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Commercial Airplanes 747 Service Bulletin ALERT Number: 747-27A2497 Original Issue: September 30, 2010 ATA System: 2722 SUBJECT: FLIGHT CONTROLS - Rudder and Rudder Trim Control System - Rudder Power Control Module Change Export of this technology is controlled under the United States Export Administration Regulations (EAR) (15 CFR 730-774). An export license may be required before it is used for development, production or use by foreign persons from specific countries. The controller of this data has the individual responsibility to abide by all export laws.

9E991ECCN:

BOEING PROPRIETARY, CONFIDENTIAL, AND/OR TRADE SECRET Copyright © 2010 The Boeing Company Unpublished Work - All Rights Reserved Boeing claims copyright in each page of this document only to the extent that the page contains copyrightable subject matter. Boeing also claims copyright in this document as a compilation and/or collective work.

This document includes proprietary information owned by The Boeing Company and/or one or more third parties.

Treatment of the document and the information it contains is governed by contract with Boeing. For more information, contact The Boeing Company, P.O. Box 3707, Seattle, Washington 98124.

Boeing, the Boeing signature, the Boeing symbol, 707, 717, 727, 737, 747, 757, 767, 777, 787, Dreamliner, BBJ, DC-8, DC-9, DC-10, KC-10, KDC-10, MD-10, MD-11, MD-80, MD-88, MD-90, P-8A, Poseidon and the Boeing livery are all trademarks owned by The Boeing Company; and no trademark license is granted in connection with this document unless provided in writing by Boeing.

Original Issue: September 30, 2010 747-27A2497 1 of 24

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Original Issue: September 30, 2010 747-27A2497 2 of 24 BOEING SERVICE BULLETIN 747-27A2497

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Table of Contents

Summary5

1. PLANNING INFORMATION9

A. Effectivity9

1. Airplanes9

2. Spares Affected ........................................ 1 0 B. Concurrent Requirements ...................................... 1 0 C. Reason ................................................ 1 0 D. Description .............................................. 1 1 E. Compliance .............................................. 1 1 F. Approval ............................................... 1 1 G. Manpower .............................................. 1 1 H. Weight and Balance Changes .................................... 1 2 I. Electrical Load Data ......................................... 1 2 J. References .............................................. 1 3

1. Existing Data .......................................... 1 3

2. Data supplied with this Service Bulletin ............................ 1 3

3. Installation Drawings Used in the Preparation of this Service Bulletin ............ 1 3 K. Publications Affected ........................................ 1 3 L. Interchangeability and Intermixability of Parts ........................... 1 3

2. MATERIAL INFORMATION ........................................ 1 5 A. Material - Price and Availability ................................... 1 5 B. Industry Support Information .................................... 1 5 C. Parts Necessary For Each Airplane ................................. 1 5

1. Kits/Parts ............................................ 1 5

2. Parts and Materials Supplied by the Operator ........................ 1 5

3. Parts Modified and Reidentified ................................ 1 5

4. Parts Removed and Not Replaced .............................. 1 5 D. Parts Necessary to Change Spares ................................. 1 5 E. Special Tooling - Price and Availability ............................... 1 5 F. Special Tooling Necessary to do this Service Bulletin ....................... 1 6

3. ACCOMPLISHMENT INSTRUCTIONS .................................. 1 7 A. GENERAL INFORMATION ..................................... 1 7 B. WORK INSTRUCTIONS ....................................... 1 7 FIGURE 1: UPPER RUDDER POWER CONTROL MODULE - REPLACEMENT ............ 2 1 FIGURE 2: LOWER RUDDER POWER CONTROL MODULE - REPLACEMENT ........... 2 3

Original Issue: September 30, 2010 747-27A2497 3 of 24 BOEING SERVICE BULLETIN 747-27A2497

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Original Issue: September 30, 2010 747-27A2497 4 of 24 BOEING SERVICE BULLETIN 747-27A2497

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Commercial Airplanes 747 Service Bulletin ALERT SummaryNumber: 747-27A2497Original Issue: September 30, 2010 ATA System: 2722 SUBJECT: FLIGHT CONTROLS - Rudder and Rudder Trim Control System - Rudder Power Control Module Change

THIS BULLETIN IS SENT TO THE OPERATORS OF RECORD OF THE AIRPLANES SHOWN IN PARAGRAPH

1.A., EFFECTIVITY. IF AN AIRPLANE HAS BEEN LEASED OR SOLD, SEND THIS SERVICE BULLETIN TO THE NEW OPERATOR. IF APPLICABLE SPARES HAVE BEEN SOLD, SEND THIS SERVICE BULLETIN TO THE NEW OWNER.

CONCURRENT REQUIREMENTS None.

BACKGROUND Accomplishment of this service bulletin ensures that the upper or lower rudder Power Control Modules (PCM) do not create a hard-over condition in the event of a manifold cracking and separation. This will be accomplished by replacing the rudder PCM manifold access cap with a two-piece cap that includes a retention feature for the yaw damper modulating piston assembly in the rudder PCM. The secondary retention engages an existing window in the sleeve of the yaw damper modulating piston assembly. This restricts the yaw damper modulating piston assembly from significantly shifting and causing considerable uncommanded input to the Rudder PCM main control valve in an event where the primary retention endcap is detached or compromised. Uncommanded input to the Rudder PCM main control valve may create a hard-over condition. A hard-over condition can result in a high speed runway excursion after touchdown in a landing.

