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1. PLANNING INFORMATION
A. Effectivity
NOTE: The ignition exciters V/I/N 10-631045-1 (GE P/N 9238M66P07) will be introduced
in production on the following engines.
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
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
H. Tooling
Not affected.
J. References/Publications Affected
NOTE: The following reference documents are for engine manufacturer's internal use
only:Business Plan G38-85-56
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.
(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.
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).
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
of black. The gray wrinkle finish enamel shall conform to MIL-E-5558, Type I.
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
(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
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
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
Figure 1, Sheet 1 of 3
Figure 1, Sheet 2 of 3
Figure 1, Sheet 3 of 3