds
based on the factors listed.

Thresholds are developed based on prior shop visit and sampling inspection
experience. Beyond the threshold it is expected that the module will not have the
life remaining to make another complete engine installation/run (i.e. the module
will limit the installed engine life).

Time and flight cycle accounting by engine/module/EMU will be required.

Modules are considered continued-time after shop visit minimum or performance
workscopes, and zero-timed only after full overhaul level workscope
(TSO/CSO=0). Rotating parts will not be reinstalled unless they have more than
the number of cycles of life remaining (stub life) to obtain the expected on-wing
life.

GE Proprietary Information 1-5 Workscope Planning Guide

Subject to restrictions on the cover or first page
 CF6-80C2
GE Aviation Workscope Planning Guide

1.7. Engine Accessories Soft Time Recommendations.

Two separate maintenance plans concerning engine accessories are discussed

in this document:

A. Option 1: Engine accessories are maintained at the shop visit in order to

baseline the components such that they are intended to stay on the engine
for the full upcoming run. The advantage of Plan A is that minimal on-wing
maintenance of accessories can be expected. The disadvantage is that the
accessories can need to be overhauled significantly before they have
consumed their predicted usable life, which increases shop costs.

B. Option 2: Manage engine accessories to maximize use of the predicted

component usable life. The advantage of Plan B is that shop cost can be
reduced if there is usable life remaining on the accessory. The
disadvantage is that the components can have to be managed on wing,
which increases logistics and maintenance burden.

1.8. Level of Work.

This guide recommends a workscope to be carried out on engine run

modules/hardware inducted into the overhaul shop and it recommends a build
standard for assembly of hardware into a serviceable engine. Four levels of work
are designated for incoming engines/modules:

A. The Assembled Engine Workscope applies to an engine that has been

removed after being installed for a short time period or an engine removed
for any reason and it is not expected to be inducted into the shop for a
performance-level shop visit.

B. Shop Visit Minimum Workscope.

• Applies to all engine shop visits with modules having no apparent

hardware failure or performance problems, if the module is removed or
accessible. Engines/modules worked to this level must have
demonstrated adequate performance margin incoming to the shop.

• Performance or full overhaul thresholds not exceeded

• Engine Manual Condition Maintenance Chapters (72-00-XX) apply

GE Proprietary Information 1-6 Workscope Planning Guide

Subject to restrictions on the cover or first page
 CF6-80C2
GE Aviation Workscope Planning Guide

C. Performance Workscope.

• Primarily intended to restore the engine flow path to reclaim engine

performance (EGT and SFC margin), as well as flow path hardware
integrity.

• Performance threshold exceeded (full overhaul threshold not exceeded)

• Shop visit minimum workscope recommendations apply at this level.

Performance restoration for the booster and LPT modules is
accomplished at the full overhaul level

D. Full Overhaul Workscope

• Full overhaul threshold exceeded

• Entails thorough piece-part inspection and refurbishment (including all

life-limited rotating part NDT inspections) per Engine Manual Overhaul
Chapters (72-XX-00)

• Extension of performance workscope. All elements of shop visit

minimum and performance workscopes apply at full overhaul

E. Critical Items and High Priority Service Bulletins

• Incorporation of critical items and high-priority Service Bulletins can

require further module disassembly and force a higher level of work

1.9. Inspection Limits/Level of Disassembly.

A. Unless otherwise stated, the following inspection criteria is applicable:

(1) Modules, EMUs, assemblies and subassemblies.

• Engine manual condition maintenance limits (72-00-XX)

(2) Piece-parts

• Engine manual (72-XX-00) for full overhaul disassembly.

• Life-limited rotating parts inspections to include FPI and other

applicable NDT inspections.

GE Proprietary Information 1-7 Workscope Planning Guide

Subject to restrictions on the cover or first page
 CF6-80C2
GE Aviation Workscope Planning Guide

• Engine Manual Condition Maintenance Chapter (72-00-XX) if parts

exposed at below full overhaul thresholds.

(3) Component and accessories.

• Bench test or overhaul to applicable component maintenance

manual.

1.10. Engine Assembly Workscope.

A. Efforts must be made to group performance/durability level overhauled

modules together in order to maximize EGT margin. Four levels of build
standard can be defined with Category I representing the highest possible
EGT margin capability engine and Category IV the lowest.

(1) Category I

• All modules restored to performance or full overhaul level

(2) Category II

• HPC rotor, HPC stator, combustor, HPT stage 1 and 2 nozzle

assemblies, and HPT rotor restored to performance or full overhaul
level

(3) Category III

• Intermix of serviceable and performance or full overhaul level

modules in HPC or HPT

(4) Category IV

• All modules restored to serviceability level

• Rotating part residual lives (stub lives) at the time of assembly

must be such that they do not limit the installed life of the engine.
Recommended minimum stub lives must be determined based on
the operator’s maximum on-wing cycle goal following the shop
visit.

GE Proprietary Information 1-8 Workscope Planning Guide

Subject to restrictions on the cover or first page
 CF6-80C2
GE Aviation Workscope Planning Guide

1.11. Assembled Engine Workscope.

A. The assembled engine workscope applies to an engine that has been

removed after being installed for a short time period or an engine removed for
any reason and it is not expected to be inducted into the shop for a
performance-level shop visit. The purpose of the assembled engine
workscope is to assess the overall condition of the engine and modules for
future engine operational performance, or to determine the extent of overhaul
which can be required during a shop visit. Controls and accessories are
accessible and must be serviced according to the controls and accessory
recommendations:

(1) The engine must be preserved prior to removal, if the duration of

non-operation is unknown or planned to be more than two months.

(2) Review the operating records of the installed engine and verify whether
or not any special inspections such as overtemperature or overspeed
inspections are required. These records, along with performance trend
data, must also allow the assessment of the engine‘s future performance
potential.

1.12. Individual Engine Workscope.

A. Refer to Figure 1-1.

GE Proprietary Information 1-9 Workscope Planning Guide

Subject to restrictions on the cover or first page
 CF6-80C2
GE Aviation Workscope Planning Guide

Individual Engine Workscope

Figure 1-1

GE Proprietary Information 1-10 Workscope Planning Guide

Subject to restrictions on the cover or first page
 CF6-80C2
GE Aviation Workscope Planning Guide

SECTION 2

Consolidated Inspection and Servicing Recommendations

2.0. Purpose.

A. This section of the Workscope Planning Guide provides a consolidated listing

of all GE Aviation’s recommended scheduled inspection and servicing
intervals applicable to installed CF6-80C2 engines. Its purpose is for
maintenance planning only. Procedures, limits, and specific requests are
defined in the referenced publications.

NOTE: This section of the workscope planning guide replaces Consolidated

Engine Service Memorandum (CESM) No. 004 Revision 12
(CF6-80C2 Consolidated Inspection/Servicing Recommendations).
CESM No. 004 will be cancelled upon issuance of this document.

B. This document is intended for use as a maintenance planning aid to be used

by CF6-80C2 operators to establish an on-condition maintenance program to
control engine reliability and operating costs. The inspections and the
inspection intervals are based upon engine fleet history gathered by GE over
the life of the engine service and is reviewed continuously and revised as
required.

C. The recommendations included here-in are based on operation in typical

revenue service. If engines are operated in unusual service (pilot training,
high cycle-to-hour service, etc.) or in detrimental environmental conditions
(hot and harsh, sandstorms, heavy construction, undeveloped airstrips, etc.),
GE recommends that the operator must develop a customized inspection and
servicing plan. GE Aviation is available to assist in developing a customized
inspection and servicing plan, if required.

2.1. Scheduled Maintenance Checks.

A. Most airlines have established a maintenance plan based on the Maintenance

Planning Document (MPD) for the airplane type that they are operating.
MPDs for each airplane type can define intervals by different terminologies.
Most MPDs refer to “Letter Checks” or equivalent. As such, the recommended
intervals in this document are intended to align with the MPD specified
maintenance intervals where possible. Intervals listed in hours and/or cycles
are considered maximum. Each airline can adjust the recommended interval
to be compatible with its own aircraft maintenance check plan. Refer to Table
2-1 for inspections and servicing interval defined by engine section. Refer to
Appendix A, Table 2-2 for inspections and service recommendations by
interval.

GE Proprietary Information 2-1 Workscope Planning Guide

Subject to restrictions on the cover or first page
 CF6-80C2
GE Aviation Workscope Planning Guide

2.2. Abbreviations.

AGB - ACCESSORY GEARBOX

AI - AIRBUS INDUSTRIE
AMM - AIRCRAFT MAINTENANCE MANUAL
BCA - BOEING COMMERCIAL AIRCRAFT
BSI - BORESCOPE INSPECTION
CESM - COMMERCIAL ENGINE SERVICE MEMORANDUM
CRF - COMPRESSOR REAR FRAME
CSI - FLIGHT CYCLES SINCE INSTALLATION
CSN - FLIGHT CYCLES SINCE NEW
CW - COMPLIED WITH
DOD - DOMESTIC OBJECT DAMAGE
ECS - ENVIRONMENTAL CONTROL SYSTEM
FC - FLIGHT CYCLES
FH - FLIGHT HOURS
FOD - FOREIGN OBJECT DAMAGE
HPC - HIGH-PRESSURE COMPRESSOR
HPT - HIGH-PRESSURE TURBINE
LPT - LOW-PRESSURE TURBINE
MM - MAINTENANCE MANUAL
NDT - NON-DESTRUCTIVE TESTING
OGV - OUTLET GUIDE VANES
S/B - SERVICE BULLETIN
SCAV - SCAVENGE
SOAP - SPECTROGRAPHIC OIL ANALYSIS PROGRAM
SUBSQ - SUBSEQUENT
TSI - FLIGHT HOURS SINCE INSTALLATION (TIME
SINCE INSTALLATION)
TSN - FLIGHT HOURS SINCE NEW (TIME SINCE NEW)
VBV - VARIABLE BYPASS VALVE
VSV - VARIABLE STATOR VANE

GE Proprietary Information 2-2 Workscope Planning Guide

Subject to restrictions on the cover or first page
 CF6-80C2
GE Aviation Workscope Planning Guide

Table 2-1. Table of Inspections.

Procedure Definition
Recommended
Engine Area Inspection or Service (AMM Section or
Interval
Service Bulletin)

Engine Servicing Service engine oil system. Daily AI 12-13-79

BCA 747 12-13-03
BCA 767 12-13-01
MD-11 12-12-01
Check oil system for fuel Daily AI 79-00-00
contamination. BCA 79-00-00
MD-11 79-00-00
Service starter oil. A Check or equivalent. AI 12-13-80
BCA 747 12-13-06
BCA 767 12-13-02
MD-11 12-12-03
Change starter oil. 2A Check or equivalent. AI 12-13-80
BCA 747 12-13-06
BCA 767 12-13-02
MD-11 12-12-03
Clean core gas path. As defined by operator’s CESM 0018
plan.
Visual inspection of inlet, Before each flight. AI 72-21-00,
fan blades, spinner 78-11-01
cover, and exhaust. BCA 72-31-00,
78-11-00
MD-11 72-30-00,
78-11-00
Visual inspection of fan Before each flight. Visual
cowl and core cowl
including latches for
condition and security.
Engine Mounts Visual inspection of the C Check or equivalent. AI 71-21-00
visible portions of BCA 71-21-00
NOTE: Aft engine mount forward engine mount MD-11 71-20-01
inspections are including the platform,
applicable for Airbus and links, and attachment
MD-11. For Boeing 747 hardware as well as the
and 767, refer to Boeing fan frame strut lugs.
instructions. Removal of the mount
from the engine solely
for inspection is not
required.
Clean and fluorescent Each engine removal. AI 71-21-00
penetrant inspect BCA 71-21-00
forward engine mount MD-11 71-20-01
pylon attachment
hardware.

GE Proprietary Information 2-3 Workscope Planning Guide

Subject to restrictions on the cover or first page
 CF6-80C2
GE Aviation Workscope Planning Guide

Table 2-1. Table of Inspections. (Cont.)

Procedure Definition
Recommended
Engine Area Inspection or Service (AMM Section or Service
Interval
Bulletin)

Engine Mounts Visual inspection of the C Check or equivalent. AI 71-22-00

(Continued) visible portions of the aft MD-11 71-20-02
engine mount including
the links, link bolts, and
attachment hardware.

Clean and fluorescent Each engine removal. AI 71-22-00

penetrant inspect aft MD-11 71-20-02
engine mount pylon
attachment hardware.
Visual inspection of the Each engine removal. AI 54-51-85
visible portions of the MD-11 71-20-03
Pylon Adapter Beam (aft
mount Upper Beam).
Fluorescent penetrant 20,000 FC CMM 71-20-05
inspection of the Pylon
Adapter Beam (aft mount
Upper Beam) after
disassembly from
aircraft.
Visual inspection of the C Check or equivalent. CMM 71-20-05
visible portions of the aft
engine mount Lower
Beam Assembly.
Fluorescent penetrant Each engine shop CMM 71-20-05
inspection of the aft visit.
engine mount Lower
Beam Assembly after
disassembly from the
engine.

GE Proprietary Information 2-4 Workscope Planning Guide

Subject to restrictions on the cover or first page
 CF6-80C2
GE Aviation Workscope Planning Guide

Table 2-1. Table of Inspections. (Cont.)

Procedure Definition
Recommended
Engine Area Inspection or Service (AMM Section or Service
Interval
Bulletin)

Engine External Check cowl inner C Check or equivalent. Visual

Examination surfaces for cracks, hot
spots, and distortion.
NOTE: These engine cowl
Post Rohr S/B 71-0105: C Check or equivalent. ROHR S/B 71-0105
inspections are
Detailed inspection of
applicable for Airbus and
inlet cowl for condition
MD-11 aircraft only. For
and security. Inspect for:
Boeing 747 and 767,
refer to Boeing - Evidence of
instructions. leading edge
Erosion
- Lip skin cracks,
buckling and dents
- Loose or missing
fasteners
- Barrel land abrasions,
delaminations,
gouges.
Pre Rohr S/B 71-0105: Initial Inspection 2500 ROHR S/B 71-0105
Detailed inspection of FH; Recurring Inspection
inlet cowl for condition C Check or equivalent.
and security in
accordance with Rohr
S/B 71-0105.
Check freedom of C Check or equivalent. AI 71-13-01, 71-13-02
operation and condition MD-11 71-12-03,
of fan cowl and core 71-14-03
cowl pressure relief door
latches.
Perform fan cowl and C Check or equivalent. AI 71-13-01, 71-13-02
core cowl door latch MD-11 71-12-01,
adjustments/tests. 71-14-01

GE Proprietary Information 2-5 Workscope Planning Guide

Subject to restrictions on the cover or first page
 CF6-80C2
GE Aviation Workscope Planning Guide

Table 2-1. Table of Inspections. (Cont.)

Procedure Definition
Recommended
Engine Area Inspection or Service (AMM Section or Service
Interval
Bulletin)

Engine External Visual inspection of the C Check or equivalent. AI 71-13-02

Examination fan cowl for fit, condition, MD-11 71-12-01
(Continued) and security of the
following:
- Steps and gaps
- Tap test for
panel disbond
- Top and bottom
edges for nicks,
cracks, and
scratches
- Forward and aft door
lands for holes, cracks,
and scratches.
Visual inspection of the C Check or equivalent. AI 71-13-01
core cowl for condition MD-11 71-14-01
and security of the
following:
- Panel skin for cracks,
dents, buckles, holes,
nicks, and scratches
- Frame longeron,
intercoastal fireshield
for cracks, dents,
gouges, holes, and
scratches
- Fairing for cracks,
dents, holes, and
scratches
- Fastener joints for
dents, nicks, and
scratches.
Check for evidence of C Check or equivalent. AI 71-70-00
fuel or oil leaks. BCA 71-71-00
MD-11 71-70-00

GE Proprietary Information 2-6 Workscope Planning Guide

Subject to restrictions on the cover or first page
 CF6-80C2
GE Aviation Workscope Planning Guide

Table 2-1. Table of Inspections. (Cont.)

Procedure Definition
Recommended
Engine Area Inspection or Service (AMM Section or Service
Interval
Bulletin)

Engine External Visual inspection of the C Check or equivalent. AI 72-65-00

Examination accessory gearbox for BCA 72-60-00
(Continued) visible leaks and the MD-11 72-65-00
gearbox and gearbox
mounts for damage.
Visual inspection of the C Check or equivalent. AI 72-63-00
transfer gearbox for BCA 72-60-00
damage. MD-11 72-63-00
Visual inspection of the C Check or equivalent. AI 71-70-00
drain tubes for condition BCA 71-71-00
and security. MD-11 71-70-00
General visual inspection C Check or equivalent. AI 71-70-00
of the strut drain tube for BCA 71-71-00
blockage. MD-11 71-70-00
Visual inspection of fuel, C Check or equivalent. AI 72-09-03
oil, and air tubes. BCA 72-00-00
MD-11 72-00-01
Visual inspection of the 4500 FH AD 2009-05-02
fuel manifold for S/B 73-0326
p-clamp chafing.
Visual inspection of the C Check or equivalent. AI 72-09-03
ignition cooling tubes BCA 747 72-00-00
and associated BCA 767 75-00-00
hardware. MD-11 72-00-01
Visual inspection of the C Check or equivalent. AI 72-56-00
stage 7 tubes and BCA 747 72-50-00
associated hardware for BCA 767 75-00-00
condition and security. MD-11 72-54-03
Visual inspection of the C Check or equivalent. AI 72-34-00
sump pressurization BCA 747 72-40-00
tubes and associated BCA 767 75-00-00
hardware. MD-11 72-40-00
Visual inspection of C Check or equivalent. AI 72-09-04
engine brackets and BCA 72-00-00
clamps. MD-11 72-00-01

GE Proprietary Information 2-7 Workscope Planning Guide

Subject to restrictions on the cover or first page
 CF6-80C2
GE Aviation Workscope Planning Guide

Table 2-1. Table of Inspections. (Cont.)

Procedure Definition
Recommended
Engine Area Inspection or Service (AMM Section or Service
Interval
Bulletin)

Engine External Visual inspection of the C Check or equivalent. AI 72-34-00

Examination compressor rear frame BCA 72-40-00
(Continued) assembly for cracks, hot MD-11 72-40-00
spots, and distortion.
Visual inspection of the C Check or equivalent. AI 72-58-00
turbine rear frame BCA 72-50-00
assembly for cracks, hot MD-11 72-56-00
spots, and distortion.
Inspect for chafing C Check or equivalent. BCA 72-36-00
between the ECS duct
clamp and HPC stator
case stage 8 manifold at
the 12 o’clock position.

NOTE: Applies to Boeing

747 and 767 applications
only.
Inspect for chafing C Check or equivalent. BCA 72-36-00
between the ECS
bleed duct and HPC
stator case stage 7
manifold at the 12
o’clock position.

NOTE: Applies to Boeing

747 and 767 applications
only.
Visual inspection of C Check or equivalent. AI 73-21-04
cables for wear and BCA 73-21-18
chafing damage with MD-11 73-21-04
adjacent and/or
clamping hardware.
Visual inspection of fire C Check or equivalent. AI 71-30-00
seals for damage. BCA 71-00-00
MD-11 71-30-00

GE Proprietary Information 2-8 Workscope Planning Guide

Subject to restrictions on the cover or first page
 CF6-80C2
GE Aviation Workscope Planning Guide

Table 2-1. Table of Inspections. (Cont.)

Procedure Definition
Recommended
Engine Area Inspection or Service (AMM Section or Service
Interval
Bulletin)

Fan Visual inspection of fan A Check or equivalent AI 72-21-00

blade condition. or 400 FC. BCA 72-31-02
MD-11 72-30-00
Inspect fan blade and 760-3800 FC CESM 1
fan disk dovetail CESM 43
coatings. Relubricate AI 72-21-00
dovetail and mid-span BCA 72-31-02
shrouds with approved MD-11 72-30-00
lubrication.

NOTE: Fan blade and

disk re-lubrication
interval must be decided
based on each
operator’s experience.
Nominal recommended
starting interval is 1000
cycles, but can be
adjusted based on
experience.
Visually inspect fan case A Check or equivalent AI 72-22-00
abradable shroud or 400 FC. BCA 72-32-00
condition. MD-11 72-32-00
Visually inspect aft inner A Check or equivalent AI 72-22-00
acoustic panel liner or 400 FC. BCA 72-32-00
segment with bright light MD-11 72-32-00
for damage and the
support brackets for
looseness.
Visual inspection of the C Check or equivalent. AI 72-23-00
fan frame and case. BCA 72-33-00
MD-11 72-33-00
High Pressure
Inspect all stages C Check or equivalent. AI 72-32-00
Compressor
(IGV through stage 5) VSV BCA 72-36-00
levers for bending,
MD-11 72-37-00
Looseness and metal-to-
metal contact between
vane and case.

GE Proprietary Information 2-9 Workscope Planning Guide

Subject to restrictions on the cover or first page
 CF6-80C2
GE Aviation Workscope Planning Guide

Table 2-1. Table of Inspections. (Cont.)

Procedure Definition
Recommended
Engine Area Inspection or Service (AMM Section or
Interval
Service Bulletin)

Combustor Borescope inspect liner and Do concurrently with AI 72-41-00

dome areas via borescope HPT blade inspections. BCA 72-00-00
ports B2-1 through B2-5. MD-11 72-00-07
HPT Stage 1 Nozzle Borescope inspect the S1 Do concurrently with AI 72-51-00
nozzle via combuster HPT blade inspections. BCA 72-00-00
borescope ports B2-1 MD-11 72-00-07
through
B2-5.
HPT Stage 1 and Stage 2 Borescope inspect the S1 500 FC or 2000 FH, AI 72-53-00
Blades and S2 blades via borescope whichever comes first. BCA 72-00-00
ports B3-1 and B3-2. MD-11 72-00-07
Fuel System
Replace fuel filter element. 4500 FH AI 73-12-03
BCA 73-11-02
NOTE 1: Replace fuel filter MD-11 73-11-04
element at 150 FH and 450
FH following aircraft
delivery, each volcanic ash
encounter, or each major
fuel tank repair or cleaning.
Thereafter, revert to 4500
FH intervals.

NOTE 2: Reduced intervals

can be required if
contaminated, or dirty fuel
is received. Monitor
instances of frequent fuel
filter clog and change
interval accordingly.

NOTE 3: If evidence of cloth

fragments (lent, fibers, fuzz)
are found in the filter,
inspect the Main Fuel Pump
interstage strainer for
contamination.
Ignition System Audible check each ignition On Condition AI 74-00-00
system independently. BCA 74-00-00
MD-11 74-00-00

GE Proprietary Information 2-10 Workscope Planning Guide

Subject to restrictions on the cover or first page
 CF6-80C2
GE Aviation Workscope Planning Guide

Table 2-1. Table of Inspections. (Cont.)

Procedure Definition
Recommended
Engine Area Inspection or Service (AMM Section or
Interval
Service Bulletin)

Ignition System Replace igniter plug. 500 FC AI 74-00-00

BCA 74-21-02
NOTE: Inclement weather MD-11 74-20-03
operation with continuous
ignition will reduce ignition
system life. Use AMM inspections
to determine optimum igniter
replacement interval.
Air System Inspect VSV/VBV feedback C Check or equivalent. AI 75-31-01, 75-32-04
cables for distress. BCA 75-31-00,
75-32-00
NOTE: Not applicable to FADEC MD-11 75-31-00,
engines. 75-32-00
Visual inspection of the VSV C Check or equivalent. AI 75-31-08
actuation system. BCA 75-31-00
MD-11 75-31-00
Visual inspection of the VBV C Check or equivalent. AI 75-32-01
actuation system. BCA 75-32-00
MD-11 75-32-00
Check position of bore cooling C Check or equivalent. AI 75-12-00
valves. BCA 75-21-01
MD-11 75-24-01
NOTE: On pre-S/B 75-0157 FADEC
engines and pre-S/B 75-0198 PMC
engines only.

Replace IDG Air/Oil cooler. 5028 Flight Cycles since SB 75-0204

new for the cooler.
Part number 9377M64P06 (VPN
35E38-6) only.

Engine Indicating EGT probes resistance check. Do concurrently AI 77-21-04

System with HPT blade BCA 77-21-00
NOTE: See S/B 77-0050 for inspections. MD-11 77-21-00
details. Resistance check need
only be done on the following
part numbers:

GE Proprietary Information 2-11 Workscope Planning Guide

Subject to restrictions on the cover or first page
 CF6-80C2
GE Aviation Workscope Planning Guide

Table 2-1. Table of Inspections. (Cont.)

Procedure
Recommended Definition (AMM
Engine Area Inspection or Service
Interval Section or Service
Bulletin)
9373M91P05, 9373M93P03,
Engine Indicating
1696M81P10,
System
(Continued) 1696M81P12, and
1696M81P16.
C Check or equivalent.
Disconnect and clean the AI 73-21-04
electrical connectors at the BCA 73-21-18
following locations: MD-11 73-21-04
- CIT (T25) sensor
- Oil pressure transmitter
- Fuel filter pressure
transmitter
- Starter air valve
- EGT junction box
- TEO (oil temperature) sensor
- CRF vibration sensor
- Number 1 bearing vibration
sensor

Visually inspect CRF vibration C Check or equivalent. AI 77-32-03

sensor (accelerometer) body BCA 77-31-02
and connector. MD-11 77-32-03

Oil System Inspect lube and scavenge C Check or equivalent. AI 79-00-00

pump TGB, AGB, B-sump, C- BCA 79-21-06
sump, and D-sump inlet MD-11 79-22-09
screens.

NOTE: If engines have used

something other than High
Thermal Stability (HTS) oils
since last overhaul, the
recommended D-sump
inspection interval is 1000 FC
and 2000 FC after overhaul
and 400 FC subsequently.
Inspect the Master Magnetic A Check or equivalent AI 79-22-03
Chip Detector. BCA 79-21-05
MD-11 79-36-01

GE Proprietary Information 2-12 Workscope Planning Guide

Subject to restrictions on the cover or first page
 CF6-80C2
GE Aviation Workscope Planning Guide

Table 2-1. Table of Inspections. (Cont.)

Procedure
Recommended Definition (AMM
Engine Area Inspection or Service
Interval Section or Service
Bulletin)
Oil System (Continued) Replace oil scavenge filter AI 79-22-01
4500 FH
element. BCA 79-21-04
MD-11 79-22-05

Starter Inspect starter magnetic chip 2A Check or equivalent. AI 80-13-01

detector plug for metal BCA 747 80-11-01
particles. BCA 767 80-11-01
MD-11 80-12-01

Inspect starter system C Check or equivalent. AI 80-13-08

ducts/clamping for condition BCA 80-11-05
and security. MD-11 80-12-05

Exhaust Detailed visual inspection of C Check or equivalent. AI 78-11-01, 78-11-

the turbine exhaust nozzle 02
and plug for cracks or BCA 78-00-00
damage. MD-11 78-11-00,
78-12-00
Detailed visual inspection of C Check or equivalent. AI 78-11-01, 78-11-
the turbine exhaust nozzle 02
fasteners for condition and BCA 78-00-00
security. MD-11 78-11-00,
78-12-00

GE Proprietary Information 2-13 Workscope Planning Guide

Subject to restrictions on the cover or first page
 CF6-80C2
GE Aviation Workscope Planning Guide

2.3. Appendix A.

A. Refer to Table 2-2.

Table 2-2. Inspections Defined by Interval.

Recommended Procedure Definition (AMM

Inspection or Service
Interval Section or Service Bulletin)

Before each flight Visual inspection of inlet, fan blades, spinner AI 72-21-00 and 78-11-01
cover, and exhaust. BCA 72-31-00 and 78-11-00
MD-11 72-30-00 and 78-11-00

Before each flight Visual inspection of fan cowl and core cowl Visual
including latches for condition and security.

Daily Service engine oil system. AI 12-13-79

BCA 747 12-13-03
BCA 767 12-13-01
MD-11 12-12-01

Daily Check oil system for fuel contamination. AI 79-00-00

BCA 79-00-00
MD-11 79-00-00

A Check Service starter oil. AI 12-13-80

or equivalent BCA 747 12-13-06
BCA 767 12-13-02
MD-11 12-12-03

A Check Inspect the Master Magnetic Chip Detector. AI 79-22-03

or equivalent BCA 79-21-05
MD-11 79-36-01

On Condition Ignition System Audible check each Ignition AI 74-00-00

System independently. BCA 74-00-00
MD-11 74-00-00

500 FC Replace igniter plug. AI 74-00-00

BCA 74-21-02
NOTE: Inclement weather operation with MD-11 74-20-03
continuous ignition will reduce ignition system
life. Use AMM inspections to determine
optimum igniter replacement interval.

500 FC or 2000 FH, Borescope inspect the S1 and S2 blades AI 72-53-00

whichever comes first via borescope ports B3-1 and B3-2. BCA 72-00-00
MD-11 72-00-07

GE Proprietary Information 2-14 Workscope Planning Guide

Subject to restrictions on the cover or first page
 CF6-80C2
GE Aviation Workscope Planning Guide

Table 2-2. Inspections Defined by Interval. (Cont.)

Recommended Procedure Definition (AMM

Inspection or Service
Interval Section or Service Bulletin)

4500 FH Visual inspection of the fuel manifold for AD 2009-05-02

p-clamp chafing. S/B 73-0326

4500 FH Replace fuel filter element. AI 73-12-03

BCA 73-11-02
NOTE 1: Replace fuel filter element at 150 FH and MD-11 73-11-04
450 FH following aircraft delivery, each volcanic
ash encounter, or each major fuel tank repair.
Thereafter, revert to 4500 FH intervals.

NOTE 2: Reduced intervals can be required if

contaminated, or dirty fuel is received. Monitor
instances of frequent fuel filter clog and change
interval accordingly.

NOTE 3: If evidence of cloth fragments (lent, fibers,

and fuzz) are found in the filter, inspect the Main
Fuel Pump Interstage Strainer for contamination.

4500 FH Replace oil scavenge filter element. AI 79-22-01

BCA 79-21-04
MD-11 79-22-05

A Check or equivalent Visual inspection of fan blade condition. AI 72-21-00

or 400 FC BCA 72-31-02
MD-11 72-30-00

A Check or equivalent Visually inspect fan case abradable shroud AI 72-22-00

or 400 FC condition. BCA 72-32-00
MD-11 72-32-00

A Check or equivalent Visually inspect aft inner acoustic panel liner AI 72-22-00
or 400 FC segment with bright light for damage and the BCA 72-32-00
support brackets for looseness. MD-11 72-32-00

2A Check or Change starter oil. AI 12-13-80

equivalent BCA 747 12-13-06
BCA 767 12-13-02
MD-11 12-12-03

2A Check or Inspect starter magnetic chip detector plug for AI 80-13-01

equivalent metal particles. BCA 747 80-11-01
BCA 767 80-11-01
MD-11 80-12-01

GE Proprietary Information 2-15 Workscope Planning Guide

Subject to restrictions on the cover or first page
 CF6-80C2
GE Aviation Workscope Planning Guide

Table 2-2. Inspections Defined by Interval. (Cont.)

Recommended Procedure Definition (AMM

Inspection or Service
Interval Section or Service Bulletin)

Do concurrently Borescope inspect stage 3 blade leading AI 72-31-00

with HPT blade edges via borescope port B1-2. BCA 72-00-00
inspections MD-11 72-00-07
NOTE: This only applies to post- Service
Bulletin 72-0975 blades. It does not apply to
pre-Service Bulletin 72-0975 blades or post-
Service Bulletin 72-1060 blades.

Do concurrently Borescope inspect combustor liner and dome AI 72-41-00

with HPT blade areas via borescope ports B2-1 through B2-5. BCA 72-00-00
inspections MD-11 72-00-07

Do concurrently Borescope inspect the S1 nozzle via AI 72-51-00

with HPT blade combuster borescope ports B2-1 through B2- BCA 72-00-00
inspections 5. MD-11 72-00-07

Do concurrently EGT probes resistance check. AI 77-21-04

with HPT blade BCA 77-21-00
inspections. NOTE: See S/B 77-0050 for details. Resistance MD-11 77-21-00
check need only be done on the following part
numbers:

9373M91P05, 9373M93P03, 1696M81P10,

1696M81P12 and 1696M81P16.

On Condition Audible check each ignition system AI 74-00-00

independently. BCA 74-00-00
MD-11 74-00-00

As defined by Clean core gas path. CESM 0018

operator’s plan

GE Proprietary Information 2-16 Workscope Planning Guide

Subject to restrictions on the cover or first page
 CF6-80C2
GE Aviation Workscope Planning Guide

Table 2-2. Inspections Defined by Interval. (Cont.)

Recommended Procedure Definition (AMM

Inspection or Service
Interval Section or Service Bulletin)

760-3800 FC Inspect fan blade and fan disk dovetail CESM 1

coatings. Re-lubricate dovetail and mid-span CESM 43
shrouds with approved lubrication. AI 72-21-00
BCA 72-31-02
NOTE: Fan blade and disk re-lubrication MD-11 72-30-00
interval must be decided based on each
operator’s experience. Nominal recommended
starting interval is 1000 cycles, but can be
adjusted based on experience.

Initial Inspection Pre Rohr S/B 71-0105: Detailed inspection of ROHR S/B 71-0105
inlet cowl for condition and security in
2500 FH; Recurring accordance with Rohr S/B 71-0105.
Inspection C Check

C Check or equivalent Visual inspection of forward engine mount AI 71-21-00

including the platform, links, and attachment BCA 71-21-00
hardware as well as the fan frame strut lugs. MD-11 71-20-01

C Check or equivalent Visual inspection of the visible portions of the AI 71-22-00

aft engine mount including the links, link bolts, MD-11 71-20-02
and attachment hardware.

C Check or equivalent Visual inspection of the visible portions of the CMM 71-20-05
aft engine mount Lower Beam Assembly.

C Check or equivalent Check cowl inner surfaces for cracks, hot Visual
spots, and distortion.

C Check or equivalent Post Rohr S/B 71-0105: Detailed inspection of ROHR S/B 71-0105
inlet cowl for condition and security. Inspect
for:
- Evidence of leading edge erosion
- Lip skin cracks, buckling and dents
- Loose or missing fasteners
- Barrel land abrasions, delaminations,
gouges

C Check or equivalent Check freedom of operation and condition of AI 71-13-01, 71-13-02

fan cowl and core cowl pressure relief door MD-11 71-12-03, 71-14-03
latches.

GE Proprietary Information 2-17 Workscope Planning Guide

Subject to restrictions on the cover or first page
 CF6-80C2
GE Aviation Workscope Planning Guide

Table 2-2. Inspections Defined by Interval. (Cont.)

Recommended Procedure Definition (AMM

Inspection or Service
Interval Section or Service Bulletin)

C Check or equivalent Perform fan cowl and core cowl door latch AI 71-13-01, 71-13-02
adjustments/tests. MD-11 71-12-01, 71-14-01

C Check or equivalent Visual inspection of the fan cowl for fit, AI 71-13-02
condition, and security of the following: MD-11 71-12-01
- Steps and gaps
- Tap test for panel disbond
- Top and bottom edges for nicks, cracks,
and scratches
- Forward and aft door lands for holes,
cracks, and scratches

C Check or equivalent Visual inspection of the core cowl for condition AI 71-13-01
and security of the following: MD-11 71-14-01
- Panel skin for cracks, dents, buckles,
holes, nicks, and scratches
- Frame longeron, intercoastal fireshield for
cracks, dents, gouges, holes, and
scratches
- Fairing for cracks, dents, holes, and
scratches
- Fastener joints for dents, nicks, and
scratches

C Check or equivalent Check for evidence of fuel or oil leaks. AI 71-70-00

BCA 71-71-00
MD-11 71-70-00

C Check or equivalent Visual inspection of the accessory gearbox for AI 72-65-00

visible leaks, and visual inspect the gearbox BCA 72-60-00
and gearbox mounts for damage. MD-11 72-65-00

C Check Visual inspection of the transfer gearbox for AI 72-63-00

or equivalent damage. BCA 72-60-00
MD-11 72-63-00

C Check Visual inspection of the drain tubes for AI 71-70-00

or equivalent condition and security. BCA 71-71-00
MD-11 71-70-00

GE Proprietary Information 2-18 Workscope Planning Guide

Subject to restrictions on the cover or first page
 CF6-80C2
GE Aviation Workscope Planning Guide

Table 2-2. Inspections Defined by Interval. (Cont.)

Recommended Procedure Definition (AMM

Inspection or Service
Interval Section or Service Bulletin)

C Check General visual inspection of the strut drain tube for AI 71-70-00
or equivalent blockage. BCA 71-71-00
MD-11 71-70-00

C Check Visual inspection of fuel, oil, and air tubes. AI 72-09-03

or equivalent BCA 72-00-00
MD-11 72-00-01

C Check Visual inspection of the ignition cooling tubes and AI 72-09-03

or equivalent associated hardware. BCA 747 72-00-00
BCA 767 75-00-00
MD-11 72-00-01

C Check Visual inspection of the stage 7 tubes and AI 72-56-00

or equivalent associated hardware for condition and security. BCA 747 72-50-00
BCA 767 75-00-00
MD-11 72-54-03

C Check Visual inspection of the sump pressurization tubes AI 72-34-00

or equivalent and associated hardware. BCA 747 72-40-00
BCA 767 75-00-00
MD-11 72-40-00

C Check or Visual inspection of engine brackets and clamps. AI 72-09-04

equivalent BCA 72-00-00
MD-11 72-00-01

C Check or Disconnect and clean the electrical connectors at AI 73-21-04

equivalent the following locations: BCA 73-21-18
MD-11 73-21-04
- CIT (T25) sensor
- Oil pressure transmitter
- Fuel filter pressure transmitter
- Starter air valve
- EGT junction box
- TEO (oil temperature) sensor
- CRF vibration sensor
- No. 1 bearing vibration sensor

C Check or Visual inspection of the compressor rear frame AI 72-34-00

equivalent assembly for cracks, hot spots, and distortion. BCA 72-40-00
MD-11 72-40-00

GE Proprietary Information 2-19 Workscope Planning Guide

Subject to restrictions on the cover or first page
 CF6-80C2
GE Aviation Workscope Planning Guide

Table 2-2. Inspections Defined by Interval. (Cont.)

Recommended Procedure Definition (AMM

Inspection or Service
Interval Section or Service Bulletin)

C Check or Visual inspection of the turbine rear frame assembly for AI 72-58-00
equivalent cracks, hot spots, and distortion. BCA 72-50-00
MD-11 72-56-00

C Check or Inspect for chafing between the ECS duct clamp and BCA 72-36-00
equivalent HPC stator case stage 8 manifold at the 12 o’clock
position.

NOTE: Applies to Boeing 747 and 767 applications only.

C Check or Inspect for chafing between the ECS BCA 72-36-00

equivalent bleed duct and HPC stator case stage
7 manifold at the 12 o’clock position.

NOTE: Applies to Boeing 747 and 767 applications only.

C Check or Visual inspection of cables for wear and chafing AI 73-21-04

equivalent damage with adjacent and/or clamping hardware. BCA 73-21-18
MD-11 73-21-04

C Check or Visual inspection of fire seals for damage. AI 71-30-00

equivalent BCA 71-00-00
MD-11 71-30-00

C Check or Visual inspection of the fan frame and case. AI 72-23-00

equivalent BCA 72-33-00
MD-11 72-33-00

C Check or Inspect all stages (IGV through stage 5) VSV levers for AI 72-32-00
equivalent bending, looseness and metal-to-metal contact BCA 72-36-00
between vane and case. MD-11 72-37-00

C Check or Inspect VSV/VBV feedback cables for distress. AI 75-31-01, 75-32-04

equivalent BCA 75-31-00, 75-32-00
NOTE: Not applicable to FADEC engines. MD-11 75-31-00, 75-32-00

C Check or Visual inspection of the VSV actuation system. AI 75-31-08

equivalent BCA 75-31-00
MD-11 75-31-00

C Check or Visual inspection of the VBV actuation system. AI 75-32-01

equivalent BCA 75-32-00
MD-11 75-32-00

GE Proprietary Information 2-20 Workscope Planning Guide

Subject to restrictions on the cover or first page
 CF6-80C2
GE Aviation Workscope Planning Guide

Table 2-2. Inspections Defined by Interval. (Cont.)

Recommended Procedure Definition (AMM

Inspection or Service
Interval Section or Service Bulletin)

C Check or equivalent Check position of bore cooling valves. AI 75-12-00

BCA 75-21-01
NOTE: On pre-S/B 75-0157 FADEC engines and MD-11 75-24-01
pre-S/B 75-0198 PMC engines only.

C Check or equivalent Visually inspect CRF vibration sensor AI 77-32-03

(accelerometer) body and connector. BCA 77-31-02
MD-11 77-32-03

C Check or equivalent Check for missing nuts and bolts at exhaust AI 78-10-00
plug to turbine rear frame attach points (do BCA 78-11-00
not remove center body for this check). MD-11 78-11-00

C Check or equivalent Inspect lube and scavenge pump TGB, AGB, B- AI 79-00-00
sump, C-sump, and D-sump inlet screens. BCA 79-21-06
MD-11 79-22-09
NOTE: If engines have used something other
than High Thermal Stability (HTS) oils since last
overhaul, the recommended
D-sump inspection interval is 1000 FC and
2000 FC after overhaul and 400 FC
subsequently.

C Check or equivalent Inspect starter system ducts/clamping for AI 80-13-08

condition and security. BCA 80-11-05
MD-11 80-12-05

C Check or equivalent Detailed visual inspection of the turbine AI 78-11-01, 78-11-02

exhaust nozzle and plug for cracks or damage. BCA 78-00-00
MD-11 78-11-00, 78-12-00

C Check or equivalent Detailed visual inspection of the turbine AI 78-11-01, 78-11-02

exhaust nozzle fasteners for condition and BCA 78-00-00
security. MD-11 78-11-00, 78-12-00

Each engine Clean and fluorescent penetrant inspect AI 71-21-00

removal forward engine mount pylon attachment BCA 71-21-00
hardware. MD-11 71-20-01

Each engine Clean and fluorescent penetrant inspect aft AI 71-22-00

removal engine mount pylon attachment hardware. MD-11 71-20-02

Each engine Visual inspection of the visible portions of the AI 54-51-85

removal Pylon Adapter Beam (aft mount Upper Beam). MD-11 71-20-03

GE Proprietary Information 2-21 Workscope Planning Guide

Subject to restrictions on the cover or first page
 CF6-80C2
GE Aviation Workscope Planning Guide

Table 2-2. Inspections Defined by Interval. (Cont.)

Recommended Procedure Definition (AMM

Inspection or Service
Interval Section or Service Bulletin)

Each engine Fluorescent penetrant inspection of the aft CMM 71-20-05

shop visit engine mount Lower Beam Assembly after
disassembly from the engine.

20,000 FC Fluorescent penetrant inspection of the Pylon CMM 71-20-05

Adapter Beam (aft mount Upper Beam) after
disassembly from aircraft.

GE Proprietary Information 2-22 Workscope Planning Guide

Subject to restrictions on the cover or first page
 CF6-80C2
GE Aviation Workscope Planning Guide

SECTION 3

Modular Thresholds

3.0. Modular Thresholds.

A. Table 3-1 defines general guidelines for soft time recommendations for level of
work for each module. As discussed in Section 1.2., GE recommends that the
specific level of work timing be developed based on the Objectives discussion
in this guide. The recommendations below were based on the most recent
average engine experience.

B. In order to meet the intent of these maintenance threshold recommendations,

the specified maintenance should be done at the next scheduled shop visit
after the indicated module(s) have exceeded the recommended intervals. If
the engine is sent to the shop for unscheduled maintenance, GE recommends
that the overall level of maintenance to be done to the engine be decided on a
case by case basis.

C. Threshold recommendations below are based on the following considerations:

1) Optimal timing for “performance” restoration considering typical time on

wing expectations and high fuel costs.

2) “Overhaul” recommendations that maximize the time between full

“Overhaul”, while protecting against certain wear modes that could cause
unserviceable hardware if operated too long between “Overhaul”.

3) Convenient “Overhaul” intervals based on LLP life limits.

NOTE: Because CF6-80C2 engines are operated over a wide range of flight
lengths and operating environments, modification of these modular
thresholds may be necessary for certain operators. Additionally, the past
maintenance history of each engine including incoming hardware
standards, Services Bulletin status, and level of work previously done
can impact the level of work needed which can influence the logical
modular thresholds for that specific engine. Intervals can, and should be,
adjusted based on each operator’s engine experience based on their
unique operational factors. GE recommends that operators work with
their maintenance providers to determine the specific thresholds that are
appropriate for their engines. Reference Paragraph 1.2. for more
information.

GE Proprietary Information 3-1 Workscope Planning Guide

Subject to restrictions on the cover or first page
 CF6-80C2
GE Aviation Workscope Planning Guide

D. “Performance” workscopes are primarily intended to restore the engine flow

path to reclaim engine performance, as well as flow path hardware integrity.

E. “Overhaul” workscopes are intended to restore the engine flow path and to
inspect, and repair as necessary, the engine structural hardware.

Table 3-1. Recommended Modular Maintenance Thresholds

3.1. Fan Stage 1 Rotor.

Level TSO CSO

Minimum On Condition On Condition
Performance 12,000 hours1 2,000 cycles
Full Overhaul 39,000 hours 6,500 cycles

Note:

1. Fan Stage 1 Rotor “Performance” workscope only includes stage 1 fan blades.

3.2. Fan Booster Rotor.

Level TSO CSO

Minimum On Condition On Condition
Performance 19,500 hours 3,250 cycles
Full Overhaul 39,000 hours 6,500 cycles

3.3. Fan Stator.

Level TSO CSO

Minimum On Condition On Condition
Performance 19,500 hours 3,250 cycles
Full Overhaul 39,000 hours 6,500 cycles

GE Proprietary Information 3-2 Workscope Planning Guide

Subject to restrictions on the cover or first page
 CF6-80C2
GE Aviation Workscope Planning Guide

3.4. HPC Module.

Level TSO CSO

Minimum On Condition On Condition
Performance 19,500 hours1 3,250 cycles
Full Overhaul 39,000 hours 6,500 cycles

Note:

1. If the CDP stationary seal honeycomb is replaced in the CRF, the rotating CDP
seal on the HPC rotor should be removed and seal tooth coating reapplied. This
is recommended to avoid damaging the rotating CDP seal teeth from rubbing
during seal break-in.

3.5. CRF Module.

Level TSO CSO

Minimum On Condition On Condition
Performance 15,000 hours1,2 2,500 cycles
Full Overhaul 39,000 hours 6,500 cycles

Notes:

1. If the CDP stationary seal honeycomb is replaced in the CRF, the rotating CDP
seal on the HPC rotor should be removed and seal tooth coating reapplied. This
is recommended to avoid damaging the rotating CDP seal teeth from rubbing
during seal break-in.
2. CRF “Performance” workscope is limited to removal of the B/C sump housing in
order to replace the o-ring seal which deteriorate over time and cause oil leakage

GE Proprietary Information 3-3 Workscope Planning Guide

Subject to restrictions on the cover or first page
 CF6-80C2
GE Aviation Workscope Planning Guide

3.6. Combustor Module.

Level TSO CSO

Minimum On Condition On Condition
Full Overhaul1 15,000 hours 2,500 cycles

Note:

1. Because of the configuration of the combustor, the “Performance” and “Overhaul”

workscopes are the same. Therefore, the “Overhaul” interval recommendations for
those modules have been aligned with the “Performance” workscope threshold for
the remainder of the core modules.

3.7. HPT Stage 1 Nozzle.

Level TSO CSO

Minimum On Condition On Condition
Full Overhaul1 15,000 hours 2,500 cycles1

Note:

1. Because of the configuration of the HPT stage 1 nozzle, the “Performance” and
“Overhaul” workscopes are the same. Therefore, the “Overhaul” interval
recommendations for those modules have been aligned with the “Performance”
workscope threshold for the remainder of the core modules.

GE Proprietary Information 3-4 Workscope Planning Guide

Subject to restrictions on the cover or first page
 CF6-80C2
GE Aviation Workscope Planning Guide

3.8. HPT Stage 2 Nozzle.

Level TSO CSO

Minimum On Condition On Condition
Performance 15,000 hours 2,500 cycles
Full Overhaul 30,000 hours 5,000 cycles

3.9. HPT Rotor.

Level TSO CSO

Minimum On Condition On Condition
Performance1 15,000 hours 2,500 cycles
Full Overhaul (Config. 1 - Inco) 30,000 hours 5,000 cycles
Full Overhaul (Config. 2 - R88DT) 45,000 hours 7,500 cycles

Note:

1. Configuration 1 (Inco rotors) only. If the thermal shield has accumulated 9,000
cycles or more since new, or if the thermal shield time since new is not known, it
is recommended that the seal teeth serrations are inspected for cracks at each
Performance level shop visit. The engine manual defines an optional eddy current
inspection of the seal teeth that can be done at the rotor module level to detect
seal teeth cracks.

3.10. LPT Module.

Level TSO CSO

Minimum On Condition On Condition
Performance1,2 15,000 hours 2,500 cycles
Full Overhaul 39,000 hours 6,500 cycles

GE Proprietary Information 3-5 Workscope Planning Guide

Subject to restrictions on the cover or first page
 CF6-80C2
GE Aviation Workscope Planning Guide

Notes:

1. “Performance” restoration thresholds for the LPT apply only to the LPT stator and
are listed for convenience. “Performance” restoration of the LPT stator is entirely
optional and is not required for engine reliability. Some operators have
expressed their desire to perform “Performance” restoration of the LPT module.
Operators should evaluate cost of the LPT flow path refurbishment for
performance versus their engine performance goals to determine specific engine
workscope.
2. It is recommended that the turbine rear frame (TRF) oil supply and scavenge
tubes be removed and cleaned at each core “Performance” restoration and each
LPT “Overhaul” shop visits.

3.11. Accessory Drives Module.

Level TSO CSO

Minimum On Condition On Condition
Performance1 15,000 hours 2,500 cycles
Full Overhaul 36,000 hours 9,000 cycles

Note:

1. “Performance” restoration of the accessory gearbox is limited to removal and

refurbishment of the accessory drive carbon seals to minimize fluid leakage.

3.12. Configurations.

Level TSO CSO

Minimum Not Removed Not Removed
Full Overhaul Removed Removed

3.13. Control and accessories.

A. Refer to Section 1.5. for Threshold

.

GE Proprietary Information 3-6 Workscope Planning Guide

Subject to restrictions on the cover or first page
 CF6-80C2
GE Aviation Workscope Planning Guide

SECTION 4

Performance Effect by Module

The following pages outline the estimated performance effects for Fan, HPC,
HPT, and LPT modules. The objective of the information contained within this
guide is to communicate the effects on performance and maintenance cost
goals while maintaining high standards of engine reliability. The performance
effects contained herein are based on an average engine in the fleet. However,
there are many variable factors that can affect the specific workscope
definition for a given operator or engine.

GE Proprietary Information 4-1 Workscope Planning Guide

Subject to restrictions on the cover or first page
 CF6-80C2
GE Aviation Workscope Planning Guide

4.0. Module Performance Effects.

4.1. Performance Effects for Fan Module Airfoils Clearances and Surface
Conditions.

A. Refer to Figure 4-1.

ITEM ITEM DESCRIPTION SFC % EGT °C

NO.
1. Fan Blade Tip Clearance (For Each 0.02-Inch (0.5 mm) 0.09 -0.90
Clearance)
2. Fan Blade Leading Edge Erosion 0.41 -0.80
3. Fan Surface Finish (Overall) (60 Microinches Versus 22 0.035 -0.672
Microinches)
4. Fan Blade Pitting 0.04 -0.12
5. Fan Blade Dirt (All Sides) 0.11 -0.35
6. Splitter Erosion 0.05 -0.06
7. OGV Leading Edge Erosion 0.05 -0.06
8. Booster Airfoil Surface Finish 0.015 0.30
9. Booster Shroud Erosion (For Each 0.02-Inch (0.5 mm) 0.07 1.0
Clearance)
NOTES:
1. Fan blade pitting equivalent to 100 microinches per inch on pressure side.
2. Booster airfoil surface finish at 50 microinches per inch (new airfoil: 24
microinches per inch).
3. Erosion and dirt values are based on 6,000 hours “average” engine
operation.
4. Fan surface finish, pitting, and dirt effects are not cumulative.

Fan Module Performance Effects

Figure 4-1

GE Proprietary Information 4-2 Workscope Planning Guide

Subject to restrictions on the cover or first page
 CF6-80C2
GE Aviation Workscope Planning Guide

4.2. Performance Effects for HPC Module Airfoils Clearances and Surface
Conditions.

A. Refer to Figure 4-2, Table 4-1, and Table 4-2.

1 4

2 3

1. Blade-to-Case Clearances 4. Airfoil Chord Length

2. Vane-to Spool Clearances 5. CDP Seal Clearance
3. Airfoil Surface Finish 6. 4R Vent Seal Clearance

Performance Effects for HPC Module

Figure 4-2

Table 4-1. Performance Effects of HPC Rotor Blade and HPC Stator Vane Tip Clearances

For Each 0.01 inch (0.25 mm) Clearance or for Each 0.03 inch (0.75 mm) Chord Loss

Stage HPC Rotor Blade to Stator Case HPC Stator Vane to Rotor Land
Clearance Clearance
SFC % EGT °C SFC % EGT °C
1 0.003 0.07 --- ---
2 0.005 0.11 --- ---
3 0.007 0.15 0.008 0.16
4 0.009 0.19 0.009 0.18
5 0.011 0.23 0.009 0.19
6 0.013 0.26 0.010 0.21
7 0.014 0.29 0.011 0.22
8 0.015 0.32 0.011 0.23
9 0.016 0.34 0.012 0.25
10 0.017 0.35 0.012 0.25
11 0.018 0.36 0.013 0.26
12 0.018 0.37 0.013 0.26
13 0.018 0.38 0.013 0.27
14 0.018 0.38 --- ---
Total 0.182 3.80 0.121 2.48

GE Proprietary Information 4-3 Workscope Planning Guide

Subject to restrictions on the cover or first page
 CF6-80C2
GE Aviation Workscope Planning Guide

Table 4-2. Performance Effects of HPC Blade and Vane Surface Finish

Surface
Blade Vane Total Blade Vane Total
Finish Micro
SFC Change SFC Change SFC Change EGT Change EGT Change EGT Change
Inches
20 0.000 0.000 0.000 0.0 0.0 0.0
30 0.082 0.056 0.137 3.0 1.8 4.8
40 0.167 0.116 0.283 4.6 3.1 7.7
50 0.253 0.176 0.429 6.2 4.2 10.4
60 0.339 0.227 0.566 8.0 5.3 13.3
65 0.380 0.262 0.641 9.0 6.0 15.0

4.3. Performance Effects for CDP and 4R Vent Seal Clearances.

A. Refer to Figure 4-3.

CDP and 4R Vent Seal Clearances

1) Diameters measured on un-rubbed

surfaces of the stationary seal
2) Maximum average recommended
rub depth is 0.010 inch per seal land
3) 4R vent seal dimensions assume
that SB 72-0451 has been completed

Seal Clearance Effect on Performance

(For Each 0.01 Inch (0.25 mm) Clearance)

SFC (%) EGT (°C)

CDP 0.39 4.7
4R Vent 0.17 1.6

CDP and 4R Vent Seal Clearances

Figure 4-3

GE Proprietary Information 4-4 Workscope Planning Guide

Subject to restrictions on the cover or first page
 CF6-80C2
GE Aviation Workscope Planning Guide

4.4. Performance Effects for HPT Stage 1 Nozzle Assembly.

A. Refer to Figure 4-4.

GE Proprietary Information 4-5 Workscope Planning Guide

Subject to restrictions on the cover or first page
 CF6-80C2
GE Aviation Workscope Planning Guide

STAGE 1 NOZZLE

STAGE 1 HPT NOZZLE SUPPORT

HPT AIRFOIL SURFACE FINISH EFFECT

BASED ON 120 MICROINCHES PER INCH
AVERAGE SURFACE ROUGHNESS
(NEW AIRFOIL: 33 MICROINCHES PER INCH)

SFC (%) EGT (°C)

STAGE 1 VANE 0.173 3.21

STAGE 1 NOZZLE ASSEMBLY– A4

SFC (%) EGT (°C)

1% CHANGE IN AREA 0.15 1.27

HPT Stage 1 Nozzle Assembly - Performance Effects

Figure 4-4

GE Proprietary Information 4-6 Workscope Planning Guide

Subject to restrictions on the cover or first page
 CF6-80C2
GE Aviation Workscope Planning Guide

4.5. Performance Effects for HPT Clearances.

A. Stage 1 and 2 HPT Blade Tip Clearances.

Target grind requirements of the HPT stage 1 and 2 blade-to-shroud

clearances are stated in the engine manual. The blade-to-shroud clearances
are different for the Configuration 1 (INCO Turbine Rotor) and the
Configuration 2 (R88DT Turbine Rotor). These clearances have the greatest
effect on performance for the whole engine. For each 0.010-inch increment
of change in clearance, the stage 1 is equivalent to 5.2 takeoff EGT, 0.25
cruise SFC. Stage 2 is equivalent to 2.6 EGT, 0.13 cruise SFC. These values
are applicable to both Configuration 1 and 2 rotors.

B. HPT Interstage Seal Clearances.

For each 0.010-inch increment of change in clearance of the total HPT

interstage seal system, the performance effect is 0.9 takeoff EGT, 0.04
cruise SFC. These values are applicable to both Configuration 1 and 2
rotors.

NOTES:

1) Maximum average recommended rub depth is 0.030 inch per seal when
measured at maximum rub location on stationary seal.

2) The primary function of the HPT interstage seal clearance is to maintain

the proper HPT stage 1 and stage 2 disk post cavity temperatures.
Clearance effects on performance are minimal.

3) For Configuration 1, cold clearance calculation includes 0.0075 inch

inward and radial deflection of thermal shield during assembly.

C. Refer to Table 4-3, Figure 4-5, Figure 4-6, and Table 4-4.

Table 4-3. HPT Airfoil Surface Finish Effect*.

SFC % EGT %
Stage 2 Vane 0.106 2.45
Stage 1 Blade 0.146 2.49
Stage 1 Blade 0.053 1.25
(*) Based on 120 Microinches per Inch Average Surface Roughness (New Airfoil: 33 Microinches
per Inch).

GE Proprietary Information 4-7 Workscope Planning Guide

Subject to restrictions on the cover or first page
 CF6-80C2
GE Aviation Workscope Planning Guide

HPT BLADE TIP AND INTERSTAGE SEAL CLEARANCES

CONFIGURATION 1 (INCO 718 TURBINE ROTOR)

HPT BLADE TIP AND INTERSTAGE SEAL CLEARANCES

CONFIGURATION 2 (R88DT BOLTLESS TURBINE ROTOR)

Configuration 1 and 2 - HPT Blade Tip and Interstage Seal Clearances

Figure 4-5

GE Proprietary Information 4-8 Workscope Planning Guide

Subject to restrictions on the cover or first page
 CF6-80C2
GE Aviation Workscope Planning Guide

MAXIMUM AVERAGE
DEPTH OF RUB SHOULD
NOT EXCEED 0.020 Inch

Performance Effects for Mini-Nozzle and 5R Vent Seal Clearances Configuration 1

(INCO 718 Turbine Rotor)
Figure 4-6

Table 4-4. Mini-Nozzle and 5R Vent Seal Clearances

Stationary Seal Diameters Rotating Seal Diameters Clearances

Reference MAX MIN MAX MIN MAX MIN
A 12.012 12.008 12.002 11.998 0.047 0.003
B 12.412 12.408 12.402 12.398 0.047 0.003
C 12.812 12.808 12.802 12.798 0.047 0.003
D 13.212 13.208 13.202 13.198 0.047 0.003
E 13.612 13.608 13.602 13.598 0.047 0.003
F 15.765 15.76 15.752 15.748 0.0485 0.004
G 15.915 15.91 15.902 15.898 0.0485 0.0045
H 10.111 10.108 10.082 10.075 0.058 0.013
I 10.111 10.108 10.072 10.065 0.063 0.018

NOTE: For each 0.010-inch average increment of change in clearance of the total seal system, the
performance effect is as follows:
- Mini Nozzle - 1.0 takeoff EGT - 0.17 cruise SFC
- 5R Vent Seal — 0.8 takeoff EGT — 0.06 cruise SFC

NOTES:

1) Maximum average recommended rub depth is 0.020 inch per seal land.
2) The primary function of the mini-nozzle and 5R vent seal clearance is to maintain proper HPT
blade cooling airflow. Clearance effects on performance are minimal.

* Measured at maximum rub depth on stationary seal.

GE Proprietary Information 4-9 Workscope Planning Guide

Subject to restrictions on the cover or first page
 CF6-80C2
GE Aviation Workscope Planning Guide

4.6. Performance Effects for HPT Configuration 2 (R88DT Rotor) Forward Seal
Clearances.

A. Refer to Figure 4-7.

FWD OUTER SEAL

INDUCER

STAGE 1 STATIONARY
SUPPORT SEAL

ROTATING AIR SEAL

MAXIMUM AVERAGE
DEPHT OF RUB SHOULD
NOT EXCEED 0.020 Inch
5R ROTATING
AIR SEAL

PERFORMANCE EFFECT FOR EACH 0.010-INCH INCREASE AVERAGE IN CLEARANCE OF THE TOTAL SEAL
SYSTEM:
• MINI-NOZZLE: 1.0 TAKEOFF EGT, 0.17 CRUISE SFC
• 5R VENT SEAL: 0.8 TAKEOFF EGT, 0.06 CRUISE SFT

Configuration 2 (R88DT Boltless Turbine Rotor)

Figure 4-7

GE Proprietary Information 4-10 Workscope Planning Guide

Subject to restrictions on the cover or first page
 CF6-80C2
GE Aviation Workscope Planning Guide

4.7. Performance Effects for LPT Module.

A. Refer to Figure 4-8, Table 4-5, and Table 4-6.

MAXIMUM AVERAGE
DEPTH IF RUB SHOULD
NOT EXCEED 0.050 Inch.

Blade Tip and Interstage Seal Clearances

Figure 4-8

Table 4-5. LPT Clearance Effects on Performance (For each 0.01 inch (0.24 mm) Clearance

ITEM SFC % EGT °C

LPT Vent Seal 0.037 0.5
LPT Stage 1 0.016 0.14
LPT Stage 2 0.017 0.15
LPT Stage 3 0.018 0.16
LPT Stage 4 0.017 0.15
LPT Stage 5 0.01 0.09
LPT Interstage 2 0.015 0.13
LPT Interstage 3 0.013 0.12
LPT Interstage 4 0.012 0.10
LPT Interstage 5 0.005 0.04

GE Proprietary Information 4-11 Workscope Planning Guide

Subject to restrictions on the cover or first page
 CF6-80C2
GE Aviation Workscope Planning Guide

Table 4-6. LPT Airfoil Surface Finish Effects on Performance Based on 150 Microinches per Inch Average Surface
Roughness (New Airlfoil: 55 Microinches per Inch)

LPT VANES SFC % EGT °C

Stage 1 0.088 0.72
Stage 2 0.088 1.08
Stage 3 0.088 1.02
Stage 5 0.056 1.05
Stage 5 0.013 0.54
Total 0.333 4.41

LPT BLADES SFC % EGT °C

Stage 1 0.07 0.78
Stage 2 0.084 0.9
Stage 3 0.056 0.81
Stage 5 0.025 0.84
Stage 5 0.007 0.48
Total 0.242 3.81

GE Proprietary Information 4-12 Workscope Planning Guide

Subject to restrictions on the cover or first page
 CF6-80C2
GE Aviation Workscope Planning Guide

SECTION 5

Assembled Engine

The following pages outline the relevant tasks for performing the assembling of the
engine. The objectives of the information contained within this guide are to
communicate the extent of work to enable the user of the guide to achieve their
engine durability, performance and maintenance cost goals while maintaining high
standards of engine reliability. The recommendations contained herein are based on
an average engine in the fleet. However, there are many variable factors that can
affect the specific workscope definition for a given operator or engine.

GE Proprietary Information 5-1 Workscope Planning Guide

Subject to restrictions on the cover or first page
 CF6-80C2
GE Aviation Workscope Planning Guide

5.0. Assembled Engine Cross Section.

A. Refer to Figure 5-1.

Assembled Engine Cross Section

Figure 5-1

5.1. Engine Performance Restoration Contributors.

A. Refer to Figure 5-2.

GE Proprietary Information 5-2 Workscope Planning Guide

Subject to restrictions on the cover or first page
 CF6-80C2
GE Aviation Workscope Planning Guide

Engine Performance Restoration Contributors

Figure 5-2

GE Proprietary Information 5-3 Workscope Planning Guide

Subject to restrictions on the cover or first page
 CF6-80C2
GE Aviation Workscope Planning Guide

5.2. Assembled Engine Special Workscope - General.

Key Maintenance Tasks - Assembled Engine Reference

Perform complete borescope inspection of modules not to be exposed, AMM 72-00-00

especially: Inspection

- HPC stage 1 blade leading edge and midspan shroud --

- HPC front, middle and back stages --

- Combustor dome, inner and outer liners --

- HPT stage 1 nozzle leading edge --

- HPT stage 1 blade leading edge --

- HPT stage 1 shrouds --

- HPT stage 2 Nozzles/Blades --

- LPT stage 1-5 blades and nozzles --

Visually inspect configuration hardware, especially: 72-09-03

- D-sump oil supply and scavenge tubes --

- 7th stage cooling manifold --

- HPT/LPT ACC manifolds --

- Oil pressure transmitter tubing-check to ensure P-clamps are not --

cracked or missing

- Fuel manifold clamp areas for chafing --

Fan disk immersion-ultrasonic inspection SB 72-0935

Measure and record fan blade tip clearances E12/E13 72-00-00

Assembly

Inspect VSV/VBV linkages for looseness, worn bearings, bent lever arms, 72-00-02
actuation ring damage, VSV bushing wear (metal to metal contact) Inspection

Inspect LPT case for wear from contact with ACC manifold 72-00-04
Inspection

GE Proprietary Information 5-4 Workscope Planning Guide

Subject to restrictions on the cover or first page
 CF6-80C2
GE Aviation Workscope Planning Guide

Key Maintenance Tasks - Assembled Engine (Cont.) Reference

Inspect TRF outer panels and forward and aft flanges for cracks 72-00-04
Inspection

Remove aft engine mount system. Disassemble and inspect CMM 71-20-05
Inspection

Remove and inspect oil/fuel filters and lube pump isolation screens. AMM 79-00-00
Replace filters Inspection

Remove and inspect ECU Cables Applicable CMM

Inspection

Check EGT harness indication system if problems were reported AMM 77-21-00
Check

- Piece-part inspect EGT probes CMM 77-21-41,

77-21-52

Perform gas path cleaning during test cell run or after installation, if HPC AMM 72-00-00
module was not exposed or if borescope inspection or test cell
performance indicates that improvement is possible

GE Proprietary Information 5-5 Workscope Planning Guide

Subject to restrictions on the cover or first page
 CF6-80C2
GE Aviation Workscope Planning Guide

SECTION 6

Fan/Booster Module

The following pages outline the relevant tasks for performing Fan/Booster
module workscope planning and maintenance. The objectives of the
information contained within this guide are to communicate the extent of work
to enable the user of the guide to achieve their engine durability, performance
and maintenance cost goals while maintaining high standards of engine
reliability. The recommendations contained herein are based on an average
engine in the fleet. However, there are many variable factors that can affect the
specific workscope definition for a given operator or engine.

GE Proprietary Information 6-1 Workscope Planning Guide

Subject to restrictions on the cover or first page
 CF6-80C2
GE Aviation Workscope Planning Guide

6.0. Fan/Booster Module Assembly.

A. Refer to Figure 6-1 thru Figure 6-6.

Fan Module Cross Sections

Figure 6-1 (Sheet 1 of 2)

GE Proprietary Information 6-2 Workscope Planning Guide

Subject to restrictions on the cover or first page
 CF6-80C2
GE Aviation Workscope Planning Guide

Fan Module Cross Sections

Figure 6-1 (Sheet 2 of 2)

GE Proprietary Information 6-3 Workscope Planning Guide

Subject to restrictions on the cover or first page
 CF6-80C2
GE Aviation Workscope Planning Guide

Fan Rotor Assembly

Figure 6-2

GE Proprietary Information 6-4 Workscope Planning Guide

Subject to restrictions on the cover or first page
 CF6-80C2
GE Aviation Workscope Planning Guide

Center Vent Tube

Fan Mid Shaft

St
St
St ag St
Stage 1 ag
ag e ag
e
Fan 2 e 4
e
Blade 3 5
Seal
Wires

Spinner Seal

Stage 1 Stage 2-5

Fan Disk Booster
Spool

Forward Fan Shaft

Fan Rotor and Fan Mid-Shaft Assemblies

Figure 6-3 (Sheet 1 of 2)

GE Proprietary Information 6-5 Workscope Planning Guide

Subject to restrictions on the cover or first page
 CF6-80C2
GE Aviation Workscope Planning Guide

No. 1
Air/Oil Bearing
Seal
Spanner
Stage 1
Nut
Fan Disk
Seal

Spanner
No. 2
N1 Nut
Bearing
Sensor
Forward Fan
Shaft

Fan Rotor and Fan Mid-Shaft Assemblies

Figure 6-3 (Sheet 2 of 2)

GE Proprietary Information 6-6 Workscope Planning Guide

Subject to restrictions on the cover or first page
 CF6-80C2
GE Aviation Workscope Planning Guide

Fan Forward Case

Forward Fan Case Assembly

Figure 6-4 (Sheet 1 of 2)

GE Proprietary Information 6-7 Workscope Planning Guide

Subject to restrictions on the cover or first page
 CF6-80C2
GE Aviation Workscope Planning Guide

Kevlar Containment Ring

Aft Mating
Forward Mating Flange Flange

Captive
Inlet Flange Nut
Seal

Liner
Segment
Abradable
Forward Kevlar Kevlar Shroud
Flange Graphite Wrap Epoxy
Epoxy

H.C.
Core Microballoon Kevlar Felt
Aluminum Shroud
Case

Forward Fan Case Assembly

Figure 6-4 (Sheet 2 of 2)

GE Proprietary Information 6-8 Workscope Planning Guide

Subject to restrictions on the cover or first page
 CF6-80C2
GE Aviation Workscope Planning Guide

Fan Booster Stator Assembly

Figure 6-5

GE Proprietary Information 6-9 Workscope Planning Guide

Subject to restrictions on the cover or first page
 CF6-80C2
GE Aviation Workscope Planning Guide

Fan Aft
OGV
Case

Bulb Seal
Inner Fan Frame
Support Strut End

0.75
Forward Inch OGV
Support
Pressure
Relaxed
Flowpath Position
(Free Fan
State) Frame

Fan
Reverser
V-Clamp

Aft Fan Case and Fan Frame Assembly

Figure 6-6 (Sheet 1 of 3)

GE Proprietary Information 6-10 Workscope Planning Guide

Subject to restrictions on the cover or first page
 CF6-80C2
GE Aviation Workscope Planning Guide

Fan Frame Assembly

Fan Frame Assembly

Figure 6-6 (Sheet 2 of 3)

GE Proprietary Information 6-11 Workscope Planning Guide

Subject to restrictions on the cover or first page
 CF6-80C2
GE Aviation Workscope Planning Guide

Fan Frame
Strut Utilization

Fan Frame Assembly

Figure 6-6 (Sheet 3 of 3)

6.1. Performance Effects for Fan/Booster Module.

A. Refer to Section 4, Performance Effects by Module, which defines the

performance effects of restoring HPT clearances and airfoil surface finish.

6.2. Fan/Booster Module Minimum Workscope.

A. Refer to Figure 6-7.

GE Proprietary Information 6-12 Workscope Planning Guide

Subject to restrictions on the cover or first page
 CF6-80C2
GE Aviation Workscope Planning Guide

Process Map - Fan Module Minimum Workscope

Figure 6-7

GE Proprietary Information 6-13 Workscope Planning Guide

Subject to restrictions on the cover or first page
 CF6-80C2
GE Aviation Workscope Planning Guide

6.3. Fan Module Minimum Workscope Tasks.

A. Refer to Table 6-1.

Table 6-1. Fan Module Minimum Workscope Tasks.

Item Tasks Reference

Fan/Booster Verify compliance to accessible Category 1-3

Assembly Service Bulletins, especially documents found in --
the “Key Recommended Documents” section of
this document.

Clean and FPI forward engine mount hardware 71-21-01

and replace mount link bearings at each planned Inspection
engine shop visit

Fan Rotor Verify compliance to accessible Category 1-3

Assembly Service Bulletins, especially documents found in --
the “Key Recommended Documents” section of
this document.

72-00-21
Perform All Relevant Inspections. Inspection

Reapply stage 1 fan blade and fan disk dovetail 72-21-01

lubricant (optional as needed). 72-21-03

Fan Rotor Assembly Recondition fan blades to 72-21-01

restore leading edge profile and surface finish for Repair 003
optimal performance (optional). Repair 005

Restore fan blade RTV dovetail strips if required. 72-21-03

Forward Fan Verify compliance to accessible Category 1-3

Case Service Bulletins, especially documents found in --
the “Key Recommended Documents” section of
this document.

72-00-22
Perform All Relevant Inspections. 72-00-01

GE Proprietary Information 6-14 Workscope Planning Guide

Subject to restrictions on the cover or first page
 CF6-80C2
GE Aviation Workscope Planning Guide

Table 6-1. Fan Module Minimum Workscope Tasks. (Cont).

Item Tasks Reference

Fan Frame Verify compliance to accessible Category 1-3

Service Bulletins, especially documents found in 72-00-00
the “Key Recommended Documents” section of
this document.

72-00-23
Perform All Relevant Inspections 71-21-01
CMM 76-24-18

Fan Booster Stator

Assembly Verify compliance to accessible category 1-3
Service Bulletins, especially documents found in --
the “Key Recommended Documents” section of
this document.

72-00-01
Perform all relevant inspections 72-00-24

Fan Mid-Shaft
Verify compliance to accessible Category 1-3
Service Bulletins, especially documents found in --
the “Key Recommended Documents” section of
this document.

72-00-01
Perform all relevant inspections 72-00-24

6.4. Fan Module Performance Workscope - Discussion.

A. Experience has shown that disassembly of the fan module is not justified to
do a performance restoration between full overhaul. The fan components
that have the most influence on performance are:

(1) Stage 1 fan blades

(2) Fan OGVs

(3) Splitter fairing

GE Proprietary Information 6-15 Workscope Planning Guide

Subject to restrictions on the cover or first page
 CF6-80C2
GE Aviation Workscope Planning Guide

B. Optional - if optimal engine performance is required, then it is

recommended that:

(1) Recondition fan blades per ESM 72-21-01 at each shop visit.

(2) Inspect Fan OGVs per ESM 72-00-23 at each engine performance
shop visit and recondition as needed per ESM 72-23-08.

(3) Inspect splitter fairing per ESM 72-00-23 at each engine and
recondition as needed per ESM 72-25-04 performance shop visit.

6.5. Fan/Booster Module Full Overhaul Workscope.

A. Refer to Figure 6-8 and Figure 6-9.

GE Proprietary Information 6-16 Workscope Planning Guide

Subject to restrictions on the cover or first page
 CF6-80C2
GE Aviation Workscope Planning Guide

Process Map - Fan Rotor Overhaul Workscope

Figure 6-8

GE Proprietary Information 6-17 Workscope Planning Guide

Subject to restrictions on the cover or first page
 CF6-80C2
GE Aviation Workscope Planning Guide

Process Map - Fan Stator Overhaul Workscope

Figure 6-9

GE Proprietary Information 6-18 Workscope Planning Guide

Subject to restrictions on the cover or first page
 CF6-80C2
GE Aviation Workscope Planning Guide

6.6. Fan Module Full Overhaul Workscope Tasks

A. Refer to Table 6-2.

Table 6-2. Fan Module Overhaul Workscope Tasks.

Item Tasks Reference

Fan Rotor Verify compliance to accessible Category 1-6

Service Bulletins, especially documents found in
the “Key Recommended Documents” section of --
this document. Consider compliance with
applicable Category 7 Service Bulletins.

Perform all relevant rotor inspections in 05-21-00

accordance with tasks and subtasks in the 72-21-03
appropriate ESM. 72-21-04

Fan Booster Blades

Clean and repair booster blades as required. 72-21-02

Fan Rotor Stage 1

Blades Recondition fan blades to restore leading edge 72-21-01
profile and surface finish for optimal Repair 003
performance. Repair 005
Repair blade dovetail coatings as required. Repair 007

Fan Frame Verify compliance to accessible Category 1-6

Service Bulletins, especially documents found in
the “Key Recommended Documents” section of --
this document. Consider compliance with
applicable Category 7 Service Bulletins.

Perform All Relevant Inspections. 72-23-01

Pressure Check A-sump at assembly. 72-23-00

Repair loose or missing OGV metal leading edges. 72-23-08

Restore surface finish to optimize performance.

Check VBV door linkage for looseness and rig 72-23-00

system as required.

GE Proprietary Information 6-19 Workscope Planning Guide

Subject to restrictions on the cover or first page
 CF6-80C2
GE Aviation Workscope Planning Guide

Table 6-2. Fan Module Overhaul Workscope Tasks. (Cont).

Item Tasks Reference

Fan Stator Verify compliance to accessible Category 1-6

Service Bulletins, especially documents found in
the “Key Recommended Documents” section of --
this document. Consider compliance with
applicable Category 7 Service Bulletins.

72-25-03

72-25-02
Perform All Relevant Inspections.
72-23-01

72-22-01

Hand polish or vibrotumble vanes to improve 72-21-00

surface finish.

Recontour and anodize fan stator fairing leading 72-25-04

edge as required.

GE Proprietary Information 6-20 Workscope Planning Guide

Subject to restrictions on the cover or first page
 CF6-80C2
GE Aviation Workscope Planning Guide

6.7. Critical Items, Reliability and Key Product Improvements, and Best
Practices - Fan Frame Assembly.

NOTE: The following pages highlight current critical items, a selection of other
key reliability, product improvements, and best practices. Except for
critical items, this list is not all inclusive; therefore, it is recommended that
all Category 1 - 7 Service Bulletins be evaluated for workscope inclusion.
Please refer to the most recent revision of the cited documents for further
information.

A. Priority Levels.

• Priority 1: Critical Item / Safety / AD-Mandated

• Priority 2: Other Important / Reliability item

• Priority 3: Cost of Ownership, Best Practices / Recommended

items

6.7.1. Fan Frame Assembly - Priority 1

NOTE: Always Use Latest Revision of Listed Documents

A. Refer to Table 6-3 thru 6-6 and Figure 6-10 thru Figure 6-13.

Table 6-3. Fan Frame Assembly - Priority 1.

Recommended
Item Item Description Document(s) Workscope
Level

Fan Forward Inner Improved bracket SB 72-1223 (R0, Jun-2006) Any SV

Liner Bracket design.
“ENGINE - Fan Module (72-00-01) -
Improved Brackets Improved durability Introduction of Improved Forward Inner
address cracking in Liner Brackets”
service at forward and
aft sections of bracket.

GE Proprietary Information 6-21 Workscope Planning Guide

Subject to restrictions on the cover or first page
 CF6-80C2
GE Aviation Workscope Planning Guide

Bracket Locations

Fan Forward Inner Liner Bracket

Figure 6-10

GE Proprietary Information 6-22 Workscope Planning Guide

Subject to restrictions on the cover or first page
 CF6-80C2
GE Aviation Workscope Planning Guide

NEW BRACKET

OGV INNER BOLT MS9490-08

LINER SEGMENT REPLACED BY
BOLT MS9490-10
PER S/B 72-1223
REV. 1

NEW FAN INNER

Bracket Installation LINER BRACKET

Fan Forward Inner Liner Bracket

Figure 6-11

GE Proprietary Information 6-23 Workscope Planning Guide

Subject to restrictions on the cover or first page
 CF6-80C2
GE Aviation Workscope Planning Guide

Table 6-4. Fan Frame Assembly - Priority 1.

Recommended
Item Item Description Document(s)
Workscope Level

3R Bearing Quantity 50 part number 1. SB 72-1405 (R01 Dec 2011) Specific actions
Packing 1471M25P04 packings were “FAN MODULE (72-01-00) - by engine are
Inspection shipped from the packing supplier SHOP INSPECTION FOR different based
CORRECT NO. 3 BEARING
with nonconforming (undersized PACKING” on several
holes). Some of these parts were factors.
Service bulletin provides
installed into engines during shop Reference AD for
instructions to remove current
visit. specific
packing from assembly and
requirements.
measure hole size to
Additionally, incorrect 3R
determine configuration and
bearing packings have been
acceptability of provided
installed at shop visits there were
cooling flow per engine
no part markings or inspections to
configuration. This service
verify correct packing.
bulletin is the ending action
for AD 2012-03-12.
Undersized holes reduces rotor
bore pressurization and cooling
2. AD 2012-03-12 (Effective 5-
flow which could negatively impact
Apr-2012)
certain rotor lives.
AD mandates
recommendations in SB
72-1405.

3R Packing Nonconformance
Figure 6-12

GE Proprietary Information 6-24 Workscope Planning Guide

Subject to restrictions on the cover or first page
 CF6-80C2
GE Aviation Workscope Planning Guide

B. For compliance recommendation, do as follows:

(1) Remove nonconforming 3R packing at next shop visit or before

31-Jan-2017. Refer to Table 6-4.

Table 6-5. Compliance Recommendation.

Table 6-6. Fan Frame Assembly - Priority 1.

Recommended
Item Item Description Document(s)
Workscope Level

Fan Frame Service Bulletins 72-1206 and 72- 1. SB 72-1206 (R0, Dec-2005) Within 500 cycles
1207 lists specific cast forward or 6 months of
Forward Mount mount platform and yokes that “FORWARD MOUNT ASSEMBLY the AD effective
Assembly – Cast had a particular weld repair (71- 00-00) - CAST ASSEMBLY date (9-Apr-2007)
Mount Platform during manufacture. These ENGINE MOUNT PLATFORM
and Yoke mounts have potential for REPLACEMENT” Note: This
Replacements cracking to occur from the program is listed
repaired area. These specific This Service Bulletin here for
mounts must be retired. recommends replacement of reference. The
the welded cast titanium required
forward engine mount compliance date
platforms with forged titanium has expired.
forward engine mount However, some of
platforms or non-welded cast the suspect parts
titanium forward engine mount were not found. If
platforms. a suspect part is
found, it is
2. SB 72-1207 (R1, Jul-2006) important that it
is retired and not
“FORWARD MOUNT ASSEMBLY installed on an
(71- 00-00) - CAST ASSEMBLY engine.
ENGINE MOUNT PLATFORM
AND CAST ASSEMBLY ENGINE
MOUNT YOKE REPLACEMENT”

GE Proprietary Information 6-25 Workscope Planning Guide

Subject to restrictions on the cover or first page
 CF6-80C2
GE Aviation Workscope Planning Guide

Table 6-6. Fan Frame Assembly - Priority 1. (Cont).

This Service Bulletin

recommends replacement of
the welded cast titanium
forward engine mount
platforms and/or welded cast
titanium forward engine mount
yoke with forged titanium
forward engine mount
platforms and/or forged
titanium forward engine mount
yoke or a non-welded cast
titanium part.

Airworthiness Directive AD 2007-05-14 (Effective 9-Apr-

2007)

AD mandates the requirements

of Service Bulletins 72-1206 and
72-1207 to be completed within
500 cycles or 6 months of the
AD effective date.

Forward Mount Assembly - Cast Mount Platform and Yoke Replacements

Figure 6-13

GE Proprietary Information 6-26 Workscope Planning Guide

Subject to restrictions on the cover or first page
 CF6-80C2
GE Aviation Workscope Planning Guide

6.7.2. Fan Frame Assembly - Priority 2.

NOTE: Always use latest revision of listed documents.

A. Refer to Table 6-7 thru Table 6-10 and Figure 6-14 thru Figure 6-17.

Table 6-7. Fan Frame Assembly - Priority 2.

Recommended
Item Item Description Document(s) Workscope
Level

Inlet Gearbox SB 72-1193 SB 72-1193 (R0, May-2005) Any SV

Gearshaft
PTFE Seal Introduces the production “ENGINE-General (72-00-00) - Spare Parts
version of the IGB Release for CF6-80C2 Engines”
New gearshaft which contains
improved an integral nickel-graphite Introduces improved nickel-graphite seal.
seal design / seal.
repetitive
replacement SB 72-1186 SB 72-1186 (R0, Jun-2005)

Introduces improved “ENGINE-IGB (72-61-00) - Horizontal

design for the IGB Gearshaft-PTFE Teflon Seal Replacement”
gearshaft (P/N
2121M69P01) and a Provides rework instructions to replace PTFE
repetitive replacement seal with a press fit and welded-in nickel-
procedure for previous graphite seal.
design gearshafts with
PTFE seal rings.

GE Proprietary Information 6-27 Workscope Planning Guide

Subject to restrictions on the cover or first page
 CF6-80C2
GE Aviation Workscope Planning Guide

Table 6-7. Fan Frame Assembly - Priority 2. (Cont).

Recommended
Item Item Description Document(s) Workscope
Level

SB 72-1104 SB 72-1104 (R2, Sep-2003)

This is to address PTFE “ENGINE-IGB (72-61-00) - Horizontal

seal debonding that has Gearshaft-Replacement of PTFE Seal”
been observed posing the
risk of an IFSD, ATB, or UER Not required if S/B 72-1186 is incorporated.
event. The new design
gearshaft has an integral Requires repetitive replacement of Teflon
metal seal with a nickel- Seals per the below limits.
graphite rub surface.
Engine Hours Since Cycles Since
Alternatively, a repair of Hours/Cycle New/Seal New/Seal
the old design gearshaft Ratio Replacement Replacement
incorporates a metal seal 1:1 8000 8000
ring welded to the 2:1 12000 6000
gearshaft is available. 3:1 15000 5000
Either the new integral 4:1 18000 4500
seal ring or welded metal 6:1 25500 4250
ring design eliminates the 10:1 38000 3800
risk of adhesion loss.

If the new design, or metal

ring repair are not
incorporated, repetitive
PTFE seal ring
replacement is
recommended.

NOTE:
Due to increased time on wing expectations of the engine, GE strongly recommends that either SB 72-1186 or
72-1193 be accomplished at next removal of the IGB gearshaft. It is not unusual for engines to stay on wing
longer than the PTFE seal replacement interval recommended in SB 72-1104.

GE Proprietary Information 6-28 Workscope Planning Guide

Subject to restrictions on the cover or first page
 CF6-80C2
GE Aviation Workscope Planning Guide

Inlet Gearbox Gearshaft PTFE Seal

Figure 6-14

GE Proprietary Information 6-29 Workscope Planning Guide

Subject to restrictions on the cover or first page
 CF6-80C2
GE Aviation Workscope Planning Guide

Table 6-8. Fan Frame Assembly - Priority 2.

Recommended
Item Item Description Document(s)
Workscope Level

Number 1 Bearing New packing introduced SB 72-1389 (R0, Jan-2011) Category 5

Air/Oil Seal to reduce the amount of
Preformed Packing FAN MODULE (72-00-01) - NO.1
packing stretch needed Do when the old
at installation. BEARING STATIONARY AIR/OIL packing is removed
SEAL PREFORMED PACKING from the engine.
Excessive stretch has REPLACEMENT
caused the packing to
twist during installation,
which can lead to the
packing rolling out of the
packing groove in the no.
1 bearing housing and
potentially causing
obstruction of the A sump
scavenge.

GE Proprietary Information 6-30 Workscope Planning Guide

Subject to restrictions on the cover or first page
 CF6-80C2
GE Aviation Workscope Planning Guide

Preformed Packing
(O-Ring)

Example: packing disengaged during

assembly, eventually migrating to the A sump
scavenge screen. Result was low oil quantity

Bearing Air/Oil Seal Preformed Packing

Figure 6-15

GE Proprietary Information 6-31 Workscope Planning Guide

Subject to restrictions on the cover or first page
 CF6-80C2
GE Aviation Workscope Planning Guide

Table 6-9. Fan Frame Assembly - Priority 2.

Recommended
Item Item Description Document(s)
Workscope Level

Fan Frame Service Bulletin addresses potential 1. SB 72-1116 (R2, Aug-2005) Next SV
for unserviceable wear of forward
Forward mount yokes from post SB 72-0905 “FORWARD MOUNT (71-00-00)
Mount Fail- shoulder bolts. The anti-rotation clip - FAIL-SAFE SHOULDER BOLT
Safe Shoulder on the shoulder bolt can move and INSPECTION”
Bolt cause wear on the forward yoke
Inspection clevis causing unserviceable wear. Service Bulletin defines
Wear is also possible on the clevis inspection of forward mount
hole and the shank of the shoulder yokes with post SB 72-0905
bolt. forward mount shoulder bolts
installed. Service Bulletin also
defines application of RTV
silicone to prevent future
unserviceable wear.

Forward Mount Fail-Safe Shoulder Bolt Inspection

Figure 6-16

GE Proprietary Information 6-32 Workscope Planning Guide

Subject to restrictions on the cover or first page
 CF6-80C2
GE Aviation Workscope Planning Guide

Table 6-10. Fan Frame Assembly - Priority 2.

Recommended
Item Item Description Document(s)
Workscope Level

IGB Horizontal Service Bulletin introducing an SB 72-1230 (R2, Oct-2010) Any SV

Gearshaft improved oil nozzle that contains a
Spline Wear debris screen that prevents debris “ENGINE - FAN FRAME AND CASE
from clogging the oil nozzle jet. ASSEMBLY (72-23-00) - NEW OIL
Improved Oil MANIFOLD”
Nozzle Pre-Service Bulletin oil nozzles are
prone to clogging, which restricts Introduces oil nozzle with debris
oil flow to the gear shaft spline, screen to prevent oil jet clogging
resulting in premature wear, and and potential gearshaft spline
potential decoupling of the spline. wear.

IGB Horizontal Gearshaft Spline Wear/Improved Oil Nozzle

Figure 6-17

GE Proprietary Information 6-33 Workscope Planning Guide

Subject to restrictions on the cover or first page
 CF6-80C2
GE Aviation Workscope Planning Guide

6.7.3. Fan Frame Assembly - Priority 3.

NOTE: No Priority 3 items for the fan frame assembly at this time.

6.8. Critical Items, Reliability and Key Product Improvements, and Best
Practices - Fan Stator Assembly.

NOTE: The following pages highlight current critical items, a selection of other
key reliability, product improvements, and best practices. Except for
critical items, this list is not all inclusive; therefore, it is recommended that
all Category 1 - 7 Service Bulletins be evaluated for workscope
consideration. Please refer to the most recent revision of the cited
documents for further information.

A. Priority Levels.

• Priority 1: Critical Item / Safety / AD-Mandated

• Priority 2: Other Important / Reliability item

• Priority 3: Cost of Ownership, Best Practices / Recommended

items

6.8.1. Fan Stator Assembly - Priority 1.

NOTE: No Priority 1 items for the fan stator assembly at this time.

6.8.2. Fan Stator Assembly - Priority 2.

NOTE: No Priority 2 items for the fan stator assembly at this time.

6.8.3. Fan Stator Assembly - Priority 3.

NOTE: Always Use Latest Revision of Listed Documents.

A. Refer to Table 6-11, Table 6-12, and Figure 6-18 thru 6-19.

GE Proprietary Information 6-34 Workscope Planning Guide

Subject to restrictions on the cover or first page
 CF6-80C2
GE Aviation Workscope Planning Guide

Table 6-11. Fan Stator Assembly - Priority 3.

Recommended
Item Item Description Document(s)
Workscope Level

Forward Fan Stator Stator Case 1. SB 72-1196 (R0, Aug-2005) Any SV

Case improvements by SB “ENGINE - Forward Fan Case
To address galvanic 72-1196. Assembly (72-22-00) - New
corrosion due to Three repairs (72-22- Forward Fan Case”
dissimilar materials 01 in EM) to - Corrosion protective coatings
and entrapped repair/prevent and sealants between dissimilar
moisture corrosion. metals
- Eliminates rivet row
- Provides additional drainage

2. Repair 010
- Remove/Repair fwd/aft
doubler plates

3. Repair 009 & 011

- Adds polyurethane to
repaired areas

LINER SEGMENT

AFT FAN CASE

FWD

FWD

FWD DOUBLER

FORWAD FAN CASE

Forward Fan Stator Case

Figure 6-18 (Sheet 1 of 2)

GE Proprietary Information 6-35 Workscope Planning Guide

Subject to restrictions on the cover or first page
 CF6-80C2
GE Aviation Workscope Planning Guide

Epoxy primer separates Add three drains at 6 o’clock

dissimilar materials

Forward Fan Stator Case

Figure 6-18 (Sheet 2 of 2)

Table 6-12. Fan Stator Assembly - Priority 3.

Recommended
Item Item Description Document(s)
Workscope Level

Forward Fan Stator For engines pre-SB

1. SB 72-1284 (R0, Apr-2009) Any SV
Case 72-0870 (Dec-1996,
introduced cases with “ENGINE - Forward Fan Case
Rework to Add doublers) Assembly (72-22-00) -
Forward Inside Incorporate Forward Doublers
Diameter Doublers Increases shear load to Pre-CF6-80C2 SB 72-0870
capability. Allows higher Fan Cases”
level of corrosion to be Rework to add 24 each
repaired per ESM
72-22-01 Repair 009 than doubler plates (1752M44P13)
cases without doublers to the forward case inside
diameter.

GE Proprietary Information 6-36 Workscope Planning Guide

Subject to restrictions on the cover or first page
 CF6-80C2
GE Aviation Workscope Planning Guide

Forward Fan Stator Case

Figure 6-19

GE Proprietary Information 6-37 Workscope Planning Guide

Subject to restrictions on the cover or first page
 CF6-80C2
GE Aviation Workscope Planning Guide

6.9. Critical Items, Reliability and Key Product Improvements, and Best Practices -
Fan Rotor Assembly.
NOTE: The following pages highlight current critical items, a selection of other key
reliability, product improvements, and best practices. Except for critical
items, this list is not all inclusive; therefore, it is recommended that all
Category 1 - 7 Service Bulletins be evaluated for workscope consideration.
Please refer to the most recent revision of the cited documents for further
information.

A. Priority Levels.

• Priority 1: Critical Item / Safety / AD-Mandated

• Priority 2: Other Important / Reliability item

• Priority 3: Cost of Ownership, Best Practices / Recommended items

GE Proprietary Information 6-38 Workscope Planning Guide

Subject to restrictions on the cover or first page
 CF6-80C2
GE Aviation Workscope Planning Guide

6.9.1. Fan Rotor Assembly - Priority 1.

NOTE: Always use latest revision of listed documents.

A. Refer to Table 6-13 and Figure 6-20.

Table 6-13. Fan Rotor Assembly - Priority 1.

Recommended
Item Item Description Document(s)
Workscope Level

Stage 1 Fan Disk One-time inspection on all 1. SB 72-A0478 (R0, Nov-1990) First piece part
One-Time fan disks. removal of the
“ENGINE - Fan Rotor Assembly stage 1 fan disk.
Immersion USI Immersion-ultrasonic (72-21-00) - Immersion-Ultrasonic
inspection is used to detect Inspection of Older Material Stage
possible subsurface
anomalies. 1 Fan Disk”
Inspection for “older material”
disks made from pre-1984
material and manufacturing
processes”

2. SB 72-0936 (R0, Jun-1998)

“ENGINE - Fan Rotor Assembly
(72-21-00) Inspection of Newer
Material Stage 1 Fan Disk”

Inspection for “newer material”

disks made from post-1984
material and manufacturing
processes.

GE Proprietary Information 6-39 Workscope Planning Guide

Subject to restrictions on the cover or first page
 CF6-80C2
GE Aviation Workscope Planning Guide

Stage 1 Fan Disk

Figure 6-20

GE Proprietary Information 6-40 Workscope Planning Guide

Subject to restrictions on the cover or first page
 CF6-80C2
GE Aviation Workscope Planning Guide

6.9.2. Fan Rotor Assembly - Priority 2.

NOTE: Always use latest revision of listed documents.

A. Refer to Table 6-14 and Figure 6-21.

Table 6-14. Fan Rotor Assembly - Priority 2.

Recommended
Item Item Description Document(s)
Workscope Level

Fan Rotor Service Bulletin addresses 1. SB 72-1108 (R2, Jun-2011) When shaft is
potential for formation of routed for repair
Fan Midshaft cracks in the fan mid shaft “FAN MID SHAFT (72-00-01) -
Corrosion spline area. Cracks can CORROSION PROTECTION”
Protection form due to stress corrosion
of unprotected areas of the Service Bulletin announces new
spline. This Service Bulletin fan mid shafts with improved
releases new design shafts corrosion protection and
with protective coating on provides rework to add
exposed areas. The Service protection to field parts.
Bulletin also defines a
rework to apply the
protective coating to shafts
that were delivered prior to
the new design. Cracks in
the fan mid shaft spline will
result in the affected shaft
being scrapped. In extreme
cases, it is possible that a
crack could propagate
leading to shaft separation
during operation.

GE Proprietary Information 6-41 Workscope Planning Guide

Subject to restrictions on the cover or first page
 CF6-80C2
GE Aviation Workscope Planning Guide

Fan Mid Shaft With Coated Splines

Figure 6-21

6.9.3. Fan Rotor Assembly - Priority 3.

NOTE: Always use latest revision of listed documents.

A. Refer to Table 6-15 and Figure 6-22.

Table 6-15. Fan Rotor Assembly - Priority 3.

Recommended
Item Item Description Document(s)
Workscope Level

Fan Spinner Cone Use approved Spinner 1. ESM 72-00-01 - Disassembly Any SV
Removal Best Cone removal tool.
• Utilize approved tools
Practices to prevent Use of unapproved
wrenching slot tools (such as screw • When removing spinner, assure
damage that can drivers) in the all bolts are removed prior to tool
lead to crack wrenching slots
propagation use
causes stresses that
can become crack • Move in clockwise pattern
initiation sites. around cone, slot to slot,
gradually increasing load until
spinner releases

GE Proprietary Information 6-42 Workscope Planning Guide

Subject to restrictions on the cover or first page
 CF6-80C2
GE Aviation Workscope Planning Guide

Fan Spinner Cone

Figure 6-22

GE Proprietary Information 6-43 Workscope Planning Guide

Subject to restrictions on the cover or first page
 CF6-80C2
GE Aviation Workscope Planning Guide

SECTION 7

High Pressure Compressor Module

The following pages outline the relevant tasks for performing High Pressure
Compressor module workscope planning and maintenance. The objectives of the
information contained within this guide are to communicate the extent of work to
enable the user of the guide to achieve their engine durability, performance and
maintenance cost goals while maintaining high standards of engine reliability. The
recommendations contained herein are based on an average engine in the fleet.
However, there are many variable factors that can affect the specific workscope
definition for a given operator or engine.

GE Proprietary Information 7-1 Workscope Planning Guide

Subject to restrictions on the cover or first page
 CF6-80C2
GE Aviation Workscope Planning Guide

7.0. High Pressure Compressor Rotor Cross Section.

A. Refer to Figure 7-1 thru Figure 7-8.

Blade Count
Stage Count Stage Count
1 36 8 64
2 26 9 66
NOTE: The stage 10 disk only applies to pre-Service
3 42 10 66
4 45 11 76
Bulletin 72-0954 configuration engines. Service
5 48 12 76 Bulletin 72-0954 introduced stages 10 to 14
6 54 13 76 spool shaft which integrated the stage 10 disk
7 56 14 76 and stages 11-14 spool shaft into one part.

High Pressure Compressor Rotor Cross Section

Figure 7-1

GE Proprietary Information 7-2 Workscope Planning Guide

Subject to restrictions on the cover or first page
 CF6-80C2
GE Aviation Workscope Planning Guide

High Pressure Compressor Stage 1 Disk Cross Section

Figure 7-2

GE Proprietary Information 7-3 Workscope Planning Guide

Subject to restrictions on the cover or first page
 CF6-80C2
GE Aviation Workscope Planning Guide

High Pressure Compressor Stage 2 Disk Cross Section

Figure 7-3

GE Proprietary Information 7-4 Workscope Planning Guide

Subject to restrictions on the cover or first page
 CF6-80C2
GE Aviation Workscope Planning Guide

High Pressure Compressor Stage 3-9 Spool Cross Section

Figure 7-4

GE Proprietary Information 7-5 Workscope Planning Guide

Subject to restrictions on the cover or first page
 CF6-80C2
GE Aviation Workscope Planning Guide

High Pressure Compressor Stage 10 Disk (Pre SB 72-0954)

Figure 7-5

GE Proprietary Information 7-6 Workscope Planning Guide

Subject to restrictions on the cover or first page
 CF6-80C2
GE Aviation Workscope Planning Guide

High Pressure Compressor Stage 11-14 Spool Shaft and CDP Seal (Pre SB 72-0954)
Figure 7-6

GE Proprietary Information 7-7 Workscope Planning Guide

Subject to restrictions on the cover or first page
 CF6-80C2
GE Aviation Workscope Planning Guide

High Pressure Compressor Stage 10-14 Spool Cross Section

(Post SB 72-0954, Dec 1998)
Figure 7-7

GE Proprietary Information 7-8 Workscope Planning Guide

Subject to restrictions on the cover or first page
 CF6-80C2
GE Aviation Workscope Planning Guide

Variable Stages (Inlet Guide Vanes IGVs through Stage 5)

VSV Count
Stage Count
IGV 34
1 36
2 40
3 46
4 50
5 58
6 64
7 72
8 68
9 76
10 80
11 80
12 84
13 10 (Sectors)

Static Stages (Stage 6 through Stage 13)

High Pressure Compressor Stator Vanes

Figure 7-8

GE Proprietary Information 7-9 Workscope Planning Guide

Subject to restrictions on the cover or first page
 CF6-80C2
GE Aviation Workscope Planning Guide

7.1. HPC Module Minimum Workscope.

A. Refer to Figure 7-9.

Process Map - HPC Module Minimum Workscope

Figure 7-9

GE Proprietary Information 7-10 Workscope Planning Guide

Subject to restrictions on the cover or first page
 CF6-80C2
GE Aviation Workscope Planning Guide

7.2. HPC Module Minimum Workscope Tasks.

A. Refer to Table 7-1.

Table 7-1. HPC Module Minimum Workscope Tasks.

Item Tasks Reference

HPC Module Verify compliance to accessible Category 1-3

Service Bulletins, especially documents found in --
the “Key Recommended Documents” section of
this document.

72-00-02

Perform all relevant inspections. 72-00-31

72-00-32

HPC Rotor Verify compliance to accessible Category 1-3

Service Bulletins, especially documents found in 72-00-00
the “Key Recommended Documents” section of
this document.

Perform all relevant inspections. 72-00-31

HPC Stator Verify compliance to accessible Category 1-3

Service Bulletins, especially documents found in 72-00-00
the “Key Recommended Documents” section of
this document.

Perform all relevant inspections. 72-00-32

Inspect VSV lever arms/bushings for metal-to-

metal contact 1. 72-00-32

NOTE:
1. The Aircraft Maintenance Manual (AMM) allows maximum of 50% of stages IGV to 4 and
25% of stage 5 vanes to have metal-to-metal contact between the vane stem and the
stator case. Repair of metal-to-metal vane locations while in the shop, by replacing at
least the outer bushing, is recommended to prevent an unserviceable condition on-wing
and to improve the performance of the engine.

GE Proprietary Information 7-11 Workscope Planning Guide

Subject to restrictions on the cover or first page
 CF6-80C2
GE Aviation Workscope Planning Guide

7.3. HPC Module Performance Workscope.

A. Refer to Figure 7-10.

Process Map - HPC Module Performance Workscope

Figure 7-10

GE Proprietary Information 7-12 Workscope Planning Guide

Subject to restrictions on the cover or first page
 CF6-80C2
GE Aviation Workscope Planning Guide

7.4. HPC Module Performance Workscope Tasks.

A. Refer to Table 7-2.

Table 7-2. HPC Module Performance Workscope Tasks.

Item Tasks Reference

HPC Rotor Verify compliance to accessible Category 1-6

Service Bulletins, especially documents found in
the “Key Recommended Documents” section of --
this document. Consider compliance with
accessible Category 7 Service Bulletins.

72-31-00
Perform all relevant inspections in accordance
with tasks and subtasks in the appropriate ESM. 72-00-31

Repair blades to restore tip clearances, surface 72-31-01

finish and leading and trailing edges as required 72-31-02
to enhance engine performance. Restore dovetail
coatings as required. 72-31-03

If the stationary CDP seal in the CRF module is

refurbished with new honeycomb, remove the 72-31-10
rotating CDP seal from the HPC rotor and
refurbish seal tooth coating.

HPC Stator Verify compliance to accessible Category 1-6

Service Bulletins, especially documents found in
the “Key Recommended Documents” section of --
this document. Consider compliance with
accessible Category 7 Service Bulletins.

Perform all relevant inspections in accordance 72-32-00

with tasks and subtasks in the appropriate ESM.

Replace IGV and VSV stage 1-5 bushings and

washers. Replace all stage 5 VSV lever arms. 72-32-00
During reassembly, target a VSV rotational
torque to 5-15 in-lb.

GE Proprietary Information 7-13 Workscope Planning Guide

Subject to restrictions on the cover or first page
 CF6-80C2
GE Aviation Workscope Planning Guide

7.5. HPC Module Full Overhaul Workscope

A. Refer to Figure 7-11 and 7-12.

Process Map - HPC Rotor EMU Full Overhaul Workscope

Figure 7-11

GE Proprietary Information 7-14 Workscope Planning Guide

Subject to restrictions on the cover or first page
 CF6-80C2
GE Aviation Workscope Planning Guide

Process Map - HPC Stator EMU Full Overhaul Workscope

Figure 7-12

GE Proprietary Information 7-15 Workscope Planning Guide

Subject to restrictions on the cover or first page
 CF6-80C2
GE Aviation Workscope Planning Guide

7.6. HPC Module Full Overhaul Workscope Tasks and Subtasks.

A. Refer to Table 7-3.

GE Proprietary Information 7-16 Workscope Planning Guide

Subject to restrictions on the cover or first page
 CF6-80C2
GE Aviation Workscope Planning Guide

Table 7-3. HPC Module Full Overhaul Workscope Tasks and Subtasks.

Item Tasks Reference

HPC Module Verify compliance to accessible Category 1-6

Service Bulletins, especially documents found in
the “Key Recommended Documents” section of --
this document. Consider compliance with
Category 7 Service Bulletins.

At assembly, verify minimum clearance by wax

check. 72-00-02

HPC Rotor Verify compliance to accessible Category 1-6

Service Bulletins, especially documents found in
the “Key Recommended Documents” section of --
this document. Consider compliance with
Category 7 Service Bulletins.

Perform all relevant inspections in accordance

with tasks and subtasks in the appropriate ESM. 72-31-00

Repair blades to restore tip clearances, surface

finish and leading and trailing edges as required 72-31-01
to enhance engine performance. Restore dovetail 72-31-02
coatings as required. 72-31-03

Assemble rotor and grind blades 72-31-00

Check balance HPC rotor. 72-31-00

HPC Stator Verify compliance to accessible Category 1-6

Service Bulletins, especially documents found in
the “Key Recommended Documents” section of --
this document. Consider compliance with
Category 7 Service Bulletins.

Replace IGV and VSV stage 1-5 bushings and

washers. Replace all VSV stage 5 lever arms. 72-32-00
During reassembly, target a VSV rotational torque
to 5-15 in-lb.

Perform all relevant inspections in accordance 72-32-00

with tasks and subtasks in the appropriate ESM.

Assemble and grind per engine manual. 72-32-00

GE Proprietary Information 7-17 Workscope Planning Guide

Subject to restrictions on the cover or first page
 CF6-80C2
GE Aviation Workscope Planning Guide

7.7. Critical Items, Reliability and Key Product Improvements, and Best
Practices - High Pressure Compressor Rotor Assembly

NOTE: The following pages highlight current critical items, and a selection of
other key reliability and product improvements, and best practices.
Except for critical items, this list is not all inclusive; therefore, it is
recommended that all Category 1 - 7 Service Bulletins be evaluated for
workscope inclusion. Please refer to the most recent revision of the cited
documents for further information.

A. Priority Levels.

• Priority 1: Critical Item / Safety / AD-Mandated

• Priority 2: Other Important / Reliability item

• Priority 3: Cost of Ownership, Best Practices / Recommended items

7.7.1. HPC Rotor Assembly - Priority 1.

A. Refer to Table 7-4, Table 7-5, and Figure 7-13 thru Figure 7-15.

NOTE: Always Use Latest Revision of Listed Documents.

GE Proprietary Information 7-18 Workscope Planning Guide

Subject to restrictions on the cover or first page
 CF6-80C2
GE Aviation Workscope Planning Guide

Table 7-4. HPC Rotor Assembly - Priority 1.

Recommended
Item Item Description Document(s) Workscope
Level

HPC Rotor Specific HPCR stage 3-9 1. SB 72-A0812 (R0, Nov-1995) All SV
3-9 Spool spools require inspection “ENGINE - High Pressure Compressor
for detection of possible Rotor (72-31-00) - Stage 3-9 Spool
Ultrasonic and cracking caused by dwell Ultrasonic and Eddy Current Inspection”
eddy current fatigue (all affected part
inspection numbers except Provides HPCR 3-9 spool USI / ECI
1333M66G10, procedures and compliance schedule
1854M95P08, and established by FAA AD 2002-25-08
1781M53G05/G10) or
melt-related conditions • Affects HPCR stage 3-9 spool PNs:
(all affected part - 9380M28P05
numbers). - 1333M66G01/G03/G07/G09/G10
- 1781M52P01/P02
Affects older (pre-1995) - 1781M53G01 thru G10
HPCR 3-9 spool material. - 1854M95P01 thru P08

GE Proprietary Information 7-19 Workscope Planning Guide

Subject to restrictions on the cover or first page
 CF6-80C2
GE Aviation Workscope Planning Guide

Table 7-4. HPC Rotor Assembly - Priority 1. (Cont.)

Recommended
Item Item Description Document(s)
Workscope Level

2. SB 72-A0848 (R0, Oct-1997)

“ENGINE - High Pressure Compressor
Rotor Assembly (72-31-00) - Web and
Transition Immersion Ultrasonic and
Eddy Current Inspection”

Identifies new immersion USI and ECI of

disk hub-to-web transition and web
areas on HPCR stage 3-9 spool. An
alternative module level inspection
procedure is also included.
• Affects HPCR stage 3-9 spool PNs:
- 9380M28P05
- 1333M66G01/G03/G07/G09/G10
- 1781M52P01/P02
- 1781M53G01 thru G10
- 1854M95P01 thru P08

3. SB 72-A0937 (R0, Jan-2004)

“ENGINE - HPC Rotor Assembly

(72-31-00) - New Stage 3-9 Spool ”

Introduces new HPCR stage 3-9 spool

PN 1856M15G02 with new material,
forging processes and dimensional
changes.

4. AD 2002-25-08.

GE Proprietary Information 7-20 Workscope Planning Guide

Subject to restrictions on the cover or first page
 CF6-80C2
GE Aviation Workscope Planning Guide

HPC Rotor 3-9 Spool

Figure 7-13

GE Proprietary Information 7-21 Workscope Planning Guide

Subject to restrictions on the cover or first page
 CF6-80C2
GE Aviation Workscope Planning Guide

Table 7-4. HPC Rotor Assembly - Priority 1. (Cont.)

Recommended
Item Item Description Document(s) Workscope
Level

HPC Rotor 11-14 Some stage 11-14 1. SB 72-1052 (R0, Oct-2002) Next SV
Spool spool shafts had the (One time
seal wire grooves “ENGINE - Stage 11-14 Spool Shaft
Seal wire groove repaired using a (72-31-08) - Repair of Circumferential inspection)
repair circumferential cut or Cuts in Seal Wire Grooves”
tangential cut, Per
CF6-80C2 EM, Affects all CF6-80C2 stage 11-14
72-31-08, INSPECTION, spool shafts that have been repaired
spools with this in the seal wire grooves using a
condition are not circumferential cut at locations
serviceable or
repairable. specified in the Service Bulletin.

SB 72-1052 provides An improved repair with a lower

procedure to return stress concentration effect allow
some of these spools some stage 11-14 spool shafts with
to a serviceable these circumferential cuts in specific
condition. seal wire groove locations to be
repaired and returned to service with
Operators should also the full published life, provided the
note that the seal wire repair is done within a specified
can be removed at number of flight cycles after the
overhaul. original repair.

2. AD 2005-17-05.

The AD mandates the

recommendations in SB 72-1052.

3. Engine Manual 72-31-08 Repair 12

Details of repair referenced in SB 72-
1052.

GE Proprietary Information 7-22 Workscope Planning Guide

Subject to restrictions on the cover or first page
 CF6-80C2
GE Aviation Workscope Planning Guide

Wear can be observed on both sides

of the fwd and aft grooves
(Locations 1, 2, 3 or 4, below)

Typical Seal Wire Wear

S11-14 Spool Seal Wire Grooves

Figure 7-14

GE Proprietary Information 7-23 Workscope Planning Guide

Subject to restrictions on the cover or first page
 CF6-80C2
GE Aviation Workscope Planning Guide

Table 7-5. HPC Rotor Assembly - Priority 1.

Recommended
Item Item Description Document(s) Workscope
Level

HPC Stages 10-14 One time mandatory 1. SB 72-A1122 1st Shop Visit
Spool-Shaft inspection of the stage after issue date
Stage 14 Disk Web 14 disk web area of Repair by blending away worn or of the SB.
Inspection specific 10-14 spool- fretted material on aft face of the
shafts. stage 1 disk dovetail posts.
Manufacturing
process of the suspect
spool-shafts could 2. AD 2009-07-03.
have induced cracks
in the stage 14 disk Mandates requirements of
SB 72-A1122.
web.

HPC Stages 10-14 Spool-Shaft Cross Section

Figure 7-15

GE Proprietary Information 7-24 Workscope Planning Guide

Subject to restrictions on the cover or first page
 CF6-80C2
GE Aviation Workscope Planning Guide

7.7.2. HPC Rotor Assembly - Priority 2.

NOTE: No Priority 2 items for the HPC Rotor Assembly at this time.

NOTE: Always Use Latest Revision of Listed Documents.

Table 7-6. HPC Rotor Assembly - Priority 2.

Recommended
Item Item Description Document(s) Workscope
Level

HPC Stages 11-14 One time inspection of 1. SB 72-1359 Next Shop Visit
Spool-Shaft the stage 14 disk web if Part is Above
area of specific 11-14 “HIGH PRESSURE COMPRESSOR ROTOR Defined Cycle
Stage 14 Disk Web
Inspection and Shot spool-shafts ASSEMBLY (72-31-08) - STAGE 11 Threshold
Peen manufactured before THROUGH 14 SPOOL SHAFT WEB
1990. Subject parts are INSPECTION” or
identified in the service
bulletin by part serial Eddy current inspection of stage 14 Next Time Part
number. disks of the affected spool shaft. Parts is Removed
that do not pass the eddy current From the
Manufacturing inspection must be retired. Engine if Part is
process of the suspect Below Defined
spool-shafts could Cycle
result in cracking in Threshold
the stage 14 disk web.
See Service
Bulletin for
details

GE Proprietary Information 7-25 Workscope Planning Guide

Subject to restrictions on the cover or first page
 CF6-80C2
GE Aviation Workscope Planning Guide

HPC Stages 11-14 Spool-Shaft Cross Section

Figure 7-16

GE Proprietary Information 7-26 Workscope Planning Guide

Subject to restrictions on the cover or first page
 CF6-80C2
GE Aviation Workscope Planning Guide

7.7.3. HPC Rotor Assembly - Priority 3.

A. Refer to Table 7-7 and Figure 7-17 thru Figure 7-24.

NOTE: Always Use Latest Revision of Listed Documents.

Table 7-7. HPC Rotor Assembly - Priority 3.

Recommended
Item Item Description Document(s) Workscope
Level

HPC Rotor Repair to address 1. Repair 006 ESM 72-31-04 Any SV

Stage 1 Disk Stage 1 disk post aft RD 050-933 (June-09)
face wear. “HIGH PRESSURE COMPRESSOR ROTOR
Stage 1 disk post aft ASSEMBLY - COMPRESSOR ROTOR
face wear repair DISK, STAGE 1 - REPAIR - REPAIR OF
RETAINER WEAR AREAS ON AFT FACE
OF DOVETAIL POST SURFACE E”
This procedure provides instructions to
remove worn material via blend repair.

Aft Face Wear - HPC Rotor Stage 1 Disk

Figure 7-17

GE Proprietary Information 7-27 Workscope Planning Guide

Subject to restrictions on the cover or first page
 CF6-80C2
GE Aviation Workscope Planning Guide

Table 7-7. HPC Rotor Assembly - Priority 3. (Cont.)

Recommended
Item Item Description Document(s) Workscope
Level

HPC Rotor: Repairs for replacing 1. Repair 002 ESM 72-31-22 Any SV (as
10-14 Spool Shaft spool shaft flowpath RD 050-0717 (June 2011) required by
abrasive coating. “HIGH PRESSURE COMPRESSOR ROTOR inspection)
Flowpath coating ASSEMBLY - STAGES 10-14
replacement COMPRESSOR ROTOR SPOOL/REAR
Cost effectiveness. SHAFT - REPAIR - REPLACEMENT OF
ABRADABLE COATING ON
SPOOL/SHAFT OUTSIDE DIAMETER”

• 10-14 spool shaft

2. Repair 006 ESM 72-31-08

“GES 11-14 COMPRESSOR ROTOR
SPOOL/REAR SHAFT - REPAIR -
REPLACEMENT OF ABRADABLE RUB
COAT ON SPOOL OUTSIDE DIAMETER”

• 11-14 spool shaft

Missing Rub
Coating

11-14 Spool Shaft - HPC Rotor

Figure 7-18

GE Proprietary Information 7-28 Workscope Planning Guide

Subject to restrictions on the cover or first page
 CF6-80C2
GE Aviation Workscope Planning Guide

Table 7-7. HPC Rotor Assembly - Priority 3. (Cont.)

Recommended
Item Item Description Document(s) Workscope
Level

HPC Rotor 3-9 Spool Improved repair 1. Engine Manual 72-31-06 Repair 009 Any SV (as
and HPC 10-14 Spool geometry reduces for 3-9 spool. required by
Seal wire groove stresses. inspection)
wear repair 2. Engine Manual 72-31-22 Repair 010
for 10-14 spool.

Improved SWG repair, making

tangential cut repair prime for all
spools.
• Improved SWG repair
• Tangential cut repair prime for all
spools (previously circumferential
cut repair)
PreSB 72-0937 spools can utilize SB
72-0673 repair for spools beyond the
tangential repair width limit.

Note:
Engine Shop Manual 72-31-00 Assembly allows option of not reinstalling seal wires to avoid future spool wear.
Deleting seal wire will result in a small negative performance impact.

Old - Milled Circumferentially New - Milled Tangentially

11-14 Spool Shaft - HPC Rotor

Figure 7-19

GE Proprietary Information 7-29 Workscope Planning Guide

Subject to restrictions on the cover or first page
 CF6-80C2
GE Aviation Workscope Planning Guide

Table 7-7. HPC Rotor Assembly - Priority 3. (Cont.)

Recommended
Item Item Description Document(s) Workscope
Level

HPC Stage 1 Disk Repair procedure for 1. Engine Manual 72-31-04 Repair 006 As required
Repairs aft face wear of the (Jun- 2009) when stage 1
stage 1 disk dovetail disk is removed
post. Wear occurs Repair by blending away worn or from the
from blade retainer fretted material on aft face of the engine.
contact. stage 1 disk dovetail posts.

Repair procedure for 2. Engine Manual 72-31-04 Repair 008

forward face wear of (Jun- 2011)
the stage 1 disk
dovetail. Wear occurs Repair by machining away worn or
from blade dovetail fretted material on forward face
tang contact. (Surface W) of the stage 1 disk
dovetails.

GE Proprietary Information 7-30 Workscope Planning Guide

Subject to restrictions on the cover or first page
 CF6-80C2
GE Aviation Workscope Planning Guide

HPC Stage 1 Disk Aft Dovetail Face Wear Repair

Figure 7-20

GE Proprietary Information 7-31 Workscope Planning Guide

Subject to restrictions on the cover or first page
 CF6-80C2
GE Aviation Workscope Planning Guide

HPC Stage 1 Disk Forward Dovetail Slot Face (Surface W) Repair

Figure 7-21

GE Proprietary Information 7-32 Workscope Planning Guide

Subject to restrictions on the cover or first page
 CF6-80C2
GE Aviation Workscope Planning Guide

Table 7-7. HPC Rotor Assembly - Priority 3. (Cont.)

Recommended
Item Item Description Document(s) Workscope
Level

HPC Stages 10–14 (or Repair procedure for 1. Engine Manual 72-31-23 Repair 003 As required
11–14) Spool-Shaft fretting damage in the (Mar-2012) when stages
Repairs spool-shaft seal wire 10–14 (or 11-
grooves Repair by machining away fretted 14) spool-shaft
material in spool-shaft seal wire is removed
grooves. from the
engine.
2. Engine Manual 72-31-23 Repair 004
Repair procedure for (Stages 10-14 Spool-Shafts) or
restoring wear on 72-31-08 Repair 003 (Stages 11-14
“Diameter P” of the Spool-Shafts)
spool-shaft
Restore “Diameter P” by applying
thermal spray to shaft.

3. Engine Manual 72-31-23 Repair 005

Repair procedure for
(Stages 10-14 Spool-Shafts) or 72-
restoring wear on
31-08 Repair 013 (Stages 11-14
bearing journals of the
Spool-Shafts)
spool-shaft
Restore bearing journal “Diameters BB
and BF” by applying thermal spray to
rear shaft.

GE Proprietary Information 7-33 Workscope Planning Guide

Subject to restrictions on the cover or first page
 CF6-80C2
GE Aviation Workscope Planning Guide

Stages 10-14 (or 11-14) Spool-Shaft Repair Areas

Figure 7-22

GE Proprietary Information 7-34 Workscope Planning Guide

Subject to restrictions on the cover or first page
 CF6-80C2
GE Aviation Workscope Planning Guide

Table 7-7. HPC Rotor Assembly - Priority 3. (Cont.)

Recommended
Item Item Description Document(s) Workscope
Level

Tech CF6 HPC Stage Recessed wear pad 3. SB 72-1268 (R0, Aug-2007) Any Shop Visit
1 Blade Shroud design improves (Optional by
resistance to shingling “ENGINE - High Pressure Compressor operator
Recessed Wear Pad Rotor Assembly (72-31-00) - Stage 1
Improvement damage during soft experience)
body ingestion (i.e. bird, Blades Midspan Shroud Recessed
improves FOD
resistance ice) events. Wear Pad Improvement ”
Introduces new stage 1 HPC rotor
Soft body impact on
current stage 1 HPC blade K024G05 for HPC rotor
rotor blade can result in assembly and provides modification
shingling and damage to repair to convert existing parts
midspan shroud wear
pads. Midspan shroud 4. Repair 015, ESM 72-31-01
wear pad damage is RD 050-1023 (P1 or higher)
cause for engine “High Pressure Compressor Rotor
removal. The frequency Assembly - Compressor Rotor Blades,
of ingestion events is Stage 1 - Repair - Recessed Midspan
route dependent. Wear Pad Modification”
Incorporates new braze for attaching
wear pad on midspan shroud along
with a recessed pad design for
improved soft body ingestion
tolerance.

Recessed Midspan Wear Pad - HPC Stage 1 Blade Shroud

Figure 7-23

GE Proprietary Information 7-35 Workscope Planning Guide

Subject to restrictions on the cover or first page
 CF6-80C2
GE Aviation Workscope Planning Guide

Table 7-7. HPC Rotor Assembly - Priority 3. (Cont.)

Recommended
Item Item Description Document(s) Workscope
Level

HPC Blades Introduces new blades SB 72-1060 (R0, Dec-2001) (Next) SV

Stages 3-5 that are geometrically
“ENGINE - Stage 3-5 HPC Blades
Ballistic Impact identical to the current (72-00-00) - Redesign ”
Improvement: New design (SB 72-0975),
Blades improve with material and heat • Overall
dovetail (Pre-SB treat changes for - Stages 3-5: Geometry per SB 72-
72-0975) and ballistic improved blade 0975
impact (Post SB durability.
72-0975) durability - Stage 3: Blade material to be
Titanium 6-4 (pre-SB 72-0095)
- Stages 4 & 5: Blade material to be
Titanium 4-4-2 (SB 72-0975), but
with a revised heat treat
procedure to improve ballistic
impact behavior
• Pre-SB 72-0975 Blades (Titanium 6-4):

- Stages 3-5: Incorporate dovetail

geometry changes of SB 72-0975

- Stage 3: Blade material to remain

Titanium 6-4 (pre-SB 72-0975)

- Stage 4&5: Blade material to be

Titanium 4-4-2 (SB 72-0975), but
with a revised heat treat
procedure to improve ballistic
impact behavior

• SB 72-0975 Blades (Titanium 4-4-2):

- Stages 3-5: Retain dovetail

geometry changes from SB 72-
0975
- Stage 3 Blades: return to Titanium
6-4
- Stages 4 & 5 Blades: remain
Titanium 4-4-2 (SB 72-0975), but
with a revised heat treat
procedure to improve ballistic
impact behavior

GE Proprietary Information 7-36 Workscope Planning Guide

Subject to restrictions on the cover or first page
 CF6-80C2
GE Aviation Workscope Planning Guide

Examples of brittle behavior on

SB 72-0975 HPC blades
(Secondary damage)

HPC Blades Stages 3-5

Figure 7-24

7.8. Critical Items, Reliability and Key Product Improvements, and Best
Practices - High Pressure Compressor Stator Assembly

NOTE: The following pages highlight current critical items, and a selection of
other key reliability and product improvements, and best practices.
Except for critical items, this list is not all inclusive; therefore, it is
recommended that all Category 1 - 7 Service Bulletins be evaluated for
workscope inclusion. Please refer to the most recent revision of the cited
documents for further information.

A. Priority Levels.

• Priority 1: Critical Item / Safety / AD-Mandated

• Priority 2: Other Important / Reliability item

• Priority 3: Cost of Ownership, Best Practices / Recommended items

GE Proprietary Information 7-37 Workscope Planning Guide

Subject to restrictions on the cover or first page
 CF6-80C2
GE Aviation Workscope Planning Guide

7.8.1. HPC Stator Assembly - Priority 1.

NOTE: No Priority 1 items for the HPC Stator Assembly at this time.

7.8.2. HPC Stator Assembly - Priority 2.

A. Refer to Table 7-8 and Figure 7-25.

NOTE: Always Use Latest Revision of Listed Documents.

Table 7-8. HPC Stator Assembly - Priority 2.

Recommended
Item Item Description Document(s) Workscope
Level

HPC Stage 5 VSV New, longer stage 5 SB 72-1081 (R0, Dec-2002) Any SV
Lever Arms VSV lever arms and
“ENGINE - High Pressure Compressor
Longer stage 5 VSV associated hardware (72-00-00) - New Stage 5 Lever Arms”
lever arms modifications
introduced by SB 72- Introduces a new HPC stage 5 VSV
1081. lever arm and stage 5 vane schedule
The new stage 5 VSV  Affects the models that have
lever schedule incorporated HPC Phase II Aero
reduces vibratory (CF6-80C2 SB 72-0475)
stimulus to the vane
arm, and the new  The new parts are:
longer lever arms
reduce bending - Vane actuation lever
stresses. 9673M66G21
The combination of - Connecting link 9137M95G05
reduced vibration and
bending stress results - Vane actuation arms
in a more durable 9125M65G17/G18
system.
- Actuation clevis 1999M13P01
 Provides rework of Pre- and
SB 72-0944 connecting links and
new installation instructions

GE Proprietary Information 7-38 Workscope Planning Guide

Subject to restrictions on the cover or first page
 CF6-80C2
GE Aviation Workscope Planning Guide

Lever arm length increase shifts

unison ring aft 0.255. Lever Inco 718
Bridge connector flipped 180 with shot peening
to avoid interference with
offset yoke
SB 72-1074 bushings

Rework bridge connector similar

to SB 72-944 required to prevent
interference with arm

No change to actuator New clevis required.

or control system New rig angles

Clevis connection moves

New master lever forward 1.8 inches

HPC Stage 5 VSV Lever Arms

Figure 7-25

GE Proprietary Information 7-39 Workscope Planning Guide

Subject to restrictions on the cover or first page
 CF6-80C2
GE Aviation Workscope Planning Guide

7.8.3. HPC Stator Assembly - Priority 3.

A. Refer to Table 7-9 and Figure 7-26 thru Figure 7-33.

NOTE: Always Use Latest Revision of Listed Documents.

Table 7-9. HPC Stator Assembly - Priority 3.

Recommended
Item Item Description Document(s) Workscope
Level

HPC Stator Service bulletin 1. CF6-80C2 SB 72-1366 (R00 Any SV when

introduces improved 09/29/2010) boot seal(s) are
VSV actuator lever VSV actuator lever removed
boot seal installation clevis bearing boot “CORE MODULE (72-00-02) – VSV BOOT-
Best Practices seals introduced. Old SEAL INTRODUCTION”
design tended to crack
which allowed The SB introduces a redesigned boot-
contamination to enter seal which features increased flexibility
the bearings. and reduced height. The redesigned
seals are less likely to be damaged
during installation

Best Practices for VSV 2. Best Practices:

boot seal installation • Use hand, or U-shaped sheet metal
to increase life of boot tool to hold boot seal in place during
seal and clevis installation of the clevises.
bearings. • Do NOT turn boot seals inside-out and
stretch them over the clevis arm
Minimize premature • Do NOT substitute RTV for the boot
wear and cracking of seal, may result in corrosion of bearing
the Viton boot seals. and race and lower life of parts)

GE Proprietary Information 7-40 Workscope Planning Guide

Subject to restrictions on the cover or first page
 CF6-80C2
GE Aviation Workscope Planning Guide

HPC Stator VSV Actuator Lever Boot Seal Improvement

Figure 7-26

GE Proprietary Information 7-41 Workscope Planning Guide

Subject to restrictions on the cover or first page
 CF6-80C2
GE Aviation Workscope Planning Guide

Table 7-9. HPC Stator Assembly - Priority 3. (Cont.)

Recommended
Item Item Description Document(s) Workscope
Level

HPC IGV, Stage 1 Improved inner vane SB 72-1238 (R0, Mar-2007) Any SV
and Stage 2 shroud bushing design
“ENGINE – HPC (72-32-00) – Inner VSV
Upgrade inner vane introduced by Bushing Upgrade for HPC IGV, Stage 1
shroud bushing from SB 72-1238. and Stage 2”
3-piece to 2-piece Reduces bushing
design scrap from the worn Introduces 2-piece inner vane bushing
o-ring that keeps the (PNs 1856M94P01/P02/P03/P04)
shroud bushings
halves.  Replaces 3-piece design bushings
PNs 9211M39G01/G02/G03/G04
 New design eliminates need for o-
ring and simplifies assembly (simple
snap-together)
 New design bushings manufactured
from more durable material than
previous design
 Mixing 2-piece bushing assembly
parts with 3-piece assembly parts is
not allowed
 Though not recommended,
intermixing old and new design
bushings within a stage is allowed

GE Proprietary Information 7-42 Workscope Planning Guide

Subject to restrictions on the cover or first page
 CF6-80C2
GE Aviation Workscope Planning Guide

HPC Stator Case IGV, Stage 1 and Stage 2 Inner Shroud Bushing Improvement
Figure 7-27

GE Proprietary Information 7-43 Workscope Planning Guide

Subject to restrictions on the cover or first page
 CF6-80C2
GE Aviation Workscope Planning Guide

Table 7-9. HPC Stator Assembly - Priority 3. (Cont.)

Recommended
Workscope
Item Item Description Document(s) Level

HPC Stator Case Repair procedure for 1. Engine Manual 72-32-01 Repair 024 As required
Repairs damaged threaded (Mar-2012) when the HPC
holes and mounting stator case is
pads. Repair threaded holes or mounting removed from
pads by welding restoration. Only engine
applies to damaged threaded holes
that cannot be repaired by an insert
repair.

Repair procedure for 2. Engine Manual 72-32-01 Repair 025

damaged borescope (Mar-2012)
port threads.
Repair damaged borescope port
threads by machining or installation of
a keylock insert.

HPC Stator Case

Figure 7-28

GE Proprietary Information 7-44 Workscope Planning Guide

Subject to restrictions on the cover or first page
 CF6-80C2
GE Aviation Workscope Planning Guide

HPC Stator Case Borescope Ports

Figure 7-29

GE Proprietary Information 7-45 Workscope Planning Guide

Subject to restrictions on the cover or first page
 CF6-80C2
GE Aviation Workscope Planning Guide

Table 7-9. HPC Stator Assembly - Priority 3. (Cont.)

Recommended
Workscope
Item Item Description Document(s) Level

HPC Stator Case Repair procedure for 3. Engine Manual 72-32-01 Repair 015 As required
Repairs stage 13 vane rail when the HPC
wear. Weld repair to restore worn stator case stator case is
features (forward and aft backwalls removed from
and forward and aft rail faces) engine

Repair procedures for 4. Engine Manual 72-32-01 Repair 009,

repair of worn VSV Repair 010 and Repair 017 (May-2010)
bores.
Restore worn VSV bores:
• Repair 009 - outer bushing repair
• Repair 010 - thermal spray of
counter bores
• Repair 017 - inner bushing
replacement and weld repair

GE Proprietary Information 7-46 Workscope Planning Guide

Subject to restrictions on the cover or first page
 CF6-80C2
GE Aviation Workscope Planning Guide

HPC Stator Case Stage 13 Rail Wear Locations

Figure 7-30

GE Proprietary Information 7-47 Workscope Planning Guide

Subject to restrictions on the cover or first page
 CF6-80C2
GE Aviation Workscope Planning Guide

Case VSV Bore Wear

Figure 7-31

GE Proprietary Information 7-48 Workscope Planning Guide

Subject to restrictions on the cover or first page
 CF6-80C2
GE Aviation Workscope Planning Guide

Table 7-9. HPC Stator Assembly - Priority 3. (Cont.)

Recommended
Workscope
Item Item Description Document(s) Level

HPC Stator Vane Repair procedure for 1. Engine Manual 72-32-02 Repair As required
Repairs stages 3 - 5 vane 002 (Jun-2011) when the
trunnion outer HPC VSVs
platforms to reduce Thermal spray repair for vane are removed
wear and extend vane platform. from engine
life.

GE Proprietary Information 7-49 Workscope Planning Guide

Subject to restrictions on the cover or first page
 CF6-80C2
GE Aviation Workscope Planning Guide

HPC Stator Stages 3 - 5 VSV Outer Trunnion Platform Repair

Figure 7-32

GE Proprietary Information 7-50 Workscope Planning Guide

Subject to restrictions on the cover or first page
 CF6-80C2
GE Aviation Workscope Planning Guide

Table 7-9. HPC Stator Assembly - Priority 3. (Cont.)

Recommended
Workscope
Item Item Description Document(s) Level

Tech CF6 HPC Vane Incorporates erosion 1. SB 72-1245 (R0, Dec-2007) Any Shop Visit
Erosion Coatings coating on HPC Stage 6 “ENGINE - HPC Stator Assembly (72- (Optional by
and 10 Vanes 32-00) - Introduction of Erosion operator
New erosion coating Coating for Stages 6 and 10 Vanes ”
reduces HPC vane Actual effect will vary experience)
erosion rate based on overall Releases erosion-coated stage 6
engine condition and and 10 HPC vanes.
the number of stages
on which the coatings Stage 6 HPC vanes will have
are incorporated. tungsten carbide coating applied.
Stage 10 HPC vanes will have
chromium carbide applied.

Erosion Coated Stage 6 Vane

Figure 7-33

GE Proprietary Information 7-51 Workscope Planning Guide

Subject to restrictions on the cover or first page
 CF6-80C2
GE Aviation Workscope Planning Guide

SECTION 8

CRF Module

The following pages outline the relevant tasks for performing CRF module
workscope planning and maintenance. The objectives of the information
contained within this guide are to communicate the extent of work to enable
the user of the guide to achieve their engine durability, performance and
maintenance cost goals while maintaining high standards of engine reliability.
The recommendations contained herein are based on an average engine in the
fleet. However, there are many variable factors that can affect the specific
workscope definition for a given operator or engine.

GE Proprietary Information 8-1 Workscope Planning Guide

Subject to restrictions on the cover or first page
 CF6-80C2
GE Aviation Workscope Planning Guide

8.0. CRF Module Cross Section.

A. Refer to Figure 8-1 thru Figure 8-5.

CRF Module
Figure 8-1 (Sheet 1 of 2)

GE Proprietary Information 8-2 Workscope Planning Guide

Subject to restrictions on the cover or first page
 CF6-80C2
GE Aviation Workscope Planning Guide

Legend:

1. Compressor Rear Frame Case 11. No. 4R Stationary Air/Oil Seal 23. Aft Sump Assembly
2. Igniter Plug Pad 13. No. 4R Spanner Nut/Oil Shield 24. No. 5R Spanner Nut
3. Fuel Nozzle Pad 15. No. 4R Roller Bearing 25. No. 5R Roller Bearing
4. Outer Guide Vane 16. Forward Sump Assembly 26. Oil Shield
6. Outer Insulation Blanket 17. No. 4B Ball Bearing 27. No. 5R Stationary Air/Oil Seal
7. Outlet Guide Vane Liner 18. No. 4B Spanner Nut 28. High Pressure Turbine Stationary
8. Stationary Compressor Discharge 19. No. 4B Bearing Housing Seal Support, S/B 72-005
Pressure Seal 20. Midsump Oil Seal 29. High Pressure Turbine Aft Air Seal
9. No. 4R Stationary Vent Seal 21. Sump Closure
10. Heat Shield 22. Aft Sump Assembly

CRF Module
Figure 8-1 (Sheet 2 of 2)

GE Proprietary Information 8-3 Workscope Planning Guide

Subject to restrictions on the cover or first page
 CF6-80C2
GE Aviation Workscope Planning Guide

Compressor Rear Frame Strut Utilization

Figure 8-2

4R Bearing Assembly
Figure 8-3

GE Proprietary Information 8-4 Workscope Planning Guide

Subject to restrictions on the cover or first page
 CF6-80C2
GE Aviation Workscope Planning Guide

4B Bearing Assembly
Figure 8-4

GE Proprietary Information 8-5 Workscope Planning Guide

Subject to restrictions on the cover or first page
 CF6-80C2
GE Aviation Workscope Planning Guide

5R Bearing Assembly
Figure 8-5

GE Proprietary Information 8-6 Workscope Planning Guide

Subject to restrictions on the cover or first page
 CF6-80C2
GE Aviation Workscope Planning Guide

8.1. CRF Module Cross Section.

A. Refer to Figure 8-6.

Process Map - CRF Module Minimum Workscope

Figure 8-6

GE Proprietary Information 8-7 Workscope Planning Guide

Subject to restrictions on the cover or first page
 CF6-80C2
GE Aviation Workscope Planning Guide

8.2. CRF Module Minimum Workscope Tasks.

A. Refer to Table 8-1.

Table 8-1. CRF Module Minimum Workscope Tasks

Item Tasks Reference

CRF Module Verify compliance to accessible Category 1-3

Service Bulletins, especially documents found --
in the “Key Recommended Documents”
section of this document.

Perform all inspections and identified in

referenced manual tasks and subtasks of 72-00-34
72-00-34.

8.3. CRF Module Performance Workscope.

A. Refer to Figure 8-7.

GE Proprietary Information 8-8 Workscope Planning Guide

Subject to restrictions on the cover or first page
 CF6-80C2
GE Aviation Workscope Planning Guide

Process Map - CRF Module Performance Workscope

Figure 8-7

GE Proprietary Information 8-9 Workscope Planning Guide

Subject to restrictions on the cover or first page
 CF6-80C2
GE Aviation Workscope Planning Guide

8.4. CRF Module Performance Workscope Tasks.

A. Refer to Table 8-2.

Table 8-2. CRF Module Performance Workscope Tasks

Item Tasks Reference

CRF Module Verify compliance to accessible Category 1-6

Service Bulletins, especially documents found 72-00-00
in the “Key Recommended Documents”
section of this document.

Remove 4R, 4B and 5R bearings. Inspect and 72-09-01

refurbish or replace as required. See Note 1.

Refurbish CDP stationary seal as necessary to 72-34-02

restore clearances. See Note 2.

Refurbish 4R Vent Seal as necessary to 72-34-03

restore clearances.

Replace B/C Sump O-Rings. 72-34-00

Note 1: Based on operator and shop experience, bearings can be inspected in-situ and
not removed from the CRF assembly if found serviceable.

Note 2: If the stationary CDP seal in the CRF module is refurbished with new
honeycomb, remove the rotating CDP seal from the HPC rotor and refurbish seal tooth
coating.

Caution: If the bearings are not removed from the CRF, properly preserve and cover the
bearings to prevent contamination from the shop environment. CRF bearings are
susceptible to damage during operation if exposed hard particle contamination.

8.5. CRF Module Full Overhaul Workscope.

A. Refer to Figure 8-8.

GE Proprietary Information 8-10 Workscope Planning Guide

Subject to restrictions on the cover or first page
 CF6-80C2
GE Aviation Workscope Planning Guide

Process Map - CRF Module Full Overhaul Workscope

Figure 8-8

GE Proprietary Information 8-11 Workscope Planning Guide

Subject to restrictions on the cover or first page
 CF6-80C2
GE Aviation Workscope Planning Guide

8.6. CRF Module Full Overhaul Workscope Tasks.

A. Refer to Table 8-3.

Table 8-3. CRF Module Full Overhaul Workscope Tasks.

Item Tasks Reference

CRF Module Verify compliance to Category 1-6 Service

Bulletins, especially documents found in the
“Key Recommended Documents” section of --
this document. Consider compliance with
applicable Category 7 Service Bulletins.

72-34-00
Perform piece part inspections in accordance
with appropriate task and subtasks in 72-09-01
referenced ATA sections of ESM.
72-09-02

Replace B/C sump o-rings 72-34-00

72-34-02
72-34-03
Inspect stationary mini-nozzle, CDP and 72-34-11
4R/5R vent seals and refurbish as required1.
72-34-12
72-34-17

Clean and inspect oil pressure and scavenge 72-34-00

lines. Remove and clean oil

1Note: If the stationary CDP seal in the CRF module is refurbished with new honeycomb, remove the
rotating CDP seal from the HPC rotor and refurbish seal tooth coating.

GE Proprietary Information 8-12 Workscope Planning Guide

Subject to restrictions on the cover or first page
 CF6-80C2
GE Aviation Workscope Planning Guide

8.7. Critical Items, Reliability and Key Product Improvements, and Best
Practices - CRF Module.

NOTE: The following pages highlight current critical items, and a selection of
other key reliability and product improvements, and best practices.
Except for critical items, this list is not all inclusive; therefore, it is
recommended that all Category 1 - 7 Service Bulletins be evaluated for
workscope inclusion. Please refer to the most recent revision of the cited
documents for further information.

A. Priority Levels.

• Priority 1: Critical Item / Safety / AD-Mandated

• Priority 2: Reliability item

• Priority 3: Cost of Ownership, Best Practices / Recommended items

8.7.1. CRF Module - Priority 1.

NOTE: No Priority 1 items for the CRF Module at this time.

8.7.2. CRF Module - Priority 2.

NOTE: Always Use Latest Revision of Listed Documents.

A. Refer to Table 8-4, and Figure 8-9 thru Figure 8-11.

GE Proprietary Information 8-13 Workscope Planning Guide

Subject to restrictions on the cover or first page
 CF6-80C2
GE Aviation Workscope Planning Guide

Table 8-4. CRF Module - Priority 2.

Recommended
Item Item Description Document(s) Workscope
Level

CRF Module This bulletin introduces 1. SB 72-1265 (R1, Oct-2007) Any SV

improved impingement “Engine- Compressor Rear Frame
New Part Release for tube design by removing Assembly (72-34-00)- Rework of
Sump Vent Oil foil insulation and tack Insulated Vent Duct”
Impingement Tube welds from the tube,
reducing the stress Old Part #:
concentration at these 9382M21P01/P02/P03/P04
points and increasing the New part #: 9382M21P05
durability of the hardware.
This improvement is meant
to address oil leaks caused
by impingement tube
cracks.

Original Design:
• Duct foil insulation tack welded to
impingement tube
• Impingement tube insulation sleeve

Improved (Lower Stress) Design:

• Duct foil cut back, tack welds and
insulation sleeve eliminated

Sump Vent Oil Impingement Tubes - CRF Module

Figure 8-9

GE Proprietary Information 8-14 Workscope Planning Guide

Subject to restrictions on the cover or first page
 CF6-80C2
GE Aviation Workscope Planning Guide

Table 8-4. CRF Module - Priority 2. (Cont.)

Recommended
Item Item Description Document(s) Workscope
Level

CRF Module This bulletin introduces 1. SB 72-1278 (R2, Jun-2010) Any SV

improved oil supply “Engine- Compressor Rear Frame
New Part Release for manifold design by Assembly (72-34-00)- New Oil
Oil Supply Manifold introducing brazed tabs to Manifold and Air Tubes”
prevent clamp shifting and
resulting wear the Achievement of this bulletin
manifold. requires current implementation
of the following bulletins: 72-1265,
This improvement is meant 72-1164, 72-1180
to address oil leaks caused
by oil manifold wear.

Oil Supply Manifold - CRF Module

Figure 8-10

GE Proprietary Information 8-15 Workscope Planning Guide

Subject to restrictions on the cover or first page
 CF6-80C2
GE Aviation Workscope Planning Guide

Table 8-4. CRF Module - Priority 2. (Cont.)

Recommended
Item Item Description Document(s) Workscope
Level

CRF Module New part release to 1. SB 72-1052 (R0, Aug-2003) Any SV

introduce new AFLAS O- “Engine- Compressor Rear Frame
New part release for ring seals. Assembly (72-34-11) – High
High Temperature Temperature AFLAS O-Ring Seal
AFLAS O-Rings This improvement is meant for the B-Sump and C-Sump”
to address oil leaks caused
by heat damage to O-ring Old Part #: 1375M50P02/P03/P04
seals. New part #:
1375M50P18/P19/P20/P21

High Temperature AFLAS O-Rings - CRF Module

Figure 8-11

GE Proprietary Information 8-16 Workscope Planning Guide

Subject to restrictions on the cover or first page
 CF6-80C2
GE Aviation Workscope Planning Guide

8.7.3. CRF Module - Priority 3.

NOTE: Always Use Latest Revision of Listed Documents.

Recommended
Item Item Description Document(s) Workscope
Level

Compressor Rear Wear can occur in the CRF 1. EM 72-34-01 Repair 20 (Sep-2011) When CRF is
Frame (CRF) Outer liner pin locating hole. Repair allows to oversize the hole removed from
Liner Locating Pin Repair available to return and use stepped pin to ensure
CRFs to serviceability. the engine
Hole Repair same installation/assembly as
when original pin used

2. EM 72-34-01 Repair 22 (Jun-2012)

Repair defines weld procedure for
alignment pin hole

Reworked CRF Outer Liner Locating Pin

Figure 8-12

GE Proprietary Information 8-17 Workscope Planning Guide

Subject to restrictions on the cover or first page
 CF6-80C2
GE Aviation Workscope Planning Guide

SECTION 9

Combustor Module

The following pages outline the relevant tasks for performing Combustor
module workscope planning and maintenance. The objectives of the
information contained within this guide are to communicate the extent of work
to enable the user of the guide to achieve their engine durability, performance
and maintenance cost goals while maintaining high standards of engine
reliability. The recommendations contained herein are based on an average
engine in the fleet. However, there are many variable factors that can affect
the specific workscope definition for a given operator or engine.

GE Proprietary Information 9-1 Workscope Planning Guide

Subject to restrictions on the cover or first page
 CF6-80C2
GE Aviation Workscope Planning Guide

9.0. Combustor Module Cross Section.

A. Refer to Figure 9-1 thru Figure 9-4.

Combustor Module Cross Section

Figure 9-1

GE Proprietary Information 9-2 Workscope Planning Guide

Subject to restrictions on the cover or first page
 CF6-80C2
GE Aviation Workscope Planning Guide

Combustor Outer Liner, Dome and Outer Cowl

Figure 9-2

GE Proprietary Information 9-3 Workscope Planning Guide

Subject to restrictions on the cover or first page
 CF6-80C2
GE Aviation Workscope Planning Guide

Combustor Inner Liner, Dome and Inner Cowl

Figure 9-3

GE Proprietary Information 9-4 Workscope Planning Guide

Subject to restrictions on the cover or first page
 CF6-80C2
GE Aviation Workscope Planning Guide

Combustor Mounting
Figure 9-4

GE Proprietary Information 9-5 Workscope Planning Guide

Subject to restrictions on the cover or first page
 CF6-80C2
GE Aviation Workscope Planning Guide

9.1. Combustor Module Minimum Workscope Tasks.

A. Refer to Table 9-1.

Table 9-1. Combustor Module Minimum Workscope Tasks.

Item Tasks Reference

Combustor Verify compliance to accessible Category 1-3 Service

Bulletins, especially documents found in the “Key --
Module Recommended Documents” section of this document.

Perform inspection in accordance with ESM tasks and 72-00-41

subtasks.

9.2. Combustor Module Overhaul Workscope Tasks.

A. Refer to Table 9-2.

Table 9-2. Combustor Module Overhaul Workscope Tasks.

Item Tasks Reference

Combustor Verify compliance to accessible Category 1-6 Service

Module Bulletins, especially documents found in the “Key --
Recommended Documents” section of this document.

Clean combustor components and remove the dome

and liners thermal barrier coating (TBC) prior to 72-41-00
inspection.

Perform cowl inspections in accordance with ESM

tasks and subtasks. Ultrasonic inspect outer cowl 72-41-01
rolled lip.

Perform dome inspections in accordance with ESM 72-41-02

tasks and subtasks.

GE Proprietary Information 9-6 Workscope Planning Guide

Subject to restrictions on the cover or first page
 CF6-80C2
GE Aviation Workscope Planning Guide

Table 9-2. Combustor Module Overhaul Workscope Tasks. (Cont.)

Item Tasks Reference

Reapply thermal barrier coating (TBC) to dome. 72-41-02

Combustor
Module
Inspect liners in accordance with ESM tasks and 72-41-03
subtasks. .

Reapply liner TBC. 72-41-03

9.3. Combustor Module Critical Items, Reliability and Key Product

Improvements, and Best Practices.

NOTE: The following pages highlight current critical items, and a selection of
other key reliability and product improvements, and best practices.
Except for critical items, this list is not all inclusive; therefore, it is
recommended that all Category 1 - 7 Service Bulletins be evaluated for
workscope inclusion. Please refer to the most recent revision of the cited
documents for further information.

A. Priority Levels.

• Priority 1: Critical Item / Safety / AD-Mandated

• Priority 2: Other Important / Reliability item

• Priority 3: Cost of Ownership, Best Practices / Recommended items

9.3.1. Combustor Module - Priority 1.

NOTE: No Priority 1 items for the Combustor Module at this time.

GE Proprietary Information 9-7 Workscope Planning Guide

Subject to restrictions on the cover or first page
 CF6-80C2
GE Aviation Workscope Planning Guide

9.3.2. Combustor Module - Priority 2.

A. Refer to Table 9-3 and Figure 9-5.

NOTE: Always use latest revision of listed documents.

Table 9-3. Combustor Module - Priority 2.

Recommended
Item Item Description Document(s)
Workscope Level

Combustor SB 72-1330 This Service Bulletin 1. SB 72-1330 (R02, Customer option

Module provides instructions to replace Rene September-2012) but should be
N5 and Rene N2 splashplates with strongly
Splashplate MarM-509 splashplates in the Combustor Chamber
Rework combustion chamber dome and Assembly considered when
releases new combustion chamber (72-41-00) – combustor is sent
assembly and combustion chamber Intermixing of N2, N5, for repair.
dome to the field. AND MARM-509
Splashplates

GE Proprietary Information 9-8 Workscope Planning Guide

Subject to restrictions on the cover or first page
 CF6-80C2
GE Aviation Workscope Planning Guide

New Splashplate

Splash plate Splash plate Splash plate

Missing material Missing material Flare burn through

NOTE: GE no longer sells N2 and N5 splash plates that are required to accomplish
following Service Bulletin rework instructions:

SB 72-1106 - N5 SPLASHPLATE FIELD REWORK

SB 72-1184 - N5 SPLASHPLATE WITH AIR PLASMA SPRAY COATING
SB 72-1264 - INTRODUCTION OF RENE N2 SPLASHPLATES AND INNER
LINERS WITH MULTI-HOLE SPAD

N5 Splashplate Distress (On-Wing Borescope Inspection Image)

Figure 9-5

GE Proprietary Information 9-9 Workscope Planning Guide

Subject to restrictions on the cover or first page
 CF6-80C2
GE Aviation Workscope Planning Guide

9.3.3. Combustor Module - Priority 3.

A. Refer to Table 9-4 and Figure 9-6 thru Figure 9-11.

NOTE: Always Use Latest Revision of Listed Documents.

Table 9-4. Combustor Module - Priority 3.

Recommended
Item Item Description Document(s)
Workscope Level

Combustor SB 72-0485 This Service Bulletin 1. SB 72-0485 (R01, April- Customer option
Module identifies reworked combustion 2010) but should be
chamber outer liners to help improve Combustion Chamber strongly considered
Outer Liner
Rework service life of the outer liners by the Assembly - Outer Liner when combustor is
addition of chrome carbide wear coat AFT Flange Chrome sent for repair.
to the aft flange to reduce wear. Carbide

Chrome carbide is added to the outer

liner for wear resistance and
compatibility with the chrome carbide
coated HPTS hanger support.

Combustor SB 72-0742 This Service Bulletin 1. SB 72-0742 (R03, July- Customer option
Module provides instructions to add thermal 1999) but should be
barrier coating (TBC) onto the Secondary Swirler strongly considered
Secondary
Swirler Rework secondary swirler venturi. Thermal Barrier when combustor is
Coating. sent for repair.
Thermal barrier coating (TBC) is added
to the secondary swirler venturi to
reduce thermal gradients which
cause the fatigue cracks.

GE Proprietary Information 9-10 Workscope Planning Guide

Subject to restrictions on the cover or first page
 CF6-80C2
GE Aviation Workscope Planning Guide

Combustion Chamber Dome Secondary Swirler Venturi TBC

Figure 9-6

Table 9-4. Combustor Module - Priority 3. (Cont.)

Recommended
Item Item Description Document(s)
Workscope Level

Combustor SB 72-0842 This Service 1. SB 72-0842 (R0, April-1998) Customer option

Module Bulletin provides rework Combustion Chamber Assembly - but should be
instructions for the Inner Liner Rework strongly
Inner Liner combustion chamber considered when
Rework assembly inner liner, by combustor is
modifying the aft ring sent for repair.
seal surface using
dabber weld build-up.

Improved cooling and

build-up on the wear
area on the aft seal face
improves the life of the
inner liner.

GE Proprietary Information 9-11 Workscope Planning Guide

Subject to restrictions on the cover or first page
 CF6-80C2
GE Aviation Workscope Planning Guide

Inner Liner Rework - Combustor Module

Figure 9-7

GE Proprietary Information 9-12 Workscope Planning Guide

Subject to restrictions on the cover or first page
 CF6-80C2
GE Aviation Workscope Planning Guide

Table 9-4. Combustor Module - Priority 3. (Cont.)

Recommended
Item Item Description Document(s)
Workscope Level

Combustor SB 72-1032 introduces new 1. SB 72-1032 (R3, Sepr-2012) Customer option but
Module parts and improves the should be strongly
“COMBUSTION CHAMBER
Swirler Retainer - reliability of the combustion SWIRLER RETAINER (72-41-02) considered when
New Design chamber swirler retainer. The NEW DESIGN” combustor is sent for
retainer material has repair.
changed and the material
thickness was increased.

SB 72-1072 introduces new 2. SB 72-1072 (R0, Aug,-2002)

Dome, Inner Liner parts and improves the
and Outer Liner “ENGINE – COMBUSTOR (72-
Rework reliability of the Dome, Inner
41-00) LIFE IMPROVEMENT”
Liner and Outer Liner. Part
life is improved by increasing
the cooling nugget overhang
gaps and increasing the
thickness of the thermal
barrier coating.

SB 72-1178 introduces 3. SB 72-1178 (R1, July-2007)

improved annular liner
Inner Liner SPD segments. These inner liner “ENGINE – CORE (72-00-02) –
Repair… COMBUSTION CHAMBER
SPD segments feature a
modified cooling nugget gap ASSEMBLY – INNER LINER
Standard Liner
with Improved and a material upgrade from REWORK”
Cooling HAST-X to HS188. This bulletin affects pre-low
Emission Combustion (Pre-
LEC) chamber assemblies.

SB 72-1256 releases 4. SB 72-1256 (R01, Oct-2008)

procedures to replace non
Inner Liner SPD multi-hole configuration low “ENGINE – COMBUSTION LINER
Repair… ASSEMBLY (72-41-00) – INNER
emissions combustor inner
liner panels zero, one, two, SEGMENT LINER HS188 SPD
Multi-Hole Design
and three with HS 188 REPLACEMENT FOR NON
multihole panels MULTI-HOLE CONFIGURATION
LEC ENGINES”
This bulletin only affects low
Emission Combustion (LEC)
chambers assemblies.

GE Proprietary Information 9-13 Workscope Planning Guide

Subject to restrictions on the cover or first page
 CF6-80C2
GE Aviation Workscope Planning Guide

Table 9-4. Combustor Module - Priority 3. (Cont.)

Recommended
Item Item Description Document(s)
Workscope Level

Inner Liner SPD SB 72-1263 releases a new 5. SB 72-1263 (R0, Mar-2007) Customer option but
Repair… inner liner segment part “ENGINE – COMBUSTOR should be strongly
Standard Liner number 2255M63G01 that LINER ASSEMBLY (72-41- considered when
with Improved incorporates larger cooling 00) – HS188 INNER LINER combustor is sent for
Cooling nugget gaps compared to FIELD REWORK” repair.
the original which increases
the durability of the
combustor inner liners. This bulletin only affects
low Emision Combustion
(LEC) chamber assemblies.
Inner Liner SPD SB 72-1273 introduces new
Repair… combustor inner liner SPD
6. SB 72-1273 (R0, October-
segment that will simplify the 2007)
Standard Liner inner liner repair and reduce
with Improved the need of expansion of the “Engine – Combustion
Cooling last segment diameter Chamber Assembly (72-
during combustor inner liner 41-00) – HS188 Inner Liner
repair. Rework”

This bulletin only affects

low Emision Combustion
(LEC) chamber assemblies.

GE Proprietary Information 9-14 Workscope Planning Guide

Subject to restrictions on the cover or first page
 CF6-80C2
GE Aviation Workscope Planning Guide

Current Production Multi Sector:

Sector: typical distress typical condition

New Repair for Combustor Inner Liner - Combustor Module

Figure 9-8

Table 9-4. Combustor Module - Priority 3. (Cont.)

Recommended Workscope
Item Item Description Document(s)
Level

Combustor SB 72-1174 This Service 1. SB 72-1174 (R01, Any SV

Module Bulletin provides October-2011)
instructions to apply “Engine- Combustion
Primary Swirler and Chamber
Secondary Swirler additional wear coating to
(72-41-00)- Primary and
Rework the primary and secondary Secondary Swirler T800
swirlers. Coating”

The introduction of the This rework requires

T800 wear coating has an coating of both the
improved wear rate over primary and secondary
the previous coating, swirlers.
therefore improving
durability of the swirlers
and extending the life of
the dome assembly.

GE Proprietary Information 9-15 Workscope Planning Guide

Subject to restrictions on the cover or first page
 CF6-80C2
GE Aviation Workscope Planning Guide

Primary and Secondary Swirler Coating - Combustor Module

Figure 9-9

GE Proprietary Information 9-16 Workscope Planning Guide

Subject to restrictions on the cover or first page
 CF6-80C2
GE Aviation Workscope Planning Guide

Inner Liner SPD Repair - Combustor Module

Figure 9-10

GE Proprietary Information 9-17 Workscope Planning Guide

Subject to restrictions on the cover or first page
 CF6-80C2
GE Aviation Workscope Planning Guide

Table 9-4. Combustor Module - Priority 3. (Cont.)

Recommended
Item Item Description Document(s)
Workscope Level

Combustor Dome Engine shop manual 1. ESM 72-41-02 Repair 029 (Apr- When combustor is
procedure available to 2012) routed for repair
Primary swirler tab repair swirlers with
repair wear on the
positioning tabs ESM procedure gives full
instructions to repair the
combustion chamber dome
primary swirlers by welding and
applying thermal spray to the
tabs with T800 coating for wear
resistance.

Primary Swirler Tab Wear

Figure 9-11

GE Proprietary Information 9-18 Workscope Planning Guide

Subject to restrictions on the cover or first page
 CF6-80C2
GE Aviation Workscope Planning Guide

High Pressure Turbine Module (Inco 718 Material Rotor)

SECTION 10

HPT Module

The following pages outline the relevant tasks for performing HPT module
workscope planning and maintenance. The objectives of the information
contained within this guide are to communicate the extent of work to enable
the user of the guide to achieve their engine durability, performance and
maintenance cost goals while maintaining high standards of engine reliability.
The recommendations contained herein are based on an average engine in the
fleet. However, there are many variable factors that can affect the specific
workscope definition for a given operator or engine.

GE Proprietary Information 10-1 Workscope Planning Guide

Subject to restrictions on the cover or first page
 CF6-80C2
GE Aviation Workscope Planning Guide

10.0. HPT Module - HPT Stage 1 Nozzle Assembly.

A. Refer to Figure 10-1 thru Figure 10-4.

Nozzle Segments

Air Cover Baffles

Nozzle Support

HPT Module - HPT Stage 1 Nozzle Assembly

Figure 10-1

GE Proprietary Information 10-2 Workscope Planning Guide

Subject to restrictions on the cover or first page
 CF6-80C2
GE Aviation Workscope Planning Guide

HPT Module - HPT Stage 1 Rotor Assembly

Figure 10-2

GE Proprietary Information 10-3 Workscope Planning Guide

Subject to restrictions on the cover or first page
 CF6-80C2
GE Aviation Workscope Planning Guide

HPT Module - HPT Stage 2 Rotor Assembly

Figure 10-3

GE Proprietary Information 10-4 Workscope Planning Guide

Subject to restrictions on the cover or first page
 CF6-80C2
GE Aviation Workscope Planning Guide

HPT Module - HPT Stage 2 Nozzle Assembly

Figure 10-4

GE Proprietary Information 10-5 Workscope Planning Guide

Subject to restrictions on the cover or first page
 CF6-80C2
GE Aviation Workscope Planning Guide

10.1. Configuration 1 and Configuration 2 Rotors - HPT Module Assembly.

A. There are two primary configurations of the CF6-80C2 HPT module.

Configuration 1 and Configuration 2 rotor assemblies are significantly different
from each other. Thus, they require significantly different assemblies and
inspection procedures.

B. Configuration 1 contains an HPT rotor made of Inconel 718 material. The

majority of the fleet utilizes the Configuration 1 HPT rotor. Refer to
Figure 10-5, Sheet 1.

C. Configuration 2 consists of an HPT rotor made of R88DT material. It was

introduced to meet the high thrust requirements of the CF6-80C2B8F rating. It is
certified for all CF6-80C2 Boeing FADEC ratings for the Boeing 767 airplane.
This includes the B2F, B4F, B6F, B7F and B8F ratings. Refer to Figure 10-5,
Sheet 2.

GE Proprietary Information 10-6 Workscope Planning Guide

Subject to restrictions on the cover or first page
 CF6-80C2
GE Aviation Workscope Planning Guide

CONFIGURATION 1 – (INCONEL TURBINE ROTOR)

Configuration 1 and Configuration 2 Rotors - HPT Module Assembly
Figure 10-5 (Sheet 1 of 2)

GE Proprietary Information 10-7 Workscope Planning Guide

Subject to restrictions on the cover or first page
 CF6-80C2
GE Aviation Workscope Planning Guide

CONFIGURATION 2 - (R88DT BOLTLESS TURBINE ROTOR)

Configuration 1 and Configuration 2 Rotors - HPT Module Assembly

Figure 10-5 (Sheet 2 of 2)

GE Proprietary Information 10-8 Workscope Planning Guide

Subject to restrictions on the cover or first page
 CF6-80C2
GE Aviation Workscope Planning Guide

10.2. Configuration 1 and Configuration 2 Rotors - HPT Module Assembly.

A. Many engine shop manual chapters for Configuration 1 and Configuration 2 HPT
rotor assemblies are common for both configurations. Common chapters
designate each configuration as either “CONFIG 1” or “CONFIG 2” as required.
For parts common to both configurations, such as the HPT blades and 5R
bearing spanner nut, chapters do not specify CONFIG 1 or CONFIG 2. Refer to
Table 10-1.

Table 10-1. Configuration 1 and Configuration 2 Rotor Manual Sections.

Configuration 1 Configuration 2
Manual Section
(Inconel Rotor) (R88DT) Rotor
*HPT Rotor Assembly 72-53-00 (CONFIG 1) 72-53-00 (CONFIG 2)
*HPT Rotor Blades 72-53-01 72-53-01
HPT Rotor (Inconel) Stage 1 Disk/Shaft 72-53-02 Not Applicable
*HPT Rotor Heat Shield 72-53-03 72-53-03
HPT Rotor (Inconel) Impeller Cover and Spacer 72-53-04 Not Applicable
HPT Rotor (Inconel) Thermal Shield 72-53-05 Not Applicable
HPT Rotor (Inconel) Stage 2 Disk 72-53-06 Not Applicable
HPT Rotor (Inconel) Diffuser 72-53-07 Not Applicable
*HPT Rotor Aft Air Seal 72-53-08 (CONFIG 1) 72-53-08 (CONFIG 2)
HPT Rotor (Inconel) Pressure Tube/Coupling Nut 72-53-09 Not Applicable
HPT Rotor (Inconel) Blade Retainers 72-53-10 Not Applicable
*HPT Rotor Damper Seals 72-53-11 (CONFIG 1) 72-53-11 (CONFIG 2)
*HPT Rotor 5R Bearing Spanner Nut 72-53-12 72-53-12
*HPT Rotor 5R Bearing Aft Air/Oil Seal 72-53-13 (CONFIG 1) 72-53-13 (CONFIG 2)
*HPT Rotor Hardware (Bolts, Studs, Shims, Windage
Cups, Damper Sleeves and Rings) 72-53-14 72-53-14
HPT Rotor (Inconel) Diffuser Assembly Piston Ring 72-53-15 Not Applicable
HPT Rotor (R88DT) Stage 1 Disk/Shaft Not Applicable 72-53-16
HPT Rotor (R88DT) Rotating Interstage Seal Not Applicable 72-53-17
HPT Rotor (R88DT) Stage 2 Disk Not Applicable 72-53-18
HPT Rotor (R88DT) Stage 2 Aft Blade Retainer Not Applicable 72-53-19
HPT Rotor (R88DT) Pressure Balance Seal Not Applicable 72-53-20
HPT Rotor (R88DT) Forward Outer Seal Not Applicable 72-53-21
HPT Rotor (R88DT) Rear Retaining Ring Not Applicable 72-53-22
HPT Rotor (R88DT) Pressure Balance Damper Seal Not Applicable 72-53-23

* Common Chapters for Configuration 1 and Configuration 2 Rotors.

GE Proprietary Information 10-9 Workscope Planning Guide

Subject to restrictions on the cover or first page
 CF6-80C2
GE Aviation Workscope Planning Guide

10.3. HPT Module Performance Effects.

A. See Section 4 “Performance Effects by Module” of this manual which defines the
performance effects of restoring HPT clearances and airfoil surface finish.

10.4. HPT Module Workscopes.

A. For HPT Module Minimum Workscope, refer to Figure 10-6.

B. For HPT Rotor Assembly Workscope, refer to Table 10-3.

C. For HPT Stage 1 Nozzle Minimum Workscope, refer to Figure 10-8 and
Table 10-4.

D. For HPT Stage 2 Nozzle Minimum Workscope, refer to Figure 10-9 and
Table 10-5.

E. For HPT Module Performance Workscope, refer to Figure 10-10 and

Table 10-6.

F. For HPT Rotor Full Overhaul Workscope, refer to Figure 10-12.

G. For HPT Stage 1 Nozzle Full Overhaul Workscope, refer to Figure 10-11.

H. For HPT Stage 2 Nozzle Full Overhaul Workscope, refer to Figure 10-13.

I. For HPT Full Overhaul Workscope, refer to Table 10-7.

GE Proprietary Information 10-10 Workscope Planning Guide

Subject to restrictions on the cover or first page
 CF6-80C2
GE Aviation Workscope Planning Guide

Process Map - HPT Module Minimum Workscope

Figure 10-6

GE Proprietary Information 10-11 Workscope Planning Guide

Subject to restrictions on the cover or first page
 CF6-80C2
GE Aviation Workscope Planning Guide

Table 10-2. HPT Module Minimum Workscope - Key Maintenance Tasks.

Item Tasks ATA Reference

HPT Module Verify compliance to accessible Category 1-3 --

Service Bulletins, especially documents found in
the “Key Recommended Documents” section of
this document.

If HPT module is not disassembled to sub modules,

72-00-03
perform HPT module level inspection.

Process Map - HPT Rotor Minimum Workscope

Figure 10-7

GE Proprietary Information 10-12 Workscope Planning Guide

Subject to restrictions on the cover or first page
 CF6-80C2
GE Aviation Workscope Planning Guide

Table 10-3. HPT Rotor Assembly Workscope - Key Maintenance Tasks.

Item Tasks ATA Reference

HPT Rotor Assembly Verify compliance to accessible Category 1-3 --

Service Bulletins, especially documents found in
the “Key Recommended Documents” section of
this document.

Inspection of the HPT Rotor assembly is done with

72-00-53
the assembly installed or removed. This level is for
inspection and/or repair as specified in the
approved module maintenance procedures. These
procedures contain a visual inspection and, as
necessary, a dimensional inspection of the
specified areas.

Process Map - HPT Stage 1 Nozzle Minimum Workscope

Figure 10-8

GE Proprietary Information 10-13 Workscope Planning Guide

Subject to restrictions on the cover or first page
 CF6-80C2
GE Aviation Workscope Planning Guide

Table 10-4. HPT Stage 1 Nozzle Minimum Workscope - Key Maintenance Tasks.

Item Tasks ATA Reference

HPT Stage 1 Nozzle Verify compliance to accessible Category 1-3 --

Service Bulletins, especially documents found in
the “Key Recommended Documents” section of
this document.

Perform HPT Stage 1 Nozzle Inspections in 72-00-51

accordance with ESM ATA tasks and subtasks

Ensure Aft Outer Leaf Overlap Seals are Installed 72-00-51

(reference 72-00-51-800-002 Special Procedure)

Instructions for the replacement of HPT Stage 1 72-00-51

nozzle segments in the Stage 1 HPT assembly
(reference Special Procedure 72-00-51-800-001)

Process Map - HPT Stage 2 Nozzle Minimum Workscope

Figure 10-9

GE Proprietary Information 10-14 Workscope Planning Guide

Subject to restrictions on the cover or first page
 CF6-80C2
GE Aviation Workscope Planning Guide

Table 10-5. HPT Stage 2 Nozzle Minimum Workscope - Key Maintenance Tasks.

Item Tasks ATA Reference

HPT Stage 2 Nozzle Verify compliance to accessible Category 1-3 --

Service Bulletins, especially documents found in
the “Key Recommended Documents” section of
this document.

Inspection of the HPT Stage 2 Nozzle assembly is 72-00-52

done with the assembly installed or removed. This
level is for inspection and/or repair as specified in
the approved module maintenance procedures.
These procedures contain a visual inspection and,
as necessary, a dimensional inspection of the
specified areas.

GE Proprietary Information 10-15 Workscope Planning Guide

Subject to restrictions on the cover or first page
 CF6-80C2
GE Aviation Workscope Planning Guide

Process Map - HPT Module Performance Workscope

Figure 10-10

GE Proprietary Information 10-16 Workscope Planning Guide

Subject to restrictions on the cover or first page
 CF6-80C2
GE Aviation Workscope Planning Guide

Table 10-6. HPT Module Performance Workscope - Key Maintenance Tasks.

Item Tasks ATA Reference

HPT Rotor Verify compliance to accessible Category 1-3 --

Service Bulletins, especially documents found in
the “Key Recommended Documents” section of
this document.

Perform All Inspections in accordance with 72-00-53

referenced ESM ATA tasks and subtasks.
See Note 1.

Remove and clean blades in accordance with 72-53-00

referenced ESM tasks and subtasks

Notch blade tips and borescope after engine test 72-53-00

to document blade tip rubs

Verify compliance to accessible Category 1-6 72-00-00

HPT Stage 1 Nozzle Service Bulletins, especially documents found in
NOTE: Performance the “Key Recommended Documents” section of
and Overhaul this document. Consider compliance with
workscope for the applicable Category 7 Service Bulletins.
HPT stage 1 nozzle is
very similar. It is listed Perform All Inspections on stage 1 nozzles in 72-51-02
here for convenience. accordance with referenced ESM tasks and
subtasks

Restore vane surface finish to engine manual 72-51-02

limits to achieve 45AA on convex surface and
60AA on all other surfaces

Minimize outer platform gaps between 72-51-00

segments. Minimize radial and axial mismatch of
outer platform aft seating surface.

Measure and record A4 throat flow area target to 72-51-00

nominal A4 per engine manual.

NOTE:
1. Configuration 1 (Inco rotors) only. If the thermal shield has accumulated 9,000 cycles or more since
new, or if the thermal shield time since new is not known, it is recommended that the seal teeth
serrations are inspected for cracks at each Performance level shop visit. The engine manual defines
an optional eddy current inspection of the seal teeth that can be done at the rotor module level to
detect seal teeth cracks.

GE Proprietary Information 10-17 Workscope Planning Guide

Subject to restrictions on the cover or first page
 CF6-80C2
GE Aviation Workscope Planning Guide

Table 10-6. HPT Module Performance Workscope - Key Maintenance Tasks. (Cont.)

Item Tasks ATA Reference

HPT Stage 2 Nozzle Verify compliance to accessible Category 1-3 72-00-00

Service Bulletins, especially documents found in
the “Key Recommended Documents” section of
this document.

Perform All Inspections on HPT Stage 2 Nozzles in 72-00-52

accordance with referenced ESM ATA tasks and
subtasks

Replace HPT stages 1 and 2 shrouds as 72-52-00

necessary to restore blade tip clearances to
engine manual limits.

Restore the honeycomb inter-stage stationary air 72-52-07

seals as required

GE Proprietary Information 10-18 Workscope Planning Guide

Subject to restrictions on the cover or first page
 CF6-80C2
GE Aviation Workscope Planning Guide

Process Map - HPT Stage 1 Nozzle Full Overhaul Workscope

Figure 10-11

GE Proprietary Information 10-19 Workscope Planning Guide

Subject to restrictions on the cover or first page
 CF6-80C2
GE Aviation Workscope Planning Guide

Process Map - HPT Rotor Full Overhaul Workscope

Figure 10-12

GE Proprietary Information 10-20 Workscope Planning Guide

Subject to restrictions on the cover or first page
 CF6-80C2
GE Aviation Workscope Planning Guide

Process Map - HPT Stage 2 Nozzle Full Overhaul Workscope

Figure 10-13

GE Proprietary Information 10-21 Workscope Planning Guide

Subject to restrictions on the cover or first page
 CF6-80C2
GE Aviation Workscope Planning Guide

Table 10-7. HPT Full Overhaul Workscope - Key Maintenance Tasks.

Item Tasks ATA Reference

HPT Stage 1 Nozzle Verify compliance to accessible Category 1-6 --

Service Bulletins, especially documents found in
the “Key Recommended Documents” section of
this document. Consider compliance with
applicable Category 7 Service Bulletins.

Perform All Inspections in accordance with 72-51-00

referenced ESM tasks and subtasks

Restore vane surface finish to engine manual 72-51-02

limits to achieve 45AA on convex surface and
60AA on all other surfaces

Minimize outer platform gaps between 72-51-00

segments. Minimize radial and axial mismatch of
outer platform aft seating surface.

Measure and record A4 throat flow area target to 72-51-00

nominal A4 per engine manual.

Verify compliance to accessible Category 1-6 --

HPT Rotor Service Bulletins, especially documents found in
the “Key Recommended Documents” section of
this document. Consider compliance with
applicable Category 7 Service Bulletins.

Perform All Inspections in accordance with 72-53-00

referenced ESM tasks and subtasks

All HPT rim bolts at stage 1 and 2 must be 72-53-00

scrapped whenever the rotor is disassembled

Target blade tip radius grind to achieve minimum 72-53-00

allowable clearance

Replace HPT spacer impeller cover if all index 72-53-00

positions shows signs of wear from impeller ribs

GE Proprietary Information 10-22 Workscope Planning Guide

Subject to restrictions on the cover or first page
 CF6-80C2
GE Aviation Workscope Planning Guide

Table 10-7. HPT Full Overhaul Workscope - Key Maintenance Tasks. (Cont.)

Item Tasks ATA Reference

HPT Stage 2 Nozzle Verify compliance to accessible Category 1-6 --

Service Bulletins, especially documents found in
the “Key Recommended Documents” section of
this document. Consider compliance with
applicable Category 7 Service Bulletins.

Perform All Inspections in accordance with 72-52-00

referenced ESM tasks and subtasks

Replace HPT Stages 1 and 2 shrouds as 72-52-06

necessary to restore blade tip clearances to
engine manual limits.

Assemble and grind the HPT stator 72-52-00

GE Proprietary Information 10-23 Workscope Planning Guide

Subject to restrictions on the cover or first page
 CF6-80C2
GE Aviation Workscope Planning Guide

10.5. Critical Items, Reliability and Key Product Improvements, and Best Practices -
HPT Rotor Assembly - Configuration 1 (Inco 718 Rotors).

NOTE: The following pages highlight current critical items, and a selection of other
key reliability and product improvements, and best practices. Except for
critical items, this list is not all inclusive; therefore, it is recommended that all
Category 1 - 7 Service Bulletins be evaluated for workscope inclusion.
Please refer to the most recent revision of the cited documents for further
information.

A. Refer to Figure 10-14.

HPT Rotor Assembly - Configuration 1 (Inco 718 Rotors)

Figure 10-14

GE Proprietary Information 10-24 Workscope Planning Guide

Subject to restrictions on the cover or first page
 CF6-80C2
GE Aviation Workscope Planning Guide

B. Priority Levels.

• Priority 1: Critical Item / Safety / AD-Mandated

• Priority 2: Other Important / Reliability item

• Priority 3: Cost of Ownership, Best Practices / Recommended items

10.5.1. HPT Rotor Assembly - Priority 1.

NOTE: Always Use Latest Revision of Listed Documents.

A. Refer to Table 10-8, Figure 10-15, and Figure 10-16.

Table 10-8. HPT Rotor Assembly - Priority 1.

Recommended
Item Item Description Document(s)
Workscope Level

HPT Stage 1 Rotor Mandatory rework of 1. AD 2006-16-16 Full Overhaul

HPT Stage 1 disk
HPT Stage 1 disk dovetail slot aft corner 2. SB 72-1089 (R0, May-2003)
dovetail slot bottom radius to apply “ENGINE - HPTR (72-53-00) - Stage 1
corner radius chamfer to eliminate Disk - Rework Dovetail Slot Bottom
high stress condition Corner Radius”
that can lead to
cracking and potential
engine un-
containment.

GE Proprietary Information 10-25 Workscope Planning Guide

Subject to restrictions on the cover or first page
 CF6-80C2
GE Aviation Workscope Planning Guide

HPT Stage 1 Disk Dovetail Slot Bottom Corner Radius

Figure 10-15

GE Proprietary Information 10-26 Workscope Planning Guide

Subject to restrictions on the cover or first page
 CF6-80C2
GE Aviation Workscope Planning Guide

Table 10-8. HPT Rotor Assembly - Priority 1. (Cont.)

Recommended
Item Item Description Document(s)
Workscope Level

HPT Stage 1 Rotor Certain parts were produced 1. AD 2006-16-16 Full Overhaul
with the aft break-edge
Inspection and chamfer (per 2. SB 72-1217 (R0, Jul-2006)
Re-Identification of SB 72-1089) but not marked “ENGINE - HPT Rotor
HPT Stage 1 disk with PN 1531M84G12, and Assembly (72-53-00) - Stage
some disks were produced 1 HPTR Disk Inspection and
with a cutter that generated Re-identification”
geometric variation on the
dovetail slot aft corner
break-edge chamfer.

Service Bulletin 72-1217

defines marking for
un-marked disks. It also
defines inspection
requirements for disks
produced with the break-edge
chamfer anomaly.

SB 72-1282 allows rework to 3. SB 72-1282 (R0, Mar-2008) As Required at Full

recontour of the aft dovetail Overhaul
slot chamfer of HPT Stage 1 “HPT ROTOR ASSEMBLY (72-
disks as required to allow 53-00) – RECONTOUR OF
enhanced (eddy current) STAGE 1 HPTR DISK
inspections. Some disks were DOVETAIL AFT CHAMFER TO
manufactured with geometric ENABLE EDDY CURRENT
variation that prevents the INSPECTION”
eddy current probe from
properly seating during the
inspection resulting in
erroneous inspection readings.

GE Proprietary Information 10-27 Workscope Planning Guide

Subject to restrictions on the cover or first page
 CF6-80C2
GE Aviation Workscope Planning Guide

Inspection and Re-Identification of HPT Stage 1 Disk

Figure 10-16

GE Proprietary Information 10-28 Workscope Planning Guide

Subject to restrictions on the cover or first page
 CF6-80C2
GE Aviation Workscope Planning Guide

10.5.2. HPT Rotor Assembly - Priority 2.

NOTE: Always Use Latest Revision of Listed Documents.

A. Refer to Table 10-9 and Figure 10-17 thru Figure 10-21.

Table 10-9. HPT Rotor Assembly - Priority 2.

Recommended
Item Item Description Document(s)
Workscope Level

HPT Stage 1 New Stage 1 HPT 1. SB 72-1444 (R0, Dec-2012) DSR142 Performance or
Rotor blades have a tip Full Overhaul
shelf feature to “HIGH PRESSURE TURBINE ROTOR
HPT Stage 1 improve tip ASSEMBLY (72-53-00) - INTRODUCTION OF
blades improved durability and NEW STAGE 1 HPTR BLADES”
tip cooling and redesigned blade
corrosion shank with latest 2. SB 72-1439 (R0, Dec-2012) N5
inhibiting coating chromide
on blade shank corrosion-inhibiting “HIGH PRESSURE TURBINE ROTOR
coating and ASSEMBLY (72-53-00) - INTRODUCTION OF
geometric changes NEW STAGE 1 HPTR BLADE P/N
to reduce stress 1639M70P20”
during operation
Incorporation of SB 72-1444 or 72-1439 is
highly recommended for operators who
have experienced shank corrosion or
anticipate operating a corrosive
environment

Application of 3. SB 72-1417 (R0, Feb 2012) High Pressure

corrosion inhibiting Turbine Rotor Assembly - (72-53-01) - High
coating by repair to Pressure Turbine Rotor Blades - Alteration -
pre-SB 72-1439 or Chromide Coating of the Stage 1 Blade
SB 72-1444 stage 1 Shank
HPT blades

GE Proprietary Information 10-29 Workscope Planning Guide

Subject to restrictions on the cover or first page
 CF6-80C2
GE Aviation Workscope Planning Guide

Stage 1 Blade Corrosion Protective Coating

Figure 10-17

GE Proprietary Information 10-30 Workscope Planning Guide

Subject to restrictions on the cover or first page
 CF6-80C2
GE Aviation Workscope Planning Guide

Table 10-9. HPT Rotor Assembly - Priority 2. (Cont.)

Recommended
Item Item Description Document(s)
Workscope Level

HPT Stage 2 Rotor Service bulletins 1. SB 72-1271 (R0, Aug-2007) “ENGINE - Performance or
introduce corrosion HPT Rotor Blades (72-53-01) - Full Overhaul
HPT Stage 2 blade protective coating to Introduction of Stage 2 HPT Rotor
corrosion protective the HPTR Stage 2 Blades with Under platform Corrosion
blade to prevent Protective Coating”. Repair to add
coating pitting and cracking coating
in shank area due to
type II hot corrosion. 2. SB 72-1269 (R0, Aug-2007) “ENGINE -
HPT Rotor Blades (72-53-01) -
Coating can be added Introduction of Stage 2 HPT Rotor
by repair (SB 72-1271) Blades with Under platform Corrosion
or by new blade Protective Coating”. New Blades
which have coating from production
(SB 72-1269)

AREA OF BLADE WITH CORROSION

PROTECTIVE COATING

HPT Stage 2 Blade Corrosion Protective Coating

Figure 10-18

GE Proprietary Information 10-31 Workscope Planning Guide

Subject to restrictions on the cover or first page
 CF6-80C2
GE Aviation Workscope Planning Guide

Table 10-9. HPT Rotor Assembly - Priority 2. (Cont.)

Recommended
Item Item Description Document(s)
Workscope Level

HPT Stage 2 Disk Rework HPT Stage 2 1. SB 72-1133 (R0, Jun-2004) “ENGINE Full Overhaul
disk forward flange to - HPTR (72-53-00) - Stage 2 Disk -
Rework for Life extend disk life limit Rework ”
Extension for A5F, from 9,000 cycles to
B5F, B7F, D1F 15,000 cycles
Ratings

Stage 2 Disk Forward Flange Location Stage 2 Disk Forward Flange Rework

Rework for Life Extension for A5F, B5F, B7F, D1F Ratings
Figure 10-19

GE Proprietary Information 10-32 Workscope Planning Guide

Subject to restrictions on the cover or first page
 CF6-80C2
GE Aviation Workscope Planning Guide

Table 10-9. HPT Rotor Assembly - Priority 2. (Cont.)

Recommended
Item Item Description Document(s)
Workscope Level

HPT Stage 1 Rotor Addresses erosion from 1. SB 72-1195 (R0, Aug-2005) Full Overhaul
dirt particles that travel “ENGINE - HPT Rotor Assembly
New HPT Stage 1 the HPT bore cooling (72-53-00) - New Stage 1 Disk Air
disk air baffle ring circuit. Some particles Baffle Ring for Erosion Protection”
become trapped in inner
cavity and impact the
fillet at connection
between disk hub and
shaft, causing erosion at
inner cavity fillet.

Profile of Eroded Disk HPT S1 Disk Cross-Section

with Baffle Ring Installed

New HPT Stage 1 Disk Air Baffle Ring

Figure 10-20 (Sheet 1 of 2)

GE Proprietary Information 10-33 Workscope Planning Guide

Subject to restrictions on the cover or first page
 CF6-80C2
GE Aviation Workscope Planning Guide

3D HPT S1 Disk Image with 360 Degree Image

Baffle Ring Installed of Baffle Ring

New HPT Stage 1 Disk Air Baffle Ring

Figure 10-20 (Sheet 2 of 2)

Table 10-9. HPT Rotor Assembly - Priority 2. (Cont.)

Recommended
Item Item Description Document(s)
Workscope Level

HPT Module Thermal shield seal Perform ECI on thermal shield seal Any SV
tooth crack initiation teeth per EM procedure (Jun-2013 EM
ECI of HPT Thermal leads to flange-to- update)
Shield flange crack,
particularly on older
parts. Thermal shield
catenary section
liberation can occur,
resulting in significant
downstream damage.

Enhanced ECI to help

detect cracks.

GE Proprietary Information 10-34 Workscope Planning Guide

Subject to restrictions on the cover or first page
 CF6-80C2
GE Aviation Workscope Planning Guide

HPT Rotor – Thermal Shield Thermal Shield Cross Section

Thermal Shield Flange to Flange Crack Thermal Shield Eddy Current Inspection
Historically Starts in Seal Tooth 1 or 2

ECI of HPT Thermal Shield

Figure 10-21

GE Proprietary Information 10-35 Workscope Planning Guide

Subject to restrictions on the cover or first page
 CF6-80C2
GE Aviation Workscope Planning Guide

10.5.3. HPT Rotor Assembly - Priority 3.

NOTE: Always Use Latest Revision of Listed Documents.

A. Refer to Table10-10 and Figure 10-23.

Table 10-10. HPT Rotor Assembly - Priority 3.

Recommended
Item Item Description Document(s)
Workscope Level

HPT Stage 1 Rotor Redesigned disk features 1. SB 72-1313 (R0, Dec-2008) Full Overhaul
stress decrease in the
Redesigned HPT dovetail slot bottom to “ENGINE - HPT Rotor Assembly
Stage 1 Inconel disk improve damage (72-53-00) - Introduction of
tolerance. Also eliminates CF6-80C2 Stage 1 HPTR Disk”
erosion of the forward
shaft inner transition area. Redesigned HPT stage 1 disk
not subject to AD 2006-16-06

GE Proprietary Information 10-36 Workscope Planning Guide

Subject to restrictions on the cover or first page
 CF6-80C2
GE Aviation Workscope Planning Guide

Redesigned HPT Stage 1 Inconel Disk

Figure 10-22

GE Proprietary Information 10-37 Workscope Planning Guide

Subject to restrictions on the cover or first page
 CF6-80C2
GE Aviation Workscope Planning Guide

Table 10-10. HPT Rotor Assembly - Priority 3. (Cont.)

Recommended
Item Item Description Document(s)
Workscope Level

HPT Module HPT stage 1 and stage 2 1. Engine Shop Manual 72-53-00 Any Disassembly of
rim bolts must be replaced the HPT Rotors
Replacement of any time the rotors are
Rotor Rim Bolts disassembled. Used bolts
are subject to fracture
during subsequent
operation which can lead
to significant damage to
the rotor and airfoils.

GE Proprietary Information 10-38 Workscope Planning Guide

Subject to restrictions on the cover or first page
 CF6-80C2
GE Aviation Workscope Planning Guide

Replacement of Rotor Rim Bolts

Figure 10-23

GE Proprietary Information 10-39 Workscope Planning Guide

Subject to restrictions on the cover or first page
 CF6-80C2
GE Aviation Workscope Planning Guide

10.6. Critical Items, Reliability and Key Product Improvements, and Best Practices -
HPT Rotor Assembly - Configuration 2 (R88DT Rotors).

NOTE: HPT Stage 1 and Stage 2 blades are common to the Configuration 1 HPT
rotor. This section only applies to the HPT rotors. See section above for
blades.

NOTE: The following pages highlight current critical items, and a selection of other
key reliability and product improvements, and best practices. Except for
critical items, this list is not all inclusive; therefore, it is recommended that all
Category 1 - 7 Service Bulletins be evaluated for workscope inclusion.
Please refer to the most recent revision of the cited documents for further
information.

A. Refer to Figure 10-24.

HPT Rotor Assembly - Configuration 2 (R88DT Rotors)

Figure 10-24

GE Proprietary Information 10-40 Workscope Planning Guide

Subject to restrictions on the cover or first page
 CF6-80C2
GE Aviation Workscope Planning Guide

B. Priority Levels.

• Priority 1: Critical Item / Safety / AD-Mandated

• Priority 2: Other Important / Reliability item

• Priority 3: Cost of Ownership, Best Practices / Recommended items

10.6.1. HPT Rotor Assembly - Configuration 2 (R88DT) - Priority 1.

NOTE: No current Priority 1 programs for Configuration 2 (R88DT) HPT rotors.

A. Refer to Table 10-11.

Table 10-11. HPT Rotor Assembly - Configuration 2 (R88DT) - Priority 1.

Historical Priority 1 Control and Accessory Related Items for Reference Reference

HPT Rotor R88 HPTR – Forward Outer Seal Rework. This Service Bulletin reworks the SB 72-1159
FOS mid rack seal teeth to a single tooth discourager seal configuration, to avoid seal Category 3
rack cracking and fragmentation.

10.6.2. HPT Rotor Assembly - Configuration 2 (R88DT) - Priority 2.

NOTE: Always Use Latest Revision of Listed Documents.

A. Refer to Table 10-12, Figure 10-25, and Figure 10-26.

GE Proprietary Information 10-41 Workscope Planning Guide

Subject to restrictions on the cover or first page
 CF6-80C2
GE Aviation Workscope Planning Guide

Table 10-12. HPT Rotor Assembly - Configuration 2 (R88DT) - Priority 2.

Recommended
Item Item Description Document(s)
Workscope Level

HPT Rotor Service Bulletin SB 72-1305 (R0, Jan-2009) At first shop visit
72-1305 introduces a when RIS is
R88 HPTR - 2-Piece 2-piece RIS design by “ENGINE - HIGH PRESSURE TURBINE removed from the
Rotating Interstage rework for part ROTOR ASSEMBLY (72-53-00) – HPT rotor
Seal (RIS) Design number 1778M69P04. INTRODUCTION OF 2-PIECE R88DT HPT
(Rework) The new design is ROTATING INTERSTAGE SEAL”
more flexible and
Life Extension eliminates cracking in SB 72-1441(R0, Jan-2009)
Rework the seal wire groove of
the HPT stage 1 blade ”HIGH PRESSURE TURBINE ROTOR
aft retainer portion of ASSEMBLY (72-53-00) - ROTATING
the seal. INTERSTAGE SEAL REWORK TO 2-PIECE
CONFIGURATION”
Service Bulletin
72-1441 introduces
the 2-piece RIS design
by rework for part
number 1778M69P02
seals. Environmental
control coating is also
applied to prevent
corrosion

GE Proprietary Information 10-42 Workscope Planning Guide

Subject to restrictions on the cover or first page
 CF6-80C2
GE Aviation Workscope Planning Guide

SB 1 2-Piece Rotating Interstage Seal (RIS) Design (Rework)

Figure 10-25

GE Proprietary Information 10-43 Workscope Planning Guide

Subject to restrictions on the cover or first page
 CF6-80C2
GE Aviation Workscope Planning Guide

Table 10-12. HPT Rotor Assembly - Configuration 2 (R88DT) - Priority 2. (Cont.)

Recommended
Item Item Description Document(s)
Workscope Level

HPT Rotor This Service Bulletin SB 72-1318 R00 (Sep-2008) Customer Option
introduces a new to RIS Rework
ENGINE - HPTR Assembly (72-53-00) - SB 72-1305
R88 HPTR – design rotating Introduction of Redesigned Rotating
Redesigned interstage seal that Interstage Seal
eliminates cracking in
Rotating Interstage the seal wire groove of
Seal (RIS) the HPT stage 1 blade
aft retainer portion of
the seal.

New Rotating Interstage Seal (RIS)

Design Compared to Original Design HPT Stage 1 Blade
Aft Retainer Reshaped to Lower Stress in the Seal Wire
Groove, Eliminates Cracking

R88 HPTR - Redesigned Rotating Interstage Seal (RIS)

Figure 10-26

GE Proprietary Information 10-44 Workscope Planning Guide

Subject to restrictions on the cover or first page
 CF6-80C2
GE Aviation Workscope Planning Guide

10.6.3. HPT Rotor Assembly - Configuration 2 (R88DT) - Priority 3.

NOTE: Always Use Latest Revision of Listed Documents.

A. Refer to Table 10-13 and Figure 10-27.

Table 10-13. HPT Rotor Assembly - Configuration 2 (R88DT) - Priority 3.

Recommended
Item Item Description Document(s)
Workscope Level

HPT Rotor This Service Bulletin SB 72-1020 R00 (03/22/2001) Full Overhaul
identifies a new air flow
R88DT Rotor shim between stage 1 and This Service Bulletin Improves the
stage 2 disks. The new maintainability by introducing a
shim will prevent the clip new air flow shim. Previous bolt
on the bolt from locking feature fails causing the
disengaging the anti- bolt to rotate and damages the
rotation land and disk.
damaging the stage 2 disk.

R88DT Rotor
Figure 10-27

GE Proprietary Information 10-45 Workscope Planning Guide

Subject to restrictions on the cover or first page
 CF6-80C2
GE Aviation Workscope Planning Guide

Table 10-14. HPT Rotor Assembly - Priority 3.

Recommended
Item Item Description Document(s)
Workscope Level

HPT Module SB defines application of 1. SB 72-1434 (R0, Aug-2012) Optional at any

environmental coating to shop visit when
R88 HPTR - Rotating the outer diameter “HPT ASSEMBLY (72-53-00) - RIS is removed
Interstage Seal (RIS) surfaces of the RIS to INTRODUCTION OF AN from HPT module
Improvements prevent corrosion ENHANCED ENVIRONMENTAL
DURABILITY COATING”

RIS seal tooth groove Optional environmental coating

rework to address linear application to the outside
indications caused by diameter of the RIS to protect
corrosion and high against corrosion
compressive stresses
2. SB 72-1443 (R0, Dec-2012)

“HIGH PRESSURE TURBINE ROTOR

ASSEMBLY (72-53-00) - REWORK
OF ROTATING INTERSTAGE SEALS
TO REMOVE MATERIAL BETWEEN
SEAL TEETH GROOVES”

Skim cut repair to remove

damaged material and to
re-contour seal tooth grooves to
lower compressive stresses.
Environmental coating applied
after RIS rework to protect
against corrosion

SB introduces improved 3. SB 72-1451 (R0, Oct-2013)

design part
New part design introduced
which incorporates
improvements to avoid corrosion
and linear indications on the
outside diameter surfaces of the
RIS

GE Proprietary Information 10-46 Workscope Planning Guide

Subject to restrictions on the cover or first page
 CF6-80C2
GE Aviation Workscope Planning Guide

SB 72-1434 Corrosion Resistant Coating Application

Figure 10-28

GE Proprietary Information 10-47 Workscope Planning Guide

Subject to restrictions on the cover or first page
 CF6-80C2
GE Aviation Workscope Planning Guide

SB 72-1443 RIS Rework and Coating Application

Figure 10-29

SB 72-1451 New Design RIS Features

Figure 10-30

GE Proprietary Information 10-48 Workscope Planning Guide

Subject to restrictions on the cover or first page
 CF6-80C2
GE Aviation Workscope Planning Guide

10.7. HPT Rotor Hardware - Handling Best Practices.

NOTE: The following pages outline some best practices for handling of HPT rotor
hardware. GE has observed damage from improper handling. Improper
handling can result in nicks or dents that are not serviceable and not
repairable, requiring replacement of very expensive hardware.

A. All life limited rotor parts are sensitive to nicks and dents. Some nicks or dents
can cause subsurface damage that can result in non-detectable cracks.
Therefore, there is no such thing as a “harmless” nick or dent. Blending a nick
or dent requires going below the maximum depth of the nick or dent. Testing
has demonstrated that a blend depth of 1.25x the depth of nick or dent
removes subsurface damage. However, GE has observed handling damage
that has exceeded repair limitations of the part such that maximum blending
allowed will not ensure all subsurface damage has been removed. This has
resulted in parts that were not repairable and were scrapped.

B. Refer to Figure 10-31 and Figure 10-32.

GE Proprietary Information 10-49 Workscope Planning Guide

Subject to restrictions on the cover or first page
 CF6-80C2
GE Aviation Workscope Planning Guide

Bent forward outer seal tooth due

to adjacent equipment breaking

Nick on HPT Stg 2 Disk

bore edge radius. Hit by
tooling during installation
onto machining fixture

Nick on top of HPT stage 2 disk

bore due to improper handling

Damage to diffuser vane ring tab

during rotor assembly

Damage to HPT pressure tube

coupling nut during assembly of
HPT module to HPC module

HPT Rotor Hardware - Handling Best Practices - Examples of Damaged Parts

Figure 10-31

GE Proprietary Information 10-50 Workscope Planning Guide

Subject to restrictions on the cover or first page
 CF6-80C2
GE Aviation Workscope Planning Guide

Do not ship expensive parts in

inadequate shipping containers

Use protective covers to

protect parts in the shop during
transportation or storage

Use hard-sided shipping containers

with adequate padding around the
part to keep it from moving inside the
container

HPT Rotor Hardware - Handling Best Practices

Figure 10-32

GE Proprietary Information 10-51 Workscope Planning Guide

Subject to restrictions on the cover or first page
 CF6-80C2
GE Aviation Workscope Planning Guide

10.8. Critical Items, Reliability and Key Product Improvements, and Best Practices -
HPT Stage 1 Nozzle Assembly.

NOTE: The following pages highlight current critical items, and a selection of other
key reliability and product improvements, and best practices. Except for
critical items, this list is not all inclusive; therefore, it is recommended that all
Category 1 - 7 Service Bulletins be evaluated for workscope consideration.
Please refer to the most recent revision of the cited documents for further
information.

A. Refer to Figure 10-33.

HPT Stage 1 Nozzle Assembly

Figure 10-33

GE Proprietary Information 10-52 Workscope Planning Guide

Subject to restrictions on the cover or first page
 CF6-80C2
GE Aviation Workscope Planning Guide

B. Priority Levels.

• Priority 1: Critical Item / Safety / AD-Mandated

• Priority 2: Other Important / Reliability item

• Priority 3: Cost of Ownership, Best Practices / Recommended items

10.8.1. HPT Stage 1 Nozzle Assembly - Priority 1.

NOTE: No Priority 1 items for the HPT Stage 1 Nozzle Assembly at this time.

10.8.2. HPT Stage 1 Nozzle Assembly - Priority 2.

NOTE: No Priority 2 items for the HPT Stage 1 Nozzle Assembly at this time.

10.8.3. HPT Stage 1 Nozzle Assembly - Priority 3.

NOTE: No Priority 3 items for the HPT Stage 1 Nozzle Assembly at this time.

GE Proprietary Information 10-53 Workscope Planning Guide

Subject to restrictions on the cover or first page
 CF6-80C2
GE Aviation Workscope Planning Guide

10.9. Critical Items, Reliability and Key Product Improvements, and Best Practices -
HPT Stage 2 Nozzle Assembly.

NOTE: The following pages highlight current critical items, and a selection of other
key reliability and product improvements, and best practices. Except for
critical items, this list is not all inclusive; therefore, it is recommended that all
Category 1 - 7 Service Bulletins be evaluated for workscope consideration.
Please refer to the most recent revision of the cited documents for further
information.

A. Refer to Figure 10-34.

HPT Stage 2 Nozzle Assembly

Figure 10-34

GE Proprietary Information 10-54 Workscope Planning Guide

Subject to restrictions on the cover or first page
 CF6-80C2
GE Aviation Workscope Planning Guide

B. Priority Levels.

• Priority 1: Critical Item / Safety / AD-Mandated

• Priority 2: Other Important / Reliability item

• Priority 3: Cost of Ownership, Best Practices / Recommended items

10.9.1. HPT Stage 2 Nozzle Assembly - Priority 1.

NOTE: Always Use Latest Revision of Listed Documents.

A. Refer to Table 10-15 and Figure 10-35.

Table 10-15. HPT Stage 2 Nozzle Assembly - Priority 1.

Recommended
Item Item Description Document(s)
Workscope Level

HPT Stage 2 Nozzles Pre-SB 72-0978 HPT 1. AD 2004-22-07 Full Overhaul

Stage 2 Nozzles are
360-degree periodic prone to cracking and 2. SB 72-0952 (R0, Dec-1998)
inspection of HPT potential airfoil “ENGINE - High Pressure Turbine
Stage 2 nozzles for liberation that can (72-52-00) - Stage 2 Nozzle
cracking cause significant Inspection”
secondary damage
including engine un-
containment

GE Proprietary Information 10-55 Workscope Planning Guide

Subject to restrictions on the cover or first page
 CF6-80C2
GE Aviation Workscope Planning Guide

360-Degree Periodic Inspection of HPT Stage 2 Nozzles for Cracking

Figure 10-35

GE Proprietary Information 10-56 Workscope Planning Guide

Subject to restrictions on the cover or first page
 CF6-80C2
GE Aviation Workscope Planning Guide

10.9.2. HPT Stage 2 Nozzle Assembly - Priority 2.

NOTE: Always Use Latest Revision of Listed Documents.

A. Refer to Table 10-16 and Figure 10-36 thru Figure 10-38.

Table 10-16. HPT Stage 2 Nozzle Assembly - Priority 2.

Recommended
Item Item Description Document(s)
Workscope Level

HPT Stage 2 Nozzles The new stage 2 HPT nozzles have 1. SB 72-0978 (R0, Jun- Full Overhaul
larger airfoil leading edge radii and 1999) R80
New HPT Stage 2 nozzles increased airfoil to band fillet radii “ENGINE - HPT Stage 2
decrease stresses to and improved cooling inserts. Nozzles (72-52-00) - New
minimize susceptibility to
crack Stage 2 Nozzles ”
R80 nozzles PN
2080M12G01/G02/G05/G06 and N5 2. SB 72-1099 (R0, May-
nozzles PN 2008) “ENGINE - HPT
2086M62G01/G02/G05/G06 are Stage 2 Nozzles (72-52-
available. 00) - New Design in Rene
N5 Material”
The N5 material has significantly
superior fatigue and rupture 3. SB 72-1291 (R0, May-
strength compared to R80, as it does 2008) R80/N5
not have grain boundaries in the “ENGINE - Stage 2 HPT
material structure. N5 material Nozzle (72-52-00) - New
properties will reduce nozzle scrap Tech CF6 HPT Stage 2
rate at HPT overhaul and reduce Nozzle Assembly”
cost of ownership.

GE Proprietary Information 10-57 Workscope Planning Guide

Subject to restrictions on the cover or first page
 CF6-80C2
GE Aviation Workscope Planning Guide

Leading Edge

Concave side

New HPT Stage 2 Nozzles Decrease Stresses to Minimize Susceptibility to Crack

Figure 10-36

Table 10-16. HPT Stage 2 Nozzle Assembly - Priority 2. (Cont.)

Recommended
Item Item Description Document(s)
Workscope Level

HPT Stage 2 Nozzles Reworks HPT stage 2 1. SB 72-1286 (R0, Sep-2008) R80/N5 Full Overhaul
nozzles to improve the
overall durability and “ENGINE - Stage 2 HPT Nozzle
Rework HPT Stage 2 (72-52-00) - Tech CF6 Fabrication
on wing service life of
nozzles to improve repaired stage 2 HPT Rework HPT Stage 2 Nozzle Assembly
durability and on nozzles. Release”
wing service life of
repaired nozzles

GE Proprietary Information 10-58 Workscope Planning Guide

Subject to restrictions on the cover or first page
 CF6-80C2
GE Aviation Workscope Planning Guide

Vane
Sleeve
Trail Vane

Vane Sleeve
Lead Vane

Stage 2 HPT
Nozzle

Rework HPT Stage 2 Nozzles to Improve Durability and On-Wing Service Life of Repaired
Nozzles
Figure 10-37

Table 10-16. HPT Stage 2 Nozzle Assembly - Priority 2. (Cont.)

Recommended
Item Item Description Document(s)
Workscope Level

HPT Stage 2 Nozzles Custom cooling insert SB 72-1291 (R0, Sep-2008) R80/N5 Full Overhaul
improves part Custom cooling air inserts.
durability, scrap rate
and lifecycle cost with
no impact to
performance.
Reduced thermal
stresses in nozzle
segment by improved
distribution of cooling
air

GE Proprietary Information 10-59 Workscope Planning Guide

Subject to restrictions on the cover or first page
 CF6-80C2
GE Aviation Workscope Planning Guide

HPT Stage 2 Nozzle

Figure 10-38

10.9.3. HPT Stage 2 Nozzle Assembly - Priority 3.

NOTE: No Priority 3 items for the HPT Stage 2 Nozzle Assembly at this time.

GE Proprietary Information 10-60 Workscope Planning Guide

Subject to restrictions on the cover or first page
 CF6-80C2
GE Aviation Workscope Planning Guide

SECTION 11

LPT Module

The following pages outline the relevant tasks for performing LPT module
workscope planning and maintenance. The objectives of the information
contained within this guide are to communicate the extent of work to enable the
user of the guide to achieve their engine durability, performance and
maintenance cost goals while maintaining high standards of engine reliability.
The recommendations contained herein are based on an average engine in the
fleet. However, there are many variable factors that can affect the specific
workscope definition for a given operator or engine.

GE Proprietary Information 11-1 Workscope Planning Guide

Subject to restrictions on the cover or first page
 CF6-80C2
GE Aviation Workscope Planning Guide

11.0. LPT Module.

A. Refer to Figure 11-1 thru Figure 11-8.

Stage 1 Nozzle
Cooling Air Manifold
TRF

Rear Link Mounts

Stator Case Aft Flange

Stage 1 Nozzles

LPT Rotor Shaft

Ground Handling Mount

Rotating Pressure
Balance Seal

Oil Supply Tube

LPT Case Cooling Air
Clearance Manifold
Stationary Pressure Stator
Balance Seal Case Scavenge Tube
Forward
Flange

LPT Module
Figure 11-1

GE Proprietary Information 11-2 Workscope Planning Guide

Subject to restrictions on the cover or first page
 CF6-80C2
GE Aviation Workscope Planning Guide

ACC Rear Mount

Stator Casing
Cooling Air and
5S
Instrumentation 4S
TRF
3S

2S

1S 4R 5R
3R
2R
1R

Coupling
Nut

Center Vent Support Plug No. 6R Bearing

LPT Module Cross Section

Figure 11-2

GE Proprietary Information 11-3 Workscope Planning Guide

Subject to restrictions on the cover or first page
 CF6-80C2
GE Aviation Workscope Planning Guide

LPT Stator
Figure 11-3

GE Proprietary Information 11-4 Workscope Planning Guide

Subject to restrictions on the cover or first page
 CF6-80C2
GE Aviation Workscope Planning Guide

S1 S2 S3 S4 S5

Rotor LPT Stage Blade Count

1 118
2 124
3 88
4 88
5 98

LPT Rotor
Figure 11-4

GE Proprietary Information 11-5 Workscope Planning Guide

Subject to restrictions on the cover or first page
 CF6-80C2
GE Aviation Workscope Planning Guide

Stage 1
Stage 2
Blade Blade

Shaft
Retainer Disk Seal

Balance
Weight
Seal
Disk

Balance
Weight

Nut

Nut

Bolt
Bolt Retainer

Forward Rotating
Seal

LPT Rotor — Stages 1-2

Figure 11-5

GE Proprietary Information 11-6 Workscope Planning Guide

Subject to restrictions on the cover or first page
 CF6-80C2
GE Aviation Workscope Planning Guide

Stage 5
Stage 4 Blade
Stage 3 Blade
Blade
Retainer
Disk
Retainer
Seal Disk
Balance
Weight
Disk
Shaft
Nut

Nut
Seal
Bolt
Bolt
Nut
Bolt Retainer

Rotating Oil Seal No. 6 Bearing Race

LPT Rotor - Stages 3-5

Figure 11-6

GE Proprietary Information 11-7 Workscope Planning Guide

Subject to restrictions on the cover or first page
 CF6-80C2
GE Aviation Workscope Planning Guide

Turbine Rear Frame

Figure 11-7

GE Proprietary Information 11-8 Workscope Planning Guide

Subject to restrictions on the cover or first page
 CF6-80C2
GE Aviation Workscope Planning Guide

Turbine Rear Frame - D Sump Vent System Configurations

Figure 11-8

GE Proprietary Information 11-9 Workscope Planning Guide

Subject to restrictions on the cover or first page
 CF6-80C2
GE Aviation Workscope Planning Guide

11.1. Performance Effects for LPT Module.

A. For Perfomance Effects, refer to Performance Effects by Module Section of

this manual.

11.2. LPT Module Minimum Workscope.

A. Refer to Figure 11-9.

GE Proprietary Information 11-10 Workscope Planning Guide

Subject to restrictions on the cover or first page
 CF6-80C2
GE Aviation Workscope Planning Guide

LPT and TRF Module Minimum Workscope Process Map

Figure 11-9

GE Proprietary Information 11-11 Workscope Planning Guide

Subject to restrictions on the cover or first page
 CF6-80C2
GE Aviation Workscope Planning Guide

11.3. LPT Module Minimum Workscope Tasks.

A. Refer to Table 11-1 and Figure 11-10.

Table 11-1. LPT Module Minimum Workscope Tasks.

Item Tasks Reference

Key Maintenance Verify compliance to accessible Category 1-3

Tasks - LPT Module Service Bulletins, especially documents found in --
the “Key Recommended Documents” section of
this document.

72-00-04
72-00-56
Perform all relevant inspections. 72-00-57
72-00-58
72-57-10
72-58-12
72-00-56
Clean Flame Arrestor.
72-24-00

CAUTION: The bolts securing the LPT cooling

manifold support brackets to the LPT case are
susceptible to seizure and may shear if torque is
applied to the securing nuts. These “D” headed
bolts install from the inside of the LPT case and
LPT module disassembly is required to replace
them. If necessary, the LPT cooling manifold can
be removed by just removing the
circumferentially oriented bolts that pass through
the manifold plenum.

GE Proprietary Information 11-12 Workscope Planning Guide

Subject to restrictions on the cover or first page
 CF6-80C2
GE Aviation Workscope Planning Guide

LPT and TRF Module Performance Workscope Process Map

Figure 11-10

GE Proprietary Information 11-13 Workscope Planning Guide

Subject to restrictions on the cover or first page
 CF6-80C2
GE Aviation Workscope Planning Guide

Table 11-2. LPT Module Performance Workscope Tasks.

Item Tasks Reference

Key Maintenance Verify compliance to accessible Category 1-3 72-00-00

Tasks - LPT Module Service Bulletins, especially documents found in
the “Key Recommended Documents” section of
this document.

Perform all relevant inspections. 72-56-00

72-58-12

Inspect rotor assembly if not disassembled. 72-00-57

Replace or repair LPT stator airfoils to optimize 72-56-00

performance. Refer to Performance Effects by
Module section of this manual.

Replace or repair LPT rotor airfoils to optimize 72-57-00

performance. Refer to Performance Effects by
Module section of this manual (See Note 2).

Remove and clean TRF oil tubes to remove any 72-58-00

internal oil coke (See Note 1).

Inspect TRF assembly. 72-00-58

Clean Flame Arrestor. 72-00-56

CAUTION: The bolts securing the LPT cooling manifold support brackets to the LPT case are
susceptible to seizure and may shear if torque is applied to the securing nuts.
These “D” headed bolts are installed from the inside of the LPT case and LPT
module disassembly is required to replace them if they are broken. If necessary, the
LPT cooling manifold can be removed by just removing the circumferentially
oriented bolts that pass through the manifold plenum.
NOTES:
1. Performance restoration of the LPT module is optional. However, removal of the oil
supply and scavenge tubes from the TRF is recommended at each core engine
performance restoration or overhaul to prevent oil coke accumulation inside the tubes.
2. Most LPT performance recovery is expected from restoring interstage seal
clearances and LPT stator airfoils. LPT rotor blade airfoil condition does have an
impact on performance; however, the effects are relatively small. Thus, this guide
does not suggest removal of the rotor blades for performance workscope.

11.4. LPT Module Full Overhaul Workscope.

A. Refer to Figure 11-11.

GE Proprietary Information 11-14 Workscope Planning Guide
Subject to restrictions on the cover or first page
 CF6-80C2
GE Aviation Workscope Planning Guide

LPT and TRF Module Full Overhaul Workscope Process Map

Figure 11-11

GE Proprietary Information 11-15 Workscope Planning Guide

Subject to restrictions on the cover or first page
 CF6-80C2
GE Aviation Workscope Planning Guide

11.5. LPT Module Full Overhaul Tasks.

A. Refer to Table 11-3.

Table 11-3. LPT Module Full Overhaul Tasks.

Item Tasks Reference

LPT Stator Assembly Verify compliance to Category 1-6 Service

Bulletins, especially critical reliability items and --
key product improvements. Consider compliance
with applicable Category 7 Service Bulletins.

Perform all relevant inspections. 72-56-00

72-56-03
Refurbish honeycomb interstage seals/shrouds
as required to restore clearances. 72-56-04
72-56-00
Install/assemble interstage seals.
72-00-04

LPT Rotor Assembly Verify compliance to accessible Category 1-6

Service Bulletins, especially critical reliability
items and key product improvements. Consider --
compliance with applicable Category 7 Service
Bulletins.

Perform all relevant inspections. 72-57-00

Discard all bolts and nuts after rotor disassembly. 72-00-04

Turbine Rear Frame Verify compliance to accessible Category 1-6

(TRF) Assembly Service Bulletins, especially critical reliability
items and key product improvements. Consider --
compliance with applicable Category 7 Service
Bulletins.

Inspect TRF assembly. 72-00-58

Remove and clean TRF oil tubes to remove any 72-58-00

internal oil coke.

Inspect number 6 bearing, stationary seal and 72-58-00

bearing housing. Repair or replace as necessary.

GE Proprietary Information 11-16 Workscope Planning Guide

Subject to restrictions on the cover or first page
 CF6-80C2
GE Aviation Workscope Planning Guide

11.6. Critical Items, Reliability and Key Product Improvements, and Best
Practices - LPT Stator Assembly.

NOTE: The following pages highlight current critical items, and a selection of
other key reliability and product improvements, and best practices.
Except for critical items, this list is not all inclusive; therefore, it is
recommended that all Category 1 - 7 Service Bulletins be evaluated for
workscope inclusion. Please refer to the most recent revision of the
cited documents for further information.

A. Priority Levels.

• Priority 1: Critical Item / Safety / AD-Mandated

• Priority 2: Other Important / Reliability item

• Priority 3: Cost of Ownership, Best Practices / Recommended items

11.6.1. LPT Stator Assembly - Priority 1.

A. Refer to Table 11-4, Figure 11-12, and Figure 11-13.

NOTE: Always Use Latest Revision of Listed Documents.

GE Proprietary Information 11-17 Workscope Planning Guide

Subject to restrictions on the cover or first page
 CF6-80C2
GE Aviation Workscope Planning Guide

Table 11-4. LPT Stator Assembly - Priority 1

Recommended
Item Item Description Document(s) Workscope
Level

LPT Case New part release 1. SB 72-1170 (R0, Dec-2007) Full Overhaul
introduced 24 integral
LPT Case New debris deflectors on the “Engine-Spare Parts Release for CF6-
Integral Debris Stops inner diameter of the 80C2 Engines-New LPT Case ”
case. These deflectors Affects LPT Case PN 1647M68G15
are designed to protect
the LPT hardware in the New LPT Case PN 1647M68G18
event of extensive
upstream damage. 2. SB 72-1171 (R2, May-2010)
Provides rework instructions to add
SB introduces rework debris stops to field LPT Cases PNs
instructions to add 1647M68G15/ 1336M99G03
debris stops to field Reworked LPT Case PNs 2083M94G16
hardware. / 2083M94G03

AD mandates either 3. AD 2008-21-11

new part install or field
rework by 2016. Mandates SB 72-1170 and
SB 72-1171
Effective Date 28-Nov-2008
Compliance required by 28-Nov-2016

New Integral Debris Stops - LPT Case

Figure 11-12

GE Proprietary Information 11-18 Workscope Planning Guide

Subject to restrictions on the cover or first page
 CF6-80C2
GE Aviation Workscope Planning Guide

Table 11-4. LPT Stator Assembly - Priority 1. (Cont.)

Recommended
Item Item Description Document(s) Workscope
Level

LPT Shrouds New part release 1. SB 72-1006 (R1, Apr-2001) Full Overhaul
introduced new LPT
LPT Shrouds New shrouds with improved “Engine-LPT Shrouds (72-00-04)-New
Part Design material and geometry. Design of Stage 2-4 Shrouds ”
This redesign is
intended to improve the Stage Old Part # New part #
containment capability
of the LPT module and 2 1862M62G01 2083M12G01
reliability of the engine
on whole. 3 1862M63G01 2083M13G01
4 1862M64G01 2083M14G01
AD mandates new part
install by 2010. 2. AD 2003-02-07
Mandates SB 72-1006
Effective Date Mar-2003
Compliance required by Jul-2010

LPT Overspeed New part release and 1. SB 72-1152 (R0, Nov-2004) Full Overhaul
Protection field rework introduces
new stage 4 and 5 LPT “Engine- Stages 4 and 5 LPT Nozzles (72-
LPT S4/S5 Nozzle nozzles. This redesign 56-02)- New/Reworked Nozzles for
Redesign removes material from Improved Engine Reliability ”
the inner platform of the
nozzle to allow LPT rotor Part Name Part # Qty/Eng
translation in the event
of fan midshaft Nozzle, Stage 4 9367M84P37 19
separation. This
translation would allow Nozzle, Stage 4 9367M84P38 1
the LPT rotor to clash
with the LPT stator Nozzle, Stage 5 9367M85P26 24
acting as a “brake” thus
preventing overspeed.
Note: Recommend complying with SB 72-
Set incorporation is 1153 concurrently (see Table 11-5).
required.

GE Proprietary Information 11-19 Workscope Planning Guide

Subject to restrictions on the cover or first page
 CF6-80C2
GE Aviation Workscope Planning Guide

LPT S4/S4 Nozzle Redesign

Figure 11-13

GE Proprietary Information 11-20 Workscope Planning Guide

Subject to restrictions on the cover or first page
 CF6-80C2
GE Aviation Workscope Planning Guide

11.6.2. LPT Stator Assembly - Priority 2.

NOTE: Always Use Latest Revision of Listed Documents.

A. Refer to Table 11-5, Figure 11-14, and Figure 11-15.

GE Proprietary Information 11-21 Workscope Planning Guide

Subject to restrictions on the cover or first page
 CF6-80C2
GE Aviation Workscope Planning Guide

Table 11-5. LPT Stator Assembly - Priority 2.

Recommended
Item Item Description Document(s) Workscope
Level

LPT Stage 5 Nozzle This field rework allows 1. SB 72-1153 (R0, Oct-2004) Full Overhaul
Improvement the modification of
current field stage 5 LPT “Engine-LPT Stage 5 Nozzles (72-56-02)-
LPT Stage 5 Nozzle nozzles to improve the Overlap Lug Rework for Improved
Rework overlap lug fit up of Assembly ”
adjacent nozzles.
Provides rework instructions for field
part numbers 9367M85P07/08/10/12
This rework addresses and 1327M64G06.
lug cracking that has
been observed with Reworked part incorporates reduced
early model field interference fit previously introduced
hardware. by current production nozzle,
9367M85P13.

LPT Nozzle New part release and 1. SB 72-1222 (R0, Jun-2006) Full Overhaul
field rework introduces
LPT Hollow Airfoil new stage 1 and 2 LPT “Engine-LPT Stator Assembly (72-56-00-
Internal Coating Stator Nozzles with Stage 1 and Stage 2 LPT Nozzles with
internal aluminide Internal Aluminide Coating ”
corrosion protection
coating. This redesign is Releases new and rework part
intended to address numbers for internally coated LPT
internal airfoil cavity Stage 1 and Stage 2 Nozzles.
corrosion and
intergranular oxidation Affects all stage 1 and stage 2 LPT
that has been observed Nozzles.
with previous nozzle
configurations. 2. SB 72-1349 (R0, Oct-2009)
“Engine-LPT Stator Assembly (72-56-00-
These nozzles are piece- New Stage 2 LPT Stator Nozzles With
part interchangeable Internal Coating release ”
but GE strongly
recommends set Introduces new stage 2 LPT stator
incorporation. nozzles with internal corrosion
protection coating.

3. SB 72-1350 (R0, Mar-2010)

“Engine-LPT Stator Assembly (72-56-00-
New Stage 1 LPT Stator Nozzles With
Internal Coating release ”
Introduces new stage 1 LPT stator
nozzles with internal corrosion
protection coating.

GE Proprietary Information 11-22 Workscope Planning Guide

Subject to restrictions on the cover or first page
 CF6-80C2
GE Aviation Workscope Planning Guide

LPT Hollow Airfoil Internal Coating

Figure 11-14

Table 11-5. LPT Stator Assembly - Priority 2. (Cont.)

Recommended
Item Item Description Document(s) Workscope
Level

LPT Stage 3 Nozzle This part release 1. SB 72-1354 (R2, Jan-2011) Full Overhaul
introduces new LPT
LPT Stage 3 Nozzle stage 3 nozzles with “Engine-LPT Stator Assembly (72-56-00)-
Redesign improved material and Introduction of New Stage 3 Nozzle P/N
geometry. Previous 2118M56P01 ”
nozzle designs had an
airfoil excitation mode New part is manufactured with Rene
that can be stimulated 80 material casting and incorporates
by a transient engine an improved airfoil and nozzle support
vibration which can hook geometry.
lead to high leading
edge stresses and
cracks.

GE recommends
operators install the
new stage 3 LPT Nozzles
at the first opportunity.

GE Proprietary Information 11-23 Workscope Planning Guide

Subject to restrictions on the cover or first page
 CF6-80C2
GE Aviation Workscope Planning Guide

LPT Stage 3 Nozzle Redesign

Figure 11-15

Table 11-5. LPT Stator Assembly - Priority 2. (Cont.)

Recommended
Item Item Description Document(s) Workscope
Level

LPT Shrouds New part release and 1. SB 72-1224 (R2, Jun-2009) Full Overhaul
field rework introduces
LPT S1 through S3 redesigned Stage 1 “Engine-LPT Stator Assembly (72-00-56)-
Shrouds through 3 LPT shrouds Stages 1 Through 3 LPT Shrouds with
featuring a. one-piece One-Piece Honeycomb ”
honeycomb
construction. This Stage Old Part # New part #
redesign addresses
transient thermal 1 1862M61G01-04 21862M61G07
stresses induced low
cycle fatigue cracking in 2 1862M62G01-03 2083M12G02
the sheet metal backing
of current two-piece 2 2083M12G01 2092M11G01
honeycomb 3 2083M13G01 2083M13G02
construction.

These shrouds are

piece-part
interchangeable but GE
strongly recommends
set incorporation.

GE Proprietary Information 11-24 Workscope Planning Guide

Subject to restrictions on the cover or first page
 CF6-80C2
GE Aviation Workscope Planning Guide

11.6.3. LPT Stator Assembly - Priority 3.

NOTE: Always Use Latest Revision of Listed Documents.

A. Refer to Table 11-6, Figure 11-16, and Figure 11-17.

Table 11-6. LPT Stator Assembly - Priority 3.

Recommended
Item Item Description Document(s) Workscope
Level

LPT Stator In order to prevent bolt failure 1. ESM (72-56-00) Full Overhaul
and significant engine
LPT Interstage Seals damage, GE recommends the
operators adopt the following
best practices:
2. ESM (72-00-04)
• At Preassembly of the
nozzles, interstage seals,
retainers, bolts, and nuts,
perform a nut run down CAUTION: Incorrect seating of
until nut is sealed. the retainer in the interstage
seal slots of incorrect retainer
• Check for correct nut torque can cause retainer
installation of the retainer release or bolt failure. To help
though the seal slot. assure correct retainer nut
torque wait five minutes after
• Back off nut a quarter turn applying the toque to all nuts
then assemble into the then retorque.
LPT Case.
• Verify correct installation
of the retainer through the
seal slot and torque each
nut to 73-87 lb.in, wait five
minutes and retorque.

GE Proprietary Information 11-25 Workscope Planning Guide

Subject to restrictions on the cover or first page
 CF6-80C2
GE Aviation Workscope Planning Guide

Interstage Seal Retainer Engine Manual Drop Check (Verify Proper Retainer Seating

LPT Interstage Seals - LPT Shrouds

Figure 11-16

Table 11-6. LPT Stator Assembly - Priority 3. (Cont.)

Recommended
Item Item Description Document(s) Workscope
Level

LPT Cooling Manifold Prevent shearing of D-head 1. ESM (72-00-04) Minimum or

Removal mounting bolts during Full Overhaul
manifold removal… if D-head
bolt is sheared, module Remove LPT manifold by removing
disassembly is required. nuts that fasten the manifold to the
manifold support bracket.

CAUTION: When removing the

LPT cooling manifold, do not
attempt to remove the nut
holding the manifold support
bracket to the LPT case. The nut
is susceptible to seizing, which
can result in the D-head
mounting bolt shearing if torque
is applied.

GE Proprietary Information 11-26 Workscope Planning Guide

Subject to restrictions on the cover or first page
 CF6-80C2
GE Aviation Workscope Planning Guide

th
7 stage duct support links
must be removed for LPT
Removing nut from this cooling manifold removal
bolt allows removal of the
LPT cooling manifold from
the mounting brackets Caution: Do not attempt to
remove nut from this location
(D-head bolt sheared)

NOTE: Forward LPT

cooling manifold
support bracket
shown, but applies to
the aft bracket also

D-head bolt installed from

inside of LPT case… if bolt is
sheared, LPT disassembly is
required to replaced bolt

LPT Cooling Manifold Removal

Figure 11-17

GE Proprietary Information 11-27 Workscope Planning Guide

Subject to restrictions on the cover or first page
 CF6-80C2
GE Aviation Workscope Planning Guide

11.7. Critical Items, Reliability and Key Product Improvements, and Best
Practices - LPT Rotor Assembly.

NOTE: The following pages highlight current critical items, and a selection of
other key reliability and product improvements, and best practices.
Except for critical items, this list is not all inclusive; therefore, it is
recommended that all Category 1 - 7 Service Bulletins be evaluated for
workscope consideration. Please refer to the most recent revision of
the cited documents for further information.

A. Priority Levels.

• Priority 1: Critical Item / Safety / AD-Mandated

• Priority 2: Other Important / Reliability item

• Priority 3: Cost of Ownership, Best Practices / Recommended items

11.7.1. LPT Rotor Assembly - Priority 1.

NOTE: No Priority 1 items for the LPT Rotor Assembly at this time.

11.7.2. LPT Rotor Assembly - Priority 2.

NOTE: Always Use Latest Revision of Listed Documents.

A. Refer to Table 11-17 and Figure 11-18.

GE Proprietary Information 11-28 Workscope Planning Guide

Subject to restrictions on the cover or first page
 CF6-80C2
GE Aviation Workscope Planning Guide

Table 11-7. LPT Rotor Assembly - Priority 2.

Recommended
Item Item Description Document(s) Workscope
Level

LPT Blades This field rework allows the 1. SB 72-1446 (R0, Jan-2013) Full Overhaul
modification of current fielded
LPT S4 Blades stage 4 LPT blades to improve
the aft mating face tip shroud
clearance with adjacent LPT Rotor Assembly (72-57-00) –
blades. Rework of LPT Stage 4 Blades.

The rework increases the Provides rework instructions for field

clearance between the blade part number 9373M34P04 into
tip shrouds to prevent current production part number
potential binding during 9373M34P05.
operation. Tip shroud binding
can lead to high stress in the
blades and possible blade
airfoil cracking and liberation
of the blade tip.

LPT Cooling Manifold Removal

Figure 11-18

11.7.3. LPT Rotor Assembly - Priority 3.

NOTE: Always Use Latest Revision of Listed Documents.

A. Refer to Table 11-8 and Figure 11-19.

GE Proprietary Information 11-29 Workscope Planning Guide

Subject to restrictions on the cover or first page
 CF6-80C2
GE Aviation Workscope Planning Guide

Table 11-8. LPT Rotor Assembly - Priority 3.

Recommended
Item Item Description Document(s) Workscope
Level

LPT Blades Fleet experience has 1. CMM (73-10-41) Minimum

indicated that
LPT Stage 5 Blades plugged/restricted flow
fuel nozzles can lead to The area of greatest risk is the Stage 5
LPT vibration. This blades with a mission hour to cycle
vibration can initiate ration of less than 3:1.
cracks that can
potentially lead to airfoil GE recommends that operators
liberation. inspect, clean and flow check fuel
nozzles per CMM (73-10-41) every 2000
cycles.

Initiation area on stage 5 LPT

blade fractures associated
with coked / poorly flowing
fuel nozzles

LPT Stage 5 Blades

Figure 11-19

GE Proprietary Information 11-30 Workscope Planning Guide

Subject to restrictions on the cover or first page
 CF6-80C2
GE Aviation Workscope Planning Guide

11.8. Critical Items, Reliability and Key Product Improvements, and Best
Practices - Turbine Rear Frame (TRF) Assembly.

NOTE: The following pages highlight current critical items, and a selection of
other key reliability and product improvements, and best practices.
Except for critical items, this list is not all inclusive; therefore, it is
recommended that all Category 1 - 7 Service Bulletins be evaluated for
workscope consideration. Please refer to the most recent revision of
the cited documents for further information.

A. Priority Levels.

• Priority 1: Critical Item / Safety / AD-Mandated

• Priority 2: Other Important / Reliability item

• Priority 3: Cost of Ownership, Best Practices / Recommended items

11.8.1. Turbine Rear Frame (TRF) Assembly - Priority 1.

NOTE: Always Use Latest Revision of Listed Documents.

A. Refer to Table 11-9 and Figure 11-20.

GE Proprietary Information 11-31 Workscope Planning Guide

Subject to restrictions on the cover or first page
 CF6-80C2
GE Aviation Workscope Planning Guide

Table 11-9. Turbine Rear Frame (TRF) Assembly - Priority 1

Recommended
Item Item Description Document(s) Workscope
Level

LPT Turbine Rear This AD mandated 1. SB 72-0989 (R1, Apr-2001) Full Overhaul
Frame bulletin provides
instructions for repeat “Engine-Aft Engine Mount (71-20-00)- Link
TRF Aft Engine Mount visual inspections to Design Improvement”
(MD-11, A300, A310 detect cracked or
applications only) separated links and/or Releases new links with improved
migrated bearing races. geometrical design to increase durability.

These inspections are 2. SB 72-0964 (R0, Oct-2009)

required every 400 flight
cycles and are intended “Engine-Aft Engine Mount (71-20-00)-
to address observed Links-Visual Inspections”
hardware failure in field.
Provides instructions for an on-wing
repetitive visual inspection of the left and
Alternatively, operators right aft engine mount link assemblies
can elect to replace the and all lings stocked as spares.
link assemblies with
new, more durable 3. AD 2000-12-08
hardware.
Mandates SB 72-0964 or alternatively SB
72-0989

GE Proprietary Information 11-32 Workscope Planning Guide

Subject to restrictions on the cover or first page
 CF6-80C2
GE Aviation Workscope Planning Guide

Right Hand Link Assembly

Aft Mount Lower Beam

Left Hand Link

Assembly

TRF Aft Engine Mount (MD-11, A300, A310 applications only)

Figure 11-20

GE Proprietary Information 11-33 Workscope Planning Guide

Subject to restrictions on the cover or first page
 CF6-80C2
GE Aviation Workscope Planning Guide

11.8.2. Turbine Rear Frame (TRF) Assembly - Priority 2.

NOTE: Always Use Latest Revision of Listed Documents.

A. Refer to Table 11-10 and Figure 11-21.

Table 11-10. Turbine Rear Frame (TRF) Assembly - Priority 2.

Recommended
Item Item Description Document(s) Workscope
Level

LPT Turbine Rear New part release 1. SB 72-1259 (R1, Nov-2007) Full Overhaul
Frame introduces redesigned
TRF oil supply tube with “Engine-Turbine Rear Frame Assembly
Turbine Rear Frame improved spiral wire (72-58-00)-Oil Supply Tube
(TRF) Oil Supply Tube and internal spacers. Improvement ”
This redesign is The turbine rear frame (TRF) assemblies
intended to prevent 9381M69G16/G17/G19 through
chafing that has been G29/G31/G34/G39/G40/G44/G48/G49/G50 and
observed between the the oil supply tube (TRF oil supply tube)
oil supply tube and the 1754M69G01 or oil tube (TRF oil supply tube)
outer heat shield,
1754M73G01 are affected by this Service
Bulletin.
This release also
includes instructions to This Service Bulletin releases TRF oil supply tube
center the tube within 2285M64G01 or 2285M80G01, depending on
the strut cavity, the TRF configuration. New production engines
with the new tube have re-identified the TRF
assembly as 9381M69G51.

GE Proprietary Information 11-34 Workscope Planning Guide

Subject to restrictions on the cover or first page
 CF6-80C2
GE Aviation Workscope Planning Guide

Turbine Rear Frame (TRF) Oil Supply Tube

Figure 11-21

11.8.3. Turbine Rear Frame (TRF) Assembly - Priority 3.

NOTE: No Priority 3 items for the Turbine Rear Frame Assembly at this time.

GE Proprietary Information 11-35 Workscope Planning Guide

Subject to restrictions on the cover or first page
 CF6-80C2
GE Aviation Workscope Planning Guide

SECTION 12

Accessory Drives Module

The following pages outline the relevant tasks for performing Accessory Drive module
workscope planning and maintenance. The objectives of the information contained
within this guide are to communicate the extent of work to enable the user of the
guide to achieve their engine durability, performance and maintenance cost goals
while maintaining high standards of engine reliability. The recommendations
contained herein are based on an average engine in the fleet. However, there are
many variable factors that can affect the specific workscope definition for a given
operator or engine.

GE Proprietary Information 12-1 Workscope Planning Guide

Subject to restrictions on the cover or first page
 CF6-80C2
GE Aviation Workscope Planning Guide

12.0. Accessory Drives Module.

A. Refer to Figure 12-1 thru Figure 12-5.

Horizontal
Drive Shaft AGB Assembly
Housing

Accessory Drives Module Cross Sections

Figure 12-1

GE Proprietary Information 12-2 Workscope Planning Guide

Subject to restrictions on the cover or first page
 CF6-80C2
GE Aviation Workscope Planning Guide

Pad No. 3
Hydraulic Pump

HMU
Fuel Control
(Pad No. 7)

Motoring Pad
(Pad No. 7)

Pad No. 1 (Blank)

Control Alternator
(Pad No. 9)

Accessory Gearbox Assembly (AGB)

Figure 12-2 (Sheet 1 of 2)

GE Proprietary Information 12-3 Workscope Planning Guide

Subject to restrictions on the cover or first page
 CF6-80C2
GE Aviation Workscope Planning Guide

Accessory Gearbox Assembly (AGB)

Figure 12-2 (Sheet 2 of 2)

GE Proprietary Information 12-4 Workscope Planning Guide

Subject to restrictions on the cover or first page
 CF6-80C2
GE Aviation Workscope Planning Guide

Inlet Gearbox Assembly (IGB)

Figure 12-3

GE Proprietary Information 12-5 Workscope Planning Guide

Subject to restrictions on the cover or first page
 CF6-80C2
GE Aviation Workscope Planning Guide

Transfer Gearbox Assembly (TGB)

Figure 12-4

GE Proprietary Information 12-6 Workscope Planning Guide

Subject to restrictions on the cover or first page
 CF6-80C2
GE Aviation Workscope Planning Guide

Horizontal Drive Shaft Assembly

Figure 12-5

GE Proprietary Information 12-7 Workscope Planning Guide

Subject to restrictions on the cover or first page
 CF6-80C2
GE Aviation Workscope Planning Guide

12.1. Accessory Drives Module Minimum Workscope.

A. Refer to Figure 12-6 and Table 12-1.

Process Map - Accessory Drives Module Minimum Workscope

Figure 12-6

GE Proprietary Information 12-8 Workscope Planning Guide

Subject to restrictions on the cover or first page
 CF6-80C2
GE Aviation Workscope Planning Guide

Table 12-1. Accessory Drives Module Minimum Workscope Tasks.

Item Tasks Reference

Accessory Drives Verify compliance to accessible Category 1-3

Module Service Bulletins, especially documents found --
in the “Key Recommended Documents”
section of this document.

72-00-05
72-32-11
Perform inspections in accordance with
referenced ESM tasks and subtasks. 72-65-10
72-00-05

Pressure test AGB 72-65-00

12.2. Accessory Drives Module Performance Workscope.

A. Refer to Figure 12-7 and Table 12-2

Process Map - Accessory Drives Module Performance Workscope

Figure 12-7
GE Proprietary Information 12-9 Workscope Planning Guide
Subject to restrictions on the cover or first page
 CF6-80C2
GE Aviation Workscope Planning Guide

Table 12-2. Accessory Drives Module Performance Workscope Tasks.

Item Tasks Reference

Accessory Drives Do all minimum workscope tasks (Reference 72-00-00

Module Table 12-1)

Remove and Refurbish Accessory Gearbox 72-65-03

Carbon Seals.

12.3. Accessory Drives Module Full Overhaul Workscope.

A. Refer to Figure 12-8 and Table 12-3.

D is a s s e m b le a n d In s p e c t p e r E n g in e M a n u a l
7 2 - 6 1 -0 0 /7 2 - 6 2 -0 0 /7 2 - 6 3 -0 0 /7 2 - 6 4 - 0 0 /7 2 - 6 5 - 0 0

P e r fo r m M in im u m W o r k s c o p e T a s k s

C le a n a n d In s p e c t L u b e N o z z le s p e r
E n g in e M a n u a l 7 2 -0 9 - 0 2

R e a s s e m b le M o d u le

Process Map - Accessory Drives Full Overhaul Workscope

Figure 12-8

GE Proprietary Information 12-10 Workscope Planning Guide

Subject to restrictions on the cover or first page
 CF6-80C2
GE Aviation Workscope Planning Guide

Table 12-3. Accessory Drives Module Full Overhaul Workscope Tasks

Item Tasks Reference

Accessory Drives Verify compliance to accessible Category 1-6

Module Service Bulletins, especially documents found --
in the “Key Recommended Documents”
section of this document as applicable.

72-09-02
72-61-00
72-62-00
Perform inspections in accordance with
referenced ESM tasks and subtasks. 72-63-00
72-64-00
72-65-00

Pressure check AGB 72-65-00

12.4. Critical Items, Reliability and Key Product Improvements, and Best Practices -
Accessory Drives Module.

NOTE: The following pages highlight current critical items, and a selection of other key
reliability and product improvements, and best practices. Except for critical
items, this list is not all inclusive; therefore, it is recommended that all Category
1 — 7 Service Bulletins be evaluated for workscope inclusion. Please refer to the
most recent revision of the cited documents for further information.

A. Priority Levels.

• Priority 1: Critical Item / Safety / AD-Mandated

• Priority 2: Other Important / Reliability item

• Priority 3: Cost of Ownership, Best Practices / Recommended items

12.4.1. Accessory Drives Module - Priority 1.

NOTE: No Priority 1 items for the Accessory Drives Module at this time.

GE Proprietary Information 12-11 Workscope Planning Guide

Subject to restrictions on the cover or first page
 CF6-80C2
GE Aviation Workscope Planning Guide

12.4.2. Accessory Drives Module - Priority 2.

A. Refer to Table 12-4, Figure 12-9, and Figure 12-10.

NOTE: Always Use Latest Revision of Listed Documents.

Table 12-4. Accessory Drives Module - Priority 2.

Recommended
Item Item Description Document(s)
Workscope Level
CAD Population 1: 1. SB 72-1370 (R01, Nov-2010)
Control CAD cleaning and “ACCESSORY GEARBOX (72-65-00)- Any Shop Visit
bearing replacement CONTROL ALTERNATOR DRIVE
Alternator RELIABILITY, GEARSHAFT
Drive (CAD) for suspect units at
shop visit. Early Gen IV CLEANING, AND BEARING
CAD released March REPLACEMENT CAD”
Hard Particle ’07 (SB 72-1260) (80C2) Bearing replacement and CAD cleaning
Contamination had hard particle at shop. Complying with SB 72-1370
and Over-Torque contamination from terminates the need for inspection
manufacturing required by CF6-80C2 SB 72-1357.
process.
MCD debris are to be
sent to GE Aviation for 2. SB 72-1357 (R01, Nov-2010)
“ACCESSORY GEARBOX (72-65-00)-
analysis. The CONTROL ALTERNATOR DRIVE
inspection is required On-Wing at
RELIABILITY ASSURANCE
until suspect CAD kit is INSPECTION PROGRAM” Intervals
removed and replaced Defined in SB
with one not affected This Service Bulletin provides
by SB 72-1260. instructions to remove, collect, and
inspect all master chip detector (MCD)
debris.

CAD Population 2: 3. SB 72-1435 (R01, Feb-2013)

"ACCESSORY GEARBOX (72-65-00)- Any Shop Visit
CAD Cleaning and CF6-80C2 CONTROL ALTERNATOR
bearing replacement DRIVE RELIABILITY" or On-wing By
for suspect units prior October 2013
to Oct 2013 This service bulletin provides
instructions to remove the control
CADs manufactured
between Oct 2009 alternator drive unit and send to
and March 2012 have approved source for cleaning and
possibility of hard bearing replacement.
particle
contamination from
Manufacturing
process as well as
possible over torque
condition of the CAD
spanner nut.

GE Proprietary Information 12-12 Workscope Planning Guide

Subject to restrictions on the cover or first page
 CF6-80C2
GE Aviation Workscope Planning Guide

Control Alternator Drive Shaft

Oil Path for Bearings

Control Alternator Drive (CAD)

Figure 12-9

Table 12-4. Accessory Drives Module - Priority 2. (Cont.)

Recommended
Item Item Description Document(s)
Workscope Level

Control Introduces improved Any SV

design for the control SB 72-1260 (R3, May-2010)
Alternator
Assembly alternator drive to
production and field “ENGINE- Accessory Gearbox (72-65-00)-
engines. Introduction of Low Vibration Control
Improved Alternator Drive”
control Previous CAD
alternator kit Introduces new, low-vibration control
assemblies generated alternator drive P/N 683L350G03 to replace
a high amount of old P/N 683L350G01.
vibration causing
accelerated wear and New parts introduced on ESN’s 705312 and
fatigue to surrounding up and 706800 and up.
hardware.
This change improves
the reliability and
maintainability of the
unit and surrounding
hardware by reducing
vibrational output of
the drive.

GE Proprietary Information 12-13 Workscope Planning Guide

Subject to restrictions on the cover or first page
 CF6-80C2
GE Aviation Workscope Planning Guide

Control Alternator
Figure 12-10

GE Proprietary Information 12-14 Workscope Planning Guide

Subject to restrictions on the cover or first page
 CF6-80C2
GE Aviation Workscope Planning Guide

12.4.3. Accessory Drives Module - Priority 3.

NOTE: No Priority 3 items for the Accessory Drives Module at this time.

GE Proprietary Information 12-15 Workscope Planning Guide

Subject to restrictions on the cover or first page
 CF6-80C2
GE Aviation Workscope Planning Guide

SECTION 13

Configurations Module

The following pages outline the relevant tasks for performing configurations
module workscope planning and maintenance. The objectives of the information
contained within this guide are to communicate the extent of work to enable the
user of the guide to achieve their engine durability, performance and
maintenance cost goals while maintaining high standards of engine reliability.
The recommendations contained herein are based on an average engine in the
fleet. But, there are many variable factors that can affect the specific workscope
definition for a given operator or engine.

GE Proprietary Information 13-1 Workscope Planning Guide

Subject to restrictions on the cover or first page
 CF6-80C2
GE Aviation Workscope Planning Guide

13.0. Configurations Module Assembly.

A. Refer to Figure 13-1.

Engine Right Side

Engine Left Side

Configurations Module Assembly

Figure 13-1

GE Proprietary Information 13-2 Workscope Planning Guide

Subject to restrictions on the cover or first page
 CF6-80C2
GE Aviation Workscope Planning Guide

13.1. Configurations Minimum Workscope.

A. Refer to Table 13-1, Figure 13-2, and Figure 13-3.

No Hardware Yes
Removed from
Engine?

Visually Inspect No Hardware

Hardware per Engine Full Overhaul Workscope Stays with
Manual 72-09-03 Engine?

Yes
Visually Inspect
Hardware per Engine
Manual 72-09-03

Check and Comply

with Critical Items
(Priorities 1 and 2)

Hold for engine assembly

Process Map - Configurations Minimum Workscope

Figure 13-2

GE Proprietary Information 13-3 Workscope Planning Guide

Subject to restrictions on the cover or first page
 CF6-80C2
GE Aviation Workscope Planning Guide

Table 13-1. Configurations Module Minimum Workscope - Key Maintenance Tasks.

Item Tasks Reference

Configurations Verify compliance to accessible Category 1-6

Service Bulletins, especially documents --
found in the “Key Recommended
Documents” section of this document.

Perform all inspections and identified in 72-09-03

referenced manual tasks and subtasks of
72-09-03.

GE Proprietary Information 13-4 Workscope Planning Guide

Subject to restrictions on the cover or first page
 CF6-80C2
GE Aviation Workscope Planning Guide

Remove Hardware
from Engine

Visually Inspect
Hardware per Engine
Manual 72-09-03/04

Replace or Repair
As Required
Manual 72-09-03/04

Check and Comply

with Critical Items
(Priorities 1 and 2)

Follow Best Practices

(Priority 3)

Comply with All Category

1 - 6 Service Bulletins.
Consider Compliance
with Category 7
Service Bulletins

Hold for engine assembly

Process Map - Configurations Module Full Overhaul Workscope

Figure 13-3.

GE Proprietary Information 13-5 Workscope Planning Guide

Subject to restrictions on the cover or first page
 CF6-80C2
GE Aviation Workscope Planning Guide

13.2. Configurations Module Full Overhaul Workscope.

A. Refer to Table 13-2.

Table 13-2. Configurations Module Minimum Workscope - Key Maintenance Tasks.

Item Tasks Reference

Configurations Verify compliance to accessible with Critical

Items (Priorities 1 and 2). Refer to “Key --
Recommended Documents” section of this
document.

Comply with all other Categories 1 – 6

Service Bulletins. Consider compliance of all --
Category 7 Service Bulletins.

Perform all inspections and identified in 72-09-03/04

referenced manual tasks and subtasks of
72-09-03 and 72-09-04.

13.3. Critical Items, Reliability and Key Product Improvements, and Best Practices -
Configurations Module.

NOTE: The following pages highlight current critical items, and a selection of other key
reliability and product improvements, and best practices. Except for critical items,
this list is not all inclusive; thus, it is recommended that all Category 1 — 7
Service Bulletins be evaluated for workscope inclusion. Please refer to the most
recent revision of the cited documents for further information.

A. Priority Levels.

• Priority 1: Critical Item / Safety / AD-Mandated

• Priority 2: Reliability items

• Priority 3: Cost of Ownership, Best Practices / Recommended items

GE Proprietary Information 13-6 Workscope Planning Guide

Subject to restrictions on the cover or first page
 CF6-80C2
GE Aviation Workscope Planning Guide

13.3.1. Configurations Module - Priority 1.

NOTE: Always use latest revision of listed documents.

A. Refer to Table 13-3 and Figure 13-4 thru Figure 13-9.

Table 13-3. Configurations Module - Priority 1.

Recommended
Item Item Description Document(s)
Workscope Level

Configurations Module Service Bulletin 73-0326 defines 1. SB 73-0326 (R4, Dec-2009) Repetitive at every
Fuel Manifold P-Clamp repetitive replacement of the main fuel “FUEL AND CONTROL 7,500 flight hours
Chafing manifold p-clamps and inspection of (72-00-02) - FUEL MANIFOLD
the manifold for chafing from the INSPECTION AND CLAMP
clamps. REPLACEMENT”

Chafing from p-clamps can result in

uncontained a fuel leak from the
manifold and potential for undercowl
fire.
Repetitive at every
AD 2009-05-02 Mandates repetitive 2. AD 2009-05-02 Mandates 7,500 flight hours
inspection and P-clamp replacement repetitive inspection and
per SB 73-0326. P-clamp replacement per
SB 73-0326
At each shop visit
Service Bulletin 73-0365 defines 3. SB 73-0365 (R4, Dec-2009) for post-
installation of PTFE tape onto the fuel "CORE ENGINE MODULE SB 73-0253
manifold at the p-clamp locations. (72-00-00) - FUEL MANIFOLD manifolds
PTFE tape prevents debris from PTFE TAPE INSTALLATION Customer option
gathering under the clamps and for pre SB 73-0253
prevents chafing. It also improves the manifolds
vibratory response characteristics of
the fuel manifold.
Service Bulletin 73-0371 introduces a 4. 73-0371 ( Aug-2011) Next shop visit
new fuel manifold design that "ENGINE FUEL AND
eliminates wear mechanism of CONTROL - FUEL SYSTEM
previous design, reduces weight, and (73-00-00) - INTRODUCTION
simplifies manifold maintainability. OF NEW FUEL MANIFOLD
Compliance with SB 73-0371 SYSTEM"
terminates requirements of
AD 2009-05-02.

GE Proprietary Information 13-7 Workscope Planning Guide

Subject to restrictions on the cover or first page
 CF6-80C2
GE Aviation Workscope Planning Guide

Cushion
“P-Clamp”
(24 locations)

Manifold chafing from contact

with exposed metal band of
P-clamp

P-Clamp with worn cushion

Compressor Rear Frame material revealing metal band

Post Service Bulletin 73-0253 Fuel Manifold Chafing From Worn Cushion “P-Clamp”
Figure 13-4

Fuel Manifold Aft Looking Forward

PTFE Tape at Each P-Clamp
(24 Locations)

Fuel Manifold with PTFE Tape

Wrap

Post Service Bulletin 73-0365 Fuel Manifold - Application of PTFE Tape

Figure 13-5

GE Proprietary Information 13-8 Workscope Planning Guide

Subject to restrictions on the cover or first page
 CF6-80C2
GE Aviation Workscope Planning Guide

Post Service Bulletin 73-0253 Post Service Bulletin 73-0371

Drainless Fuel Manifold Improved Design Drainless Fuel Manifold

Service Bulletin 73-0371 - Redesigned Fuel Manifold System

Figure 13-6

Table 13-3. Configurations Module - Priority 1. (Cont.)

Recommended
Item Item Description Document(s)
Workscope Level

Configurations Module This bulletin introduces a new SB 73-0337 Any SV

snap ring that improves retention (R3, Feb-2007) "ENGINE
Fuel Manifold Shroud of fuel manifold feeder tube in FUEL AND CONTROL -
Retention event of a severed tube. FUEL NOZZLES TO FUEL
MANIFOLDS (72-00-02) -
This change will prevent the fuel NEW SNAP RINGS”
manifold feeder tube from being
pushed out of the fuel manifold Old Part #: J204P0084
fuel containment shroud if the
feeder tube becomes severed. New part #: 2186M12P01
This will prevent the potential for
an uncontained fuel leak that can 1. AD 2007-11-20 Requires
cause an undercowl fire under incorporation of the snap
certain circumstances. ring at next shop visit for
drainless manifolds.

GE Proprietary Information 13-9 Workscope Planning Guide

Subject to restrictions on the cover or first page
 CF6-80C2
GE Aviation Workscope Planning Guide

Snap Ring
Groove
Snap Ring

O-Ring
Fitting

Fuel
Manifold

Fuel Shroud

Pre-Service Bulletin 73-0337 Design Post-Service Bulletin 73-0337 Design – Retaining

– Retaining Ring Pushed Out of Ring Replaced by More Rigid Snap Ring Will
Groove Allowing Fuel Manifold Retain Fuel Manifold Feeder Tube in the Fuel
Feeder Tube to Pushed Out of Fuel Containment Shroud
Containment Shroud

Fuel Manifold Shroud Retention - Configurations Module

Figure 13-7

Table 13-3. Configurations Module - Priority 1. (Cont.)

Recommended
Item Item Description Document(s)
Workscope Level

Configurations Module This bulletin introduces an 1. SB 73-0242 (R2, Apr-2013) Next SV

improved IDG cooler support "ENGINE FUEL AND
Improved IDG Cooler bracket with integral spray shield. CONTROL - (73-00-00) -
Support Bracket and It replaces a 2 piece design which SPRAY SHIELDS AND
Spray Shields. is prone to assembly error of the SUPPORT BRACKET -
fuel tube connection at line IMPROVEMENT
maintenance. This assembly error
has led to large fuel leaks and at Old Part #: 1321M88P001A
least 2 significant undercowl fires
as a result. The new design New part #: 2021M83G01
prevents assembly error.
2. AD 2013-08-20
Requires installation of the
improved bracket at next
shop visit, or on-wing if the
subject fuel tubes are
disconnected.

GE Proprietary Information 13-10 Workscope Planning Guide

Subject to restrictions on the cover or first page
 CF6-80C2
GE Aviation Workscope Planning Guide

Spray shield incorrectly installed under Spray shield correctly installed over IDG bracket
IDG bracket

Pre-Service Bulletin 73-0242 - Old Design Maintenance Error Example

Figure 13-8

Aft Spray Forward Larger Aft Forward

Shield Spray Shield
2-Piece Bracket 1-Piece Bracket
and Spray Shield Spray Shield

Pre-Service Bulletin 73-0242 Design Post-Service Bulletin 73-0242 Design

2-Piece Bracket and Spray Shield 1-Piece Integral Bracket and Spray Shield

Improved IDG Cooler Support Bracket and Spray Shields - Configurations Module
Figure 13-9

GE Proprietary Information 13-11 Workscope Planning Guide

Subject to restrictions on the cover or first page
 CF6-80C2
GE Aviation Workscope Planning Guide

13.3.2. Configurations Module – Priority 2.

NOTE: Always use latest revision of listed documents.