A lower rudder hard-over left event was reported by an operator of a 747-400 series airplane. The hard-over was caused by the lower rudder PCM manifold cracking in the area of the yaw damper cavity end-cap. This allowed the yaw damper sleeve to shift, giving the system a lower rudder left input. Three additional rudder PCM manifold cracking events have been reported by other operators. These events did not result in a hard-over, but created the need for a retention feature solution. Upon investigation, it was determined that the 747-SP fleet could be susceptible to the same failure because they use the same manifold sub-assembly as the 747-400 aircraft.

Boeing Service Related Problem (SRP) 747-SRP-27-0193 is related to this service bulletin.

ACTION (PRR 85656-R) Open access to the upper and the lower rudder PCM. Replace each rudder PCM. As an alternative, you can make the change to each PCM as given in Parker service bulletin 241700-27-333. Do the operational tests.

Close access. Put the airplane back to a serviceable condition.

Original Issue: September 30, 2010 747-27A2497 5 of 24

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EFFECTIVITY All 747SP Airplanes. Refer to Paragraph 1.A.1., Airplanes for the list of affected airplanes.

COMPLIANCE The Federal Aviation Administration (FAA) will possibly release an Airworthiness Directive related to this service bulletin. The Airworthiness Directive will make the compliance tasks and times given in this service bulletin mandatory.

Boeing recommends that the change given in this service bulletin be done within 24 months or 8,400 flight hours after the original issue date on this service bulletin, whichever occurs first.

INDUSTRY SUPPORT INFORMATION Boeing warranty remedies are not available for the configuration changes given in this service bulletin.

MANPOWER Work Package 1, Option 1: Replace the Upper Rudder PCM:

Elapsed HoursTotal Task HoursAirplanes

5.5011.00Group 1 Work Package 1, Option 2: Change the Upper Rudder PCM:

Elapsed HoursTotal Task HoursAirplanes

1.752.75Group 1 Work Package 2, Option 1: Replace the Lower Rudder PCM:

Elapsed HoursTotal Task HoursAirplanes

5.5011.00Group 1 Work Package 2, Option 2: Change the Lower Rudder PCM:

Elapsed HoursTotal Task HoursAirplanes

1.752.75Group 1

MATERIAL INFORMATION Operator Supplied Parts/Materials.

Refer to Paragraph 2.A., Material - Price and Availability

Original Issue: September 30, 2010 747-27A2497 6 of 24 BOEING SERVICE BULLETIN 747-27A2497

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BOEING SERVICE BULLETIN 747-27A2497

ALERT ALERT

POWER CONTROL MODULE (PCM)

REPLACE THE UPPER AND LOWER

RUDDER PCMS OR MAKE THE CHANGE

GIVEN IN PARKER SERVICE BULLETIN UPPER PCM INSTALLATION SHOWN.

LOWER PCM INSTALLATION SIMILAR.

1834238 Original Issue: September 30, 2010 747-27A2497

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Original Issue: September 30, 2010 747-27A2497 8 of 24 BOEING SERVICE BULLETIN 747-27A2497

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THIS BULLETIN IS SENT TO THE OPERATORS OF RECORD OF THE AIRPLANES SHOWN IN PARAGRAPH

1.A., EFFECTIVITY. IF AN AIRPLANE HAS BEEN LEASED OR SOLD, SEND THIS SERVICE BULLETIN TO THE NEW OPERATOR. IF APPLICABLE SPARES HAVE BEEN SOLD, SEND THIS SERVICE BULLETIN TO THE NEW OWNER.

1. PLANNING INFORMATION A. Effectivity

1. Airplanes This service bulletin is for the airplanes shown below. An equivalent change is on subsequent production airplanes. Refer to PRR 85656-R for data about this change.

Refer to Service Bulletin Index Document D6-30300 Part 3 for Airplane Variable Number, Line Number, and Serial Number data.

DESCRIPTIONCONFIGURATIONGROUP All 747SP airplanes.-1 Airplane Models:

747SP GroupVariable Number 1RG001 - RG009 1RG091 1RG095 1RG101 - RG104 1RG121 - RG126

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GroupVariable Number 1RG141 - RG142 1RG161 - RG164 1RG171 - RG174 1RG191 - RG193 1RG211 - RG213 1RG221 - RG222 1RH101 - RH102 1RH111 - RH112 1RH121 - RH122

2. Spares Affected Examine your spares supply for the parts or components identified in Paragraph 2.C., Parts Necessary for Each Airplane. If any parts or components are found, refer to Paragraph 2.C. for the recommended use.

B. Concurrent Requirements None.

C. Reason Accomplishment of this service bulletin ensures that the upper or lower rudder Power Control Modules (PCM) do not create a hard-over condition in the event of a manifold cracking and separation. This will be accomplished by replacing the rudder PCM manifold access cap with a two-piece cap that includes a retention feature for the yaw damper modulