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IGNITION - IGNITION SYSTEM - Introduction of Reduced Energy Ignition Exciters P/N 9238M66P07

1. PLANNING INFORMATION

A. Effectivity

Ignition exciters V/I/N 10-617980-1 (GE P/N 9238M66P05) installed onCFM56-3/3B


engines only are affected by this Service Bulletin.

NOTE: The ignition exciters V/I/N 10-631045-1 (GE P/N 9238M66P07) will be introduced
in production on the following engines.

Engines Serial Numbers


CFM56-3-B1/3B-2 720331 & up and
721348 & up
CFM56-3C-1 725101 & up

B. Reason

The reduced spark rate and reduced energy of P/N 9238M66P07 will increase igniter
sparking life. In addition, ignition lead and exciter life is extended due to the reduced duty
cycle and reduced electrical stress on these components.

C. Description

(See figures 1 (sheet 2 and 3)) This Service Bulletin announces the introduction of reduced
energy ignition exciters V/I/N 10-631045-1 (GE P/N 9238M66P07) and provides rework
instructions for V/I/N 10-617980-1 (GE P/N 9238M66P05).

D. Compliance

It is recommended that this Service Bulletin be accomplished at the operator's option.

E. Approval

The technical content of this Service Bulletin is FAA and DGAC approved.

F. Manpower

With the exciter removed, an estimated 4 man hours per exciter are required to accomplish
the rework portion of this Service Bulletin.

G. Material

The material required to accomplish this Service Bulletin may be purchased from the

AUG 01, 1985 CFM56-3 S/B 74-0002


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IGNITION - IGNITION SYSTEM - Introduction of Reduced Energy Ignition Exciters P/N 9238M66P07

ignition exciter vendor. See paragraph 3 - MATERIAL INFORMATION.

H. Tooling

No additional special tooling is required to accomplish this Service Bulletin.

I. Weight and Balance

Not affected.

J. References/Publications Affected

CFM56-3/3B/3C Illustrated Parts Catalog, CFMI-TP-PC.8 Component Maintenance Manual


74-11-12

NOTE: The following reference documents are for engine manufacturer's internal use
only:Business Plan G38-85-56

DCAS: 11752 CID: 834240 DCIA: 85-13


CID: 834240-1
Service Bulletin (CFM56-2) 74-003 Revision 2
(CFM56-2B) 74-001 Revision 1
(CFM56-2A) 74-001 Revision 1

K. Previous Modifications

None

2. ACCOMPLISHMENT INSTRUCTIONS

NOTE: Reference figure 1 for all item numbers in the following procedure.
A. Perform leak test as follows:

(1) Immerse ignition exciter for 1 minute in water maintained at a temperature of 180? to
200?F (80? to 94?C). Ignition exciter must be at room temperature before immersion.
Add a sufficient amount of wetting agent (Tergitol Non Ionic Mini-Foam IX, Union
Carbide Corp., New York City, NY 10022) to eliminate surface tension bubbles, as
required.

(2) Observe exciter for leakage evidenced by escaping air bubbles.

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IGNITION - IGNITION SYSTEM - Introduction of Reduced Energy Ignition Exciters P/N 9238M66P07

(3) Remove exciter from water and dry with a gentle blast of compressed air not
exceeding 30 psig (206.8kPa) gage.

(4) If leakage is noted around cover (5), no rewelding is necessary at this time since the
cover will be removed in the following steps for exciter conversion. Record by sketch
the area requiring repair by weld and perform repair while unit is disassembled. Careful
attention should be given to the exciter interior for signs of arc-over due to loss of the
hermetic seal. If leakage is observed around input filter (20) or high frequency
transformer (18), reweld to obtain a proper seal.

WARNING: THE OUTPUT OF THIS IGNITION EXCITER IS SUFFICIENT TO CAUSE


A LETHAL ELECTRICAL SHOCK. DO NOT TOUCH ANY EXPOSED OR
LIVE PORTION AND ALWAYS DISCONNECT LEADS FROM INPUT
POWER SOURCE BEFORE WORKING WITH THE IGNITION EXCITER.

B. Perform an operational test of the ignition exciter to determine if any obvious problems
exist. Refer to Component Maintenance Manual 74-11-12,paragraph 3. Test and Setup for
Exciter Test, Steps A and B pages 101-105. If exciter does not pass these tests,
determination of the problem should be made during disassembly.

C. Disassemble the exciter to the extent defined in Component Maintenance Manual 74-11-12,
paragraph 2. Paint Removal Instructions, pages 301 and 302, and paragraph 3. Detailed
Disassembly Procedures, steps A.(1) through A.(5) only on page 303.

CAUTION: WHEN UNSOLDERING WIRE FROM RECTIFIER MODULE (16, Fig. 1), USE
A HEAT SINK. APPLY ONLY ENOUGH HEAT TO MELT SOLDER.
OVERHEATING MAY DAMAGE RECTIFIERS.

D. Using heat sink, unsolder and remove red power transformer (23) wire from rectifier module
(16).

E. Unsolder and remove brown capacitor assembly (24) wire from tab on power transformer
(23). Free-up transformer and shift away from filter (20). Unsolder and remove black and
green transformer primary wires from filter. Remove transformer from housing.

F. Inspect insulators (7) for cuts or mutilation. Replace if necessary. To install new insulators it
may be necessary to remove terminals (10). Insert wires into new insulator and then crimp
and solder new terminals (10).

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IGNITION - IGNITION SYSTEM - Introduction of Reduced Energy Ignition Exciters P/N 9238M66P07

G. Remove old insulation tape (26) and install new piece as follows: Fold insulation tape (26)
into an "L" shape with the lower length of the "L" approximately 1.12 inches long. Apply RTV
to the backside and bottom of the tape and position to the floor in housing (2) in the location
as shown in figure 1 and per page 701 CMM 74-11-12, Equipment and Materials.

H. Place RTV sealant on bottom and side of new power transformer (23A) that will be in
contact with housing (2). Install transformer into housing with white lead and terminal on top
and next to filter (20).

I. Assemble #14 green lead from capacitor assembly (24) with terminal to input end of new
spark gap (11A) (input end is opposite exhaust tube end) with one new lockwasher (9) and
one screw (8). Tighten to 6-8 lb. -in. Slide insulator (7) over spark gap.

J. Assemble the three blue leads with terminals to output end of spark gap (output end has
exhaust tube) with one new lockwasher (9) and one screw (8). Tighten to 6-8 lb. -in. Slide
insulator (7) over spark gap.

K. Cut a piece of tape (28) 16 inches long. Wrap spark gap and insulators (7) with turns of
tape.

L. Assemble brown lead from capacitor assembly (24) to terminal on power transformer (23)
and solder.

M. Assemble black lead from transformer (23) to lead marked "A" of filter (20) by forming hooks
in ends of leads and connecting together. Solder lead. Assemble green lead from
transformer (23) to lead marked "B" of filter (20) by forming hooks in ends of leads and
connecting together Solder lead.

CAUTION: HEAT SINK THE SOLID LEAD WIRE DURING THE FOLLOWING
SOLDERING OPERATION.

N. Connect and solder the red lead from the transformer (23) to the lower solid lead of the
rectifier module (16).

O. Complete assembly of exciter per steps 2.A. (23) through 2.D(7), pg. 710-714 of the
Component Maintenance Manual with the following exceptions:

(1) Reference painting procedure, pg. 714, paragraph 2.D.(5). Paintshall be gray instead

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IGNITION - IGNITION SYSTEM - Introduction of Reduced Energy Ignition Exciters P/N 9238M66P07

of black. The gray wrinkle finish enamel shall conform to MIL-E-5558, Type I.

(2) Test values in Component Maintenance Manual 74-11-12 Testing and


Troubleshooting, pages 101 through 106 should be followed for ignition exciter P/N
10-631045-1 (TFN-30).

P. Reidentify converted exciters as follows:

On nameplate, using electric engraving tool, line out old P/N 10-617980-1B. Engrave new
P/N 10-631045-1A above old P/N location. Line out the "5" in G.E. P/N 9238M66P05 and
engrave a "7". Line out "type TFN-26" and engrave "type TFN-30" below "duty" information.
A laser marker may be used if available.

3. MATERIAL INFORMATION

A. Material Requirements

(1) For customers who choose to purchase new ignition exciters, the following material is
required to accomplish this Service Bulletin and may be acquired from the vendor by
sending a Charge Purchase Order to the address listed in paragraph 3.D. Parts
Disposition. Reference this Service Bulletin: (CFM56-3/3B) 74-002

Qty/ Unit Pkg


Part Number Eng Price Qty L/T# Key Word
V/I/N 10-631045-1 (2) Quote (1) - Exciter,
(GE P/N 9238M66P07) Ignition
# Replenishment Lead Time (L/T) in days.

(2) Ignition exciters V/I/N 10-617980-1 (GE P/N 9238M66P05) may be returned to the
vendor for rework or exchange. Send parts with a purchase order for rework to the
address listed in paragraph 3.D. Parts Disposition. Reference this Service Bulletin
(CFM56-3/3B) 74-002.

(3) For customers who choose to rework ignition exciters themselves, the following
material is required for rework of ignition exciters per this Service Bulletin and may be
acquired from the vendor by sending a Charge Purchase Order to the address listed in

AUG 01, 1985 CFM56-3 S/B 74-0002


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IGNITION - IGNITION SYSTEM - Introduction of Reduced Energy Ignition Exciters P/N 9238M66P07

paragraph 3.D. Parts Disposition. Reference this Service Bulletin (CFM56-3/3B)


74-002.

ITEM (see figure 1) V/I/N QTY NOMENCLATURE


11A 10-621055-22 1 Spark Gap
9 10-92879-41 (MS35338-41) 2 Washer, Lock
3 10-187722 1 Plate, Warning
7 10-106129 2 Insulator
6 10-621692 1 Cover, Insulator
28 10-180106-2 1.34 Ft. Tape, Insulation*
23A 10-631062 1 Transformer, Power
26 10-180193-6 .26 Ft. Tape, Insulation*
10 10-58137 4 Terminal
The above items may be purchased under conversion kit P/N 9043800.
* If purchased separately (ie. not in kit), supplied in 108 Ft. Roll.

NOTE: 1: When dealing with the vendor, the operator should ascertain that the above
vendor has complied with appropriate Airworthiness Authority Regulations.

NOTE: 2: Vendor price and delivery information is preliminary data from the vendor
solely for planning purposes and will not be updated by the engine
manufacturer to reflect future vendor price changes. All inquiries regarding
vendor data must be directed to the vendor.

B. Configuration Chart

Qty/ Qty/ Chng


New P/N Eng Key Word Old P/N Eng Operation Code
V/I/N 10-631045-1 (2) Exciter, V/I/N 10-617980-1 (2) Replace 4
(GE P/N 9238M66P07) Ignition (GE P/N 9238M66P05) or Rework
(CSN 74-00-00-02-010
(CMM 74-11-12-01-001)
.V/I/N 10-621055-22 (1) Spark Gap .V/I/N 10-621055-12 (1) Superseded 5
.V/I/N 10-631062 (1) Transformer .V/I/N 10-617975 (1) Superseded 5
Power

NOTE: 1: Change Codes

4 = Old and new parts fully interchangeable


5 = Set change - New parts will not fit or function with

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IGNITION - IGNITION SYSTEM - Introduction of Reduced Energy Ignition Exciters P/N 9238M66P07

adjacent old parts.

C. Interchangeability

Physical and functional interchangeability of ignition exciters is not affected. Detail parts
must be used in sets.

D. Parts Disposition

(1) Serviceable ignition exciters P/N 9238M66P05 replaced by this Service Bulletin may
continue in service at operator's option.

(2) To order new ignition exciters, to return parts for rework or order material for rework
per paragraph 3.A. Material Requirements, correspondence should be directed to:
Bendix Engine Products Division Jacksonville, Florida 32445-7880

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Figure 1, Sheet 1 of 3

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Figure 1, Sheet 2 of 3

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IGNITION - IGNITION SYSTEM - Introduction of Reduced Energy Ignition Exciters P/N 9238M66P07

Figure 1, Sheet 3 of 3

AUG 01, 1985 CFM56-3 S/B 74-0002


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