A. Refer to Table 13-4, Figure 13-10, and Figure 13-11.

Table 13-4. Configurations Module — Priority 2.

Recommended
Item Item Description Document(s)
Workscope Level

Configurations Module This bulletin introduces 1. SB 79-0086 (R3, Jun-2011) Next SV

improved oil pressure tube to “OIL – ACCESSORY DRIVE
Improved Oil Pressure eliminate system mis- MODULE (72-00-05) –
Tube System assembly and cracking that REWORK AND
causes oil loss in flight. REPLACEMENT OF THE OIL
Cracked oil pressure tubes PRESSURE TRANSMITTER
have led to numerous in-flight SYSTEM HARDWARE”
shutdown events due to
engine oil depletion.

Clamps Left Off During

Maintenance or Broken
Due to Vibration
Integral
Tabs

Crack
Locations

Pre-Service Bulletin 79-0086 Design – Post-Service Bulletin 79-0086 Design –

Tube Cracked When Support Clamps Support Clamps Replaced By Integral
Were Left Off During Maintenance or Tabs. Tubing System Simplified For
When Clamps Were Broken Due to Better Maintainability
Vibration

Improved Oil Pressure Tube System — Configurations Module

Figure 13-10

GE Proprietary Information 13-12 Workscope Planning Guide

Subject to restrictions on the cover or first page
 CF6-80C2
GE Aviation Workscope Planning Guide

Table 13-4. Configurations Module — Priority 2. (Cont.)

Recommended
Item Item Description Document(s) Workscope Level

Configurations Module Block clamps have been found loose 1. Engine Shop Manual Each SV
resulting in wear thru the fuel 72-09-03 Inspection
Fuel Manifold Chafing manifold feeder tube epoxy wear
from Block Clamp. sleeve causing metal to metal
chafing between the clamp/feeder
tube (One fuel leak reported).
Make sure that block clamp is 2. Engine Shop Manual
inspected for looseness and repair 72-09-03 Repair 11 –
manifold epoxy wear sleeve. Repair of the Epoxy
Wear Sleeves
Replace worn or loose fitting block
clamps.
If wear is found on-wing, wrap 3. GE Standard Practices
manifold feeder tube with 4-5 wraps Manual C10-225 –
of Para-Aramid Tape assures a snug Application of Para-
fit between the clamp and the Aramid Tape
feeder tube.

Epoxy Wear
Sleeve Worn Away
and Tube Chafed
Through

Epoxy Wear
Sleeve

Worn Block
Clamp

Block Clamp
Locations

Block Clamp

Fuel Manifold Chafing From Block Clamp — Configurations Module

Figure 13-11

GE Proprietary Information 13-13 Workscope Planning Guide

Subject to restrictions on the cover or first page
 CF6-80C2
GE Aviation Workscope Planning Guide

Table 13-4. Configurations Module - Priority 2 (cont.).

Recommended
Item Item Description Document(s) Workscope Level
Ps3 Air Tube Service Bulletin introducing an SB 75-0197 (R2, Jul-2005) Any SV
Chafing improved air tube and
mounting bracket. “NEW PS3 AIR TUBE AND CLAMPING
Improved Ps3 IMPROVEMENT”
Tube and Pre-Service bulletin 75-0197
Mounting tubing system is susceptible to Introduces new Ps3 air tube and
Hardware cushion clamp failure and tube bracket will reduce the vibratory
chafing due to vibration. Tube stress at the clamping location.
chafing can lead to engine
control malfunction.

Improved Ps3 Tube System.

Figure 13-12

GE Proprietary Information 13-14 Workscope Planning Guide

Subject to restrictions on the cover or first page
 CF6-80C2
GE Aviation Workscope Planning Guide

Table 13-5. Configurations Module — Priority 2.

Historical Priority 2 Control and Accessory Related Items for Reference Reference

Incorporate twin pipe 11th stage air tube design on FADEC engines, Previous (Y-duct) design is SB 75-0156
prone to cracking and potential hot air leak due to duct rupture and high undercowl
temperatures. SB 75-0200

Incorporate improved HP recoup tube support brackets. Cracking and rupture of right side HP SB 75-0167 (FADEC)
recoup air tube have caused high undercowl temperatures.
SB 75-0168 (PMC)

13.3.3. Configurations Module – Priority 3.

NOTE: Always Use Latest Revision of Listed Documents.

A. Refer to Table 13-6 and Figure 13-13 thru Figure 13-15.

Table 13-6. Configurations Module - Priority 3.

Recommended
Item Item Description Document(s)
Workscope Level

Configurations Module Improper handling of fuel hoses 1. GE Standard Practices Each SV

can result in hose damage that Manual (SPM) for proper
Proper Handling of can lead to a ruptured hose during handling
Fuel Hoses operation and large under-cowl • No hose must be bent
fuel leak. to avoid possible
damage to Teflon
Avoid improper handling of hoses liners
by following procedures in the GE
Standard Practices Manual. • Kinked hoses must not
be used
• Do not twist or stretch
hose during
installation
• Never over-tighten
connectors
2. FAA SAIB NE-06-67
• Advises to ensure
hoses do not get over
bent or kinked

GE Proprietary Information 13-15 Workscope Planning Guide

Subject to restrictions on the cover or first page
 CF6-80C2
GE Aviation Workscope Planning Guide

Ruptured fuel hose originated from a “kink” that was induced into the hose during
improper handling during installation – hose was over-bent when installed

Proper Handling of Fuel Hoses - Configurations Module

Figure 13-13

Table 13-6. Configurations Module - Priority 3. (Cont.)

Recommended
Item Item Description Document(s)
Workscope Level

Configurations Bolts, nuts or inserts with damaged 1. Engine Shop Manual

Module threads require an increased running Each SV or
72-09-03 ENGINE Disassembly and
torque during assembly to overcome the HARDWARE -
Reuse of Fasteners added friction from the damaged threads. INSPECTION/CHECK Reassembly of
This results in a false final torque value, Fasteners.
and a low clamp load on the bolted joint.
A low clamp load on the bolted joint will
prevent proper squeeze of the gasket 2. Engine Shop Manual
seal. A post-maintenance leak check can 72-09-04 ENGINE
not detect an under-torqued joint HARDWARE -
condition, but over time the seal can wear INSPECTION/CHECK
and eventually leak.
It is very important to visually inspect
fastener threads before to re-use. If
damaged threads are observed, replace
the damaged bolt, nut or insert.

GE Proprietary Information 13-16 Workscope Planning Guide

Subject to restrictions on the cover or first page
 CF6-80C2
GE Aviation Workscope Planning Guide

Damaged Bolt Threads

Damaged Flange
Insert Threads Fuel Leak From 4-Bolt Tube Flange Resulted in Under-Cowl
Fire. Root Cause Was Insufficient Clamping of Flange Due to
Damaged Bolt and Insert Threads

Reuse of Fasteners - Configurations Module

Figure 13-14

GE Proprietary Information 13-17 Workscope Planning Guide

Subject to restrictions on the cover or first page
 CF6-80C2
GE Aviation Workscope Planning Guide

Table 13-6. Configurations Module - Priority 3. (Cont.)

Recommended
Item Item Description Document(s)
Workscope Level

Configurations Loop clamps must be properly 1. Engine Shop Manual Each SV or

Module installed to provide proper tube 72-09-04 ENGINE Disassembly and
support. Inspect the cushion integrity. HARDWARE - Reassembly of
Proper installation and If it appears dark and dirty it must be INSPECTION/CHECK Fasteners.
reuse of Loop Clamps replaced, as this is a sign of
contamination that can accelerate
tube wear. If the cushion material is
cracked or missing the clamp must
be replaced. If the cushion is
deformed in any manner it must also
be replaced. This is a sign that the
PTFE coating is worn away. A brown
residue left on the tube is an
indication that the PTFE coating has
been transferred from the clamp. If
this is noted, the clamp must be
replaced.
By design, cushioned loop clamps
permit the tube to slide and rotate
within the clamp; but, an excessive
space in the clamp permits too much
movement and can set up a wear
mechanism and change the natural
frequency of the tube. Both of these
can lead to tube wear through or
failure. Wear on engine tubes due to
worn or damaged P-clamps can lead
to oil, fuel or air leaks, which in turn
can lead to abnormal engine
behavior and operational events.

GE Proprietary Information 13-18 Workscope Planning Guide

Subject to restrictions on the cover or first page
 CF6-80C2
GE Aviation Workscope Planning Guide

Improperly Installed Loop

Clamp. Gap Between
Clamp Cushion and Tube

Correct and Incorrect Installation of Loop Clamps

Cracks

Dirt
Build-Up Properly Installed Loop
Transferred PTFE From Clamp Clamp. Snug Fit Between
Clamp Cushion and Tube
Examples of unserviceable cushion clamp
and transferred PTFE material to tube

Proper Installation and Reuse of Loop Clamps - Configurations Module

Figure 13-15

GE Proprietary Information 13-19 Workscope Planning Guide

Subject to restrictions on the cover or first page
 CF6-80C2
GE Aviation Workscope Planning Guide

SECTION 14

Controls and Accessories Module

The following pages outline the relevant tasks for performing Controls and Accessories
module workscope planning and maintenance. The objectives of the information
contained within this guide are to communicate the extent of work to enable the user
of the guide to achieve their engine durability, performance and maintenance cost
goals while maintaining high standards of engine reliability. The recommendations
contained herein are based on an average engine in the fleet. However, there are
many variable factors that can affect the specific workscope definition for a given
operator or engine.

GE Proprietary Information 14-1 Workscope Planning Guide

Subject to restrictions on the cover or first page
 CF6-80C2
GE Aviation Workscope Planning Guide

14.0. Engine Controls and Accessories Soft Time Discussion.

A. Historically, shop maintenance of CF6-80C2 engine controls and accessories has

been managed by soft time recommendations. The purpose of a “soft time” is to
reestablish a reliable baseline of each component such that the engine can be
operated until the next shop visit without on-wing maintenance of controls and
accessories. The “soft time” is defined as the recommended maximum hours and/or
cycles since last bench check or overhaul for a certain component to allow it to meet
that purpose. To allow additional flexibility, 2 options are presented below for
consideration:

(1) Option 1.

(a) Engine accessories are maintained at each engine shop visit in order to
baseline the components such that they are intended to stay on the
engine for the full upcoming run. The average soft time recommendation
must be adjusted to match the airline or operator’s time on wing target for
the engine.

(b) The advantage of Option 1 is that minimal on-wing maintenance of

accessories can be expected. The disadvantage is that the accessories
can need to be overhauled significantly before they have consumed their
predicted usable life, which increases shop costs.

(2) Option 2.

(a) Manage engine accessories to maximize use of the predicted component

usable life. The advantage of Option 2 is that shop cost can be reduced if
there were usable life remaining on the accessory. The disadvantage is
that the components can have to be managed on wing, which increases
logistics and maintenance burden.

B. An airline can elect to do a combination of Option 1 and Option 2. Certain

components are more difficult to change on wing, or can have a more significant
impact if they become unreliable. An example of this type of component is the HMU.
For the HMU, the airline can elect to maintain the HMU by the Option 1 method.
However, for a component that is easier to change on wing and has less impact on
the operation of the engine, such as the starter valve. The airline or operator can
elect to maintain the component by Option 2.

C. Operators or engine owners can discuss which option best suits their needs with
their maintenance provider.

GE Proprietary Information 14-2 Workscope Planning Guide

Subject to restrictions on the cover or first page
 CF6-80C2
GE Aviation Workscope Planning Guide

14.1. Engine Controls and Accessories List and Soft Time* Recommendations.

A. Refer to Table 14-1 thru Table 14-6.

Table 14-1. Fuel and Control (73-00-00).

Bench Check Overhaul

Component
Soft Time Soft Time

PMC On-Condition On-Condition

Main Engine Control 6,000 hours 18,000 hours
CIT Sensor (PMC) 10,000 hours 16,000 hours
ECU (FADEC) **Engine Shop Visit ***30,000 hours or 12,000 cycles
(whichever occurs first)
HMU (FADEC) --- 20,000 hours
Electrical Cables Engine Shop Visit ---
Main Fuel Pump --- 18,000 hours
Fuel Nozzles Engine Performance or Overhaul On-Condition
Shop Visit
Servo Fuel Heater At AGB Full Overhaul ---
IDG Fuel/Oil Cooler At AGB Full Overhaul ---
* Refer to Engine Controls and Accessories Soft Time Discussion, paragraph 14.0.
** Download ECU non-volatile memory (NVM) to identify stored faults for fault isolation.
*** Reference FADEC International (SL-F1-0012).

Table 14-2. Ignition System (74-00-00).

Bench Check Overhaul

Component
Soft Time Soft Time

Igniter Plug 500 flight cycles- Replace ---

Exciter Engine Shop Visit ---
Ignition Lead Engine Shop Visit ---
* Refer to Engine Controls and Accessories Soft Time Discussion, paragraph 14.0.

GE Proprietary Information 14-3 Workscope Planning Guide

Subject to restrictions on the cover or first page
 CF6-80C2
GE Aviation Workscope Planning Guide

Table 14-3. Air System (75-00-00).

Bench Check Overhaul

Component
Soft Time Soft Time
VSV Feedback Cable (PMC) Pull Check at Engine Shop Visit As Required
VBV Feedback Cable (PMC) Pull Check at Engine Shop Visit As Required
VSV Actuator (PMC) --- 16,000 hours
VBV Actuator (PMC) --- 18,000 hours
VSV Actuator (FADEC) --- 18,000 hours
VBV Actuator (FADEC) --- 20,000 hours
Air Signal Solenoid Valve (If Installed) --- Engine Shop Visit
(FADEC)
HPT/LPT ACC Valve (FADEC) On Condition 15,000 hours
Core Compartment Cooling Valve Engine Shop Visit As Required
(CCCV)
IDG Valve Engine Shop Visit 20,000 hours
Nacelle Anti-Ice Valve Engine Shop Visit As Required
Bore Cooling Valves Engine Shop Visit As Required
* Refer to Engine Controls and Accessories Soft Time Discussion, paragraph 14.0.

Table 14-4. Engine Indicating System (77-00-00).

Bench Check Overhaul

Component
Soft Time Soft Time
N1 Hydromechanical Sensor (PMC) --- 18,000 hours
N1 Electrical Sensor (PMC) On-Condition ---
N1 Sensor (FADEC) On-Condition ---
N2 Sensor (FADEC) On-Condition ---
Thermocouple Leads Engine Shop Visit ---
Thermocouple Probes Engine Shop Visit ---
EGT Junction Box Engine Shop Visit ---
Control Alternator Engine Shop Visit ---
Low Oil Pressure Switch Engine Shop Visit 20,000 hours
Fuel Filter Differential Pressure Switch Engine Shop Visit 20,000 hours
Oil Filter Differential Pressure Switch Engine Shop Visit 20,000 hours
Fuel Pressure Transmitter On-Condition ---
Oil Pressure Transmitter Engine Shop Visit 20,000 hours
* Refer to Engine Controls and Accessories Soft Time Discussion, paragraph 14.0.

GE Proprietary Information 14-4 Workscope Planning Guide

Subject to restrictions on the cover or first page
 CF6-80C2
GE Aviation Workscope Planning Guide

Table 14-5. Oil System (79-00-00).

Bench Check Overhaul

Component
Soft Time Soft Time
Oil Tank Engine Shop Visit ---
Lube and Scavenge Pump --- 20,000 hours
Fuel/Oil Heat Exchanger Engine Shop Visit ---
Oil Level Sensor On-Condition ---
IDG Air/Oil Cooler (see Note 1) Engine Shop Visit As Required
IDG Over-Pressure Relief Valve Engine Shop Visit ---
Oil Tank Cap Inspect per CMM at Every Engine ---
Shop Visit
* Refer to Engine Controls and Accessories Soft Time Discussion, paragraph 14.0.

Note 1: For IDG part number 9377M64P06 only, replace the IDG Air/Oil cooler with a new unit at no more than 5,028
flight cycles since new for the cooler.

Table 14-6. Starting System (80-00-00) - Airbus and MD-11 Applications Only For Boeing 747 or 767, Refer to
Boeing for Recommendations.

Bench Check Overhaul

Component
Soft Time Soft Time
Starter --- 30,000 hours
Starter Valve --- Each shop visit
* To minimize the potential for starter air valve faults on-wing. GE recommends that the valve be removed from the
engine at approximately 10,000 hours (since last valve overhaul) and sent for refurbishment.

14.2. Controls and Accessories Minimum Workscope.

A. Refer to Figure 14-1 and Table14-7.

GE Proprietary Information 14-5 Workscope Planning Guide

Subject to restrictions on the cover or first page
 CF6-80C2
GE Aviation Workscope Planning Guide

Process Map - Controls and Accessories Minimum Workscope

Figure 14-1

GE Proprietary Information 14-6 Workscope Planning Guide

Subject to restrictions on the cover or first page
 CF6-80C2
GE Aviation Workscope Planning Guide

Table 14-7. Controls and Accessories Minimum Workscope - Key Maintenance Tasks.

Item Tasks Reference

Controls and Verify compliance to accessible Critical Items --

Accessories Module listed “Key Recommended Documents” section of
this document.

Consider implementation of all accessible --

Category 1-7 Service Bulletins.

Verify that time and cycles since overhaul of Applicable CMMs

each component does not exceed soft time.
Perform bench check or component overhaul as
required.

Perform all inspections and identified in 73-00-00

referenced manual tasks and subtasks of 73-00- 74-00-00
00, 74-00-00, 75-00-00, 77-00-00, 75-00-00
79-00-00. 77-00-00
79-00-00

14.3. Controls and Accessories Full Overhaul Workscope.

A. Refer to Figure 14-2 and Table14-8.

GE Proprietary Information 14-7 Workscope Planning Guide

Subject to restrictions on the cover or first page
 CF6-80C2
GE Aviation Workscope Planning Guide

Process Map - Controls and Accessories Full Overhaul Workscope

Figure 14-2

GE Proprietary Information 14-8 Workscope Planning Guide

Subject to restrictions on the cover or first page
 CF6-80C2
GE Aviation Workscope Planning Guide

Table 14-8. Controls and Accessories Full Overhaul Workscope — Key Maintenance Tasks.

Full Overhaul - Key Maintenance Tasks – Fuel and Control - General Reference

Verify compliance to accessible with Critical Items (Priorities 1 and 2), refer to “Key --
Recommended Documents” section of this document.

Comply with all other Categories 1 – 6 Service Bulletins. Consider compliance of all Category --
7 Service Bulletins.

Full Overhaul - Key Maintenance Tasks - Fuel and Control - 73-00-00 Reference

Remove and clean CIT and T2 sensor screens (PMC only) --

Remove IDG fuel/oil cooler and clean, inspect and test per CMM CMM 73-11-71

Remove fuel nozzles. Clean and flowcheck to remove presence of coking to minimize CMM 73-11-47
secondary downstream HPT and LPT flowpath hardware distress CMM 73-11-47 Cleaning

Remove ECU cables and inspect/repair per CMM recommendations Applicable CMM

Remove control alternator rotor and stator and inspect per CMM CMM 73-21-81

Full Overhaul - Key Maintenance Tasks - Air System – 75-00-00 Reference

Leak check VSV/VBV actuators by pumping to fully extended position --

Pull check VSV/VBV feedback cables (PMC only) --

Full Overhaul - Key Maintenance Tasks - Engine Indicating System – 77-00-00 Reference

Test EGT harness and junction boxes Applicable CMM

CMM 77-21-41
Remove and bench test EGT probes at every engine shop visit CMM 77-21-52
CMM 73-24-14

GE Proprietary Information 14-9 Workscope Planning Guide

Subject to restrictions on the cover or first page
 CF6-80C2
GE Aviation Workscope Planning Guide

Table 14-8. Controls and Accessories Full Overhaul Workscope - Key Maintenance Tasks. (Cont.)

Full Overhaul - Key Maintenance Tasks - Oil System – 79-00-00 Reference

Remove fuel/oil heat exchanger, inspect, pressure check, and preserve per CMM CMM 79-22-22

Inspect Oil Tank Cap. Replace O-Rings and locknut to minimize low engine oil pressure
CMM 79-11-02
indications

Inspect Servo Fuel Heat Exchanger with particular attention to the outer housing for CMM 79-11-22
distortion CMM 79-11-21

Check oil tank pressurizing valve and relief valve CMM 79-11-11

Full Overhaul - Key Maintenance Tasks - Starting System – 80-00-00 Reference

Overhaul starter and starter air valve to maximize on-wing reliability CMM

GE Proprietary Information 14-10 Workscope Planning Guide

Subject to restrictions on the cover or first page
 CF6-80C2
GE Aviation Workscope Planning Guide

14.4. Controls and Accessories Module-Critical Items, Reliability and Key Product
Improvements, and Best Practices.

NOTE: The following pages highlight current critical items, and a selection of other
key reliability and product improvements, and best practices. Except for critical
items, this list is not all inclusive; therefore, it is recommended that all
Category 1 - 7 Service Bulletins be evaluated for workscope inclusion. Please
refer to the most recent revision of the cited documents for further information.

B. Priority Levels.

• Priority 1: Critical Item / Safety / AD-Mandated

• Priority 2: Reliability items

• Priority 3: Cost of Ownership, Best Practices / Recommended items

14.4.1. Controls and Accessories Module - Priority 1.

NOTE: Always use latest revision of listed documents.

A. Refer to Table 14-9, Figure 14-3, and Figure 14-4.

GE Proprietary Information 14-11 Workscope Planning Guide

Subject to restrictions on the cover or first page
 CF6-80C2
GE Aviation Workscope Planning Guide

Table 14-9. Controls and Accessories Module - Priority 1.

Recommended
Item Item Description Document(s)
Workscope Level

Controls and Accessories ECU software that improves 1. SB 73-0375 (R1, Dec-2009) At next SV of the ECU
Module FADEC engine tolerance to or within 5 calendar
flame-out during operation in “ENGINE FUEL AND years of the issuance
Boeing FADEC (BxF) certain inclement weather CONTROL – Electronic of the service bulletin.
conditions. Control Unit (73-21-07) -
ECU Software for Improved Introduction of Software
Flameout Tolerance in Version 8.2.R” for Boeing
Inclement Weather FADEC engines.

Do as soon as
ECU Hardware Service bulletin 73-0386 2. SB 73-0386 (R1, Dec-2011) possible without
Improvements to Prevent introduces circuitry effect on revenue
Engine Shutdown Caused improvements to the ECU “ENGINE FUEL AND service but within 14
by Dual Channel Central front panel to prevent in- CONTROL – ELECTRICAL months after the
Processing Unit (CPU) flight shut-down (IFSD) CONTROL UNIT (73-21-07) - issuance date of this
Faults events caused by ignition INTRODUCTION OF NEW Service Bulletin. (Aug
system induced noise ECUS WITH FRONT PANEL 27, 2012)
creating dual channel central REWORK INSTRUCTIONS
processing unit (CPU) faults
and ECU operational issues.
Do as soon as
Service bulletin 73-0396 3. SB 73-0396 (R0, Sep-2012) possible without
introduces hardware effect on revenue
changes to the ECU that is “ENGINE FUEL AND service at next ECU
effective in reducing the CONTROL – ELECTRONIC shop visit, or engine
voltage transient induced CONTROL UNIT (73-21-07) - shop visit (ESV), but
electrical noise that ECU MODIFICATION – 400 within 60 months or
propagates to the CPU HZ IGNITION RELAY 4,500 engine flight
control lines. CONTACT NOISE REDUCTION cycles after the
WITH ECU PART NUMBER effective date of
CHANGE” Airworthiness
Directive
(AD) 2012-04-05,
whichever comes
first.

GE Proprietary Information 14-12 Workscope Planning Guide

Subject to restrictions on the cover or first page
 CF6-80C2
GE Aviation Workscope Planning Guide

Table 14-9. Controls and Accessories Module - Priority 1. (Cont.)

Recommended
Item Item Description Document(s)
Workscope Level

AD 2012-04-05 mandates 4. AD 2012-04-05 (AD was At next SV not to exceed

ECU 8.2.R Software for effective March 30, 2012) time compliance defined in
Inclement Weather and ECU AD (from AD effective date):
Front Panel Modification. Mandates removal of ECUs
that contain certain 1. ECUs pre-SB 73-0339
hardware and/or software (software loads prior to
to avoid possible in-flight 8.2.Q1) per Table 1 of the
flameout events. Affected AD, within 6 months or
ECU part numbers are 450 engine flight cycles
defined in the AD. after the effective date of
the AD, whichever occurs
Affected ECUs can be first. The intent of this
updated and returned to item is to remove prior
service by application of software versions from
the service bulletins listed service.
above.
2. ECUs with pre-SB 73-
0386 (ECU configurations
prior to Front Panel
Rework), as listed in
paragraph (g)(2) of the
AD, within 14 months or
1,050 engine flight cycles
after the effective date of
the AD, whichever occurs
first. The intent of this
item is to remove ECU’s
most susceptible for
ignition noise induced
events from service.

3. All other ECUs with P/Ns

pre-SB 73-0375 (software
loads prior to 8.2.R) and
pre-SB 73-0386 (ECU
configurations prior to
Front Panel Rework) per
Table 2 of the AD, within
60 months or 4,500
engine flight cycles after
the effective date of the
AD, whichever occurs
first.

GE Proprietary Information 14-13 Workscope Planning Guide

Subject to restrictions on the cover or first page
 CF6-80C2
GE Aviation Workscope Planning Guide

Table 14-9. Controls and Accessories Module - Priority 1. (Cont.)

Recommended
Item Item Description Document(s)
Workscope Level

AD 2007-12-07 was 5. AD 2007-12-07 Superseded by AD 2012-

superseded by AD 2012-04- 04-05
05 Mandated incorporation of
8.2.Q1 software. AMOC
allows incorporation of 8.2.R
software in lieu of 8.2.Q1 for
Boeing FADEC engines.

Service bulletin 73-0395 6. SB 73-0395 (R1, Sep-2012) Do when the ECU is routed
defines hardware for repair
modification to the latest “ENGINE FUEL AND
standard front panel CONTROL - ELECTRICAL
assembly introduced by CONTROL UNIT (73-21-07) -
CF6-80C2 S/B 73-0334 to REWORK INSTRUCTIONS
relay wiring to reduce FOR 400 HZ IGNITION RELAY
ignition relay contact noise CONTACT NOISE REDUCTION
within the ECU. MODIFICATION”

CF6-80C2 ECU Front Panel

Figure 14-3

GE Proprietary Information 14-14 Workscope Planning Guide

Subject to restrictions on the cover or first page
 CF6-80C2
GE Aviation Workscope Planning Guide

Table 14-9. Controls and Accessories Module - Priority 1. (Cont.)

Recommended
Item Item Description Document(s)
Workscope Level

Controls and ECU software that improves 1. SB 73-0352 (R2, Aug- 2010) At next SV of the ECU or
Accessories Module FADEC engine tolerance to within 5 calendar years of
flame-out during operation “ENGINE FUEL AND the issuance of the service
A300 (A5F) and MD-11 in certain inclement CONTROL - ELECTRONIC bulletin
(D1F) FADEC weather conditions. CONTROL UNIT (73-21- 07) -
INTRODUCTION OF
SOFTWARE VERSION 8.4.F”
for CF6-80C2A5F engines.

ECU Software for 2. AD 2007-21-06

Improved Flameout
Tolerance in Inclement Mandates incorporation of
Weather 8.4.F software for CF6-
80C2A5F engines.

3. SB 73-0351 (R2, Oct-2008)

“ENGINE FUEL AND

CONTROL - Electronic
Control Unit (73-21-07) –
Introduction of Software
Version 8.3.K” for CF6-
80C2D1F engines.

4. AD 2007-21-06

Mandates incorporation of
8.3.K software for CF6-
80C2D1F engines.

GE Proprietary Information 14-15 Workscope Planning Guide

Subject to restrictions on the cover or first page
 CF6-80C2
GE Aviation Workscope Planning Guide

CF6-80C2 ECU
Figure 14-4

GE Proprietary Information 14-16 Workscope Planning Guide

Subject to restrictions on the cover or first page
 CF6-80C2
GE Aviation Workscope Planning Guide

14.4.2. Controls and Accessories Module - Priority 2.

NOTE: Always use latest revision of listed documents.

A. Refer to Table 14-10, Table 14-11, and Figure 14-5.

Table 14-10. Controls and Accessories Module - Priority 2.

Item Item Description Document(s) Recommended

Workscope Level

Controls and Accessories This service bulletin identifies 1. SB 77-0074 (R0, Mar-2011) Do at next shop
Module a lot of N1 speed sensors that “ENGINE INDICATING - N1 visit or in 12
cannot meet low speed, SENSOR (77-00-00) - N1 months of the
N1 Speed Sensors With maximum gap or minimum SENSOR LOW SPEED issuance of the
Improper Acceptance Test output voltage requirement. OUTPUT TEST/RECALL” bulletin.
The service bulletin provides
instructions to test the 2. CMM 73-51-23 N1 speed
suspect sensors and to sensor acceptance test.
replace them if they do not
meet test requirements

CF6-80C2 speed sensor low,

or loss of, signal output.
Causes erratic signal or loss of
output resulting in or low N1
signal at start. Can cause
faults that require N1 sensor
replacement on-wing.

Affected speed sensor serial

numbers are listed in the
service bulletin.

GE Proprietary Information 14-17 Workscope Planning Guide

Subject to restrictions on the cover or first page
 CF6-80C2
GE Aviation Workscope Planning Guide

Raised tooth (marks 1

full rotor rotation)

N1 Speed Substandard sensors have low out

Sensor signal, below 0.5 volts peak-to-peak

N1 Speed Sensor with Improper Acceptance Test

Figure 14-5

Table14-11. Historical Priority 2.

Historical Priority 2 Control and Accessory Related Items for Reference Reference

Rework W13 FADEC harness connector to high force 4-tine pin/socket configuration for SB 77-0063
improved oil temperature (TEO) sensor signal reliability.

Replace fuel nozzles with either brazed or clipped heat shield configuration with fuel nozzles SB 73-0287
with welded heat shields. SB 73-0289

GE Proprietary Information 14-18 Workscope Planning Guide

Subject to restrictions on the cover or first page
 CF6-80C2
GE Aviation Workscope Planning Guide

14.4.3. Controls and Accessories Module - Priority 3.

NOTE: Always use latest revision of listed documents.

A. Refer to Table 14-12, Figure 14-6, and Figure 14-7.

Table 14-12. Controls and Accessories Module - Priority 3.

Recommended
Item Item Description Document(s)
Workscope Level

Controls and Accessories Improved durability HMU fuel 1. SB 73-0379 (R0, Jul-2010) When HMU is routed
Module metering valve resolver will “ENGINE AND FUEL for overhaul or repair
improve durability and reduce CONTROL - Main Engine
Improved Hidromechanical resolver related FADEC faults. Control (73-21-10) -
Unit (HMU) Fuel Metering Introduction of
Valve Resolver Hydromechanical Unit
Configured with CuNi
Resolvers for Boeing
FADEC engines

2. SB 73-0378 (R0, Aug-

2010) “ENGINE AND FUEL
CONTROL - Main Engine
Control (73-21-10) -
Introduction of
Hydromechanical Unit
Configured with CuNi
Resolvers for
CF6-80C2A5F and
CF6-80C2D1F engines.

GE Proprietary Information 14-19 Workscope Planning Guide

Subject to restrictions on the cover or first page
 CF6-80C2
GE Aviation Workscope Planning Guide

Improved HMU Fuel Metering Valve Resolver

Figure 14-6

Pre and Post Service Bulletin 73-0378/0379 HMU Design

Figure 14-7

GE Proprietary Information 14-20 Workscope Planning Guide

Subject to restrictions on the cover or first page
 CF6-80C2
GE Aviation Workscope Planning Guide

Table 14-12. Controls and Accessories Module - Priority 3. (Cont.)

Recommended
Item Item Description Document(s)
Workscope Level

Controls and Accessories Service bulletin 73- 0395 defines SB 73-0395 (R1, Sep-2012) Do when the ECU is
Module hardware modification to the routed for repair
latest standard front panel “ENGINE FUEL AND CONTROL
Boeing FADEC (BxF) assembly introduced by CF6- – ELECTRICAL CONTROL UNIT
80C2 S/B 73-0334 to relay (73-21-07) - REWORK
ECU Hardware wiring to reduce ignition relay INSTRUCTIONS FOR 400 HZ
Improvements to Prevent contact noise within the ECU. IGNITION RELAY CONTACT
Fault Messages NOISE REDUCTION
MODIFICATION”

CF6-80C2 ECU
Figure 14-8

GE Proprietary Information 14-21 Workscope Planning Guide

Subject to restrictions on the cover or first page
 CF6-80C2
GE Aviation Workscope Planning Guide

Table 14-12. Controls and Accessories Module - Priority 3. (Cont.)

Recommended
Item Item Description Document(s)
Workscope Level

Controls and Accessories Improper installation and removal 3. Engine Shop Manual Each probe removal
Module of EGT system harness and probes 72-00-04
can result in damage to the probes.
EGT Probe Damaged probes can require
• Use penetrating oil
Installation/Removal probes to be repaired or scrapped.
when removing EGT
Improper probe disassembly can
harness terminal nuts,
also lead to probe tip separation
probe bolts and probe
during operation which can cause
support
serious damage to the low pressure
turbine.
• Use probe removal tool
Enhanced EGT probe removal and for removing a stuck
installation procedures have been probe
put into the Engine Shop Manual
and all Aircraft Maintenance • Using anti-seize when
Manuals. These enhanced installing EGT probe
procedures include all best support and bolts
practices for probe maintenance.
• Route harness leads
onto probe to avoid
kinks and tight leads

• Torque harness
terminals to the
recommended values

• Borescope of LPT for

missing lower section of
probe support with
figure definition

GE Proprietary Information 14-22 Workscope Planning Guide

Subject to restrictions on the cover or first page
 CF6-80C2
GE Aviation Workscope Planning Guide

Examples of EGT Probe Damage

Stripped EGT Probe Terminal Broken EGT Probe Support

PN 9429M29G01
Puller Tool

EGT Probe Installation/Removal

Figure 14-9

GE Proprietary Information 14-23 Workscope Planning Guide

Subject to restrictions on the cover or first page
 CF6-80C2
GE Aviation Workscope Planning Guide

Table 14-12. Controls and Accessories Module - Priority 3. (Cont.)

Recommended
Item Item Description Document(s)
Workscope Level

Controls and Accessories Improper assembly of cable connectors 1. Engine Shop Manual Each SV or
Module can lead to cable damage requiring 72-00-04 Disassembly and
expensive cable repairs. Damaged Reassembly of
Proper Cable Connector connectors can also lead to poor Connectors
• Only tighten the
Assembly electrical connections and potential for
Adaptor Coupling
operational faults.
Nut with Soft Jaw
Electrical Pliers

• Tighten the nut

finger tight, then
further tighten with
the soft-jawed pliers
until the pliers slip

• Many connector
nuts have two
knurled rings, to
prevent damage,
apply torque only to
this knurled ring

Many connector nuts have two knurled

rings, to prevent damage, apply torque
only to this knurled ring

Proper Cable Connector Assembly

Figure 14-10

GE Proprietary Information 14-24 Workscope Planning Guide

Subject to restrictions on the cover or first page
 CF6-80C2
GE Aviation Workscope Planning Guide

Table 14-12. Controls and Accessories Module - Priority 3. (Cont.)

Recommended
Item Item Description Document(s)
Workscope Level

Controls and Accessories Service Bulletin introduces a new ignition 2. SB 74-0021 Customer Option,
Module exciter with stainless steel electrical (R0, Oct-2010) Do When Exciter
connectors to prevent oxidation on the “IGNITION - Ignition is sent for
Ignition Exciters With connectors. The Service Bulletin also Exciter (74-11-10) - Overhaul
Stainless Steel Connectors defines rework of pre-Service Bulletin units Introduction of New
to implement the stainless steel Unison Ignition
connectors. Exciter VIN 10-
The electrical connectors on pre-Service 631045-3 (P/N
Bulletin ignition exciters are susceptible to 9238M66P11) and
Rework of Unison
oxidation. The oxidation is a cosmetic issue
only and does not affect the operation of Ignition Exciters VIN
the unit. However, some units have been 10-631045-2 (P/N
9238M66P08) and
removed from engines due to the
oxidation. The connectors can be cleaned VIN 10-631045-1
and repainted. Or, the new stainless steel (P/N 9238M66P07)”
connectors can be installed and will not
oxidize.

Ignition Exciter with Oxidation on Electrical Connector

Figure 14-11

GE Proprietary Information 14-25 Workscope Planning Guide

Subject to restrictions on the cover or first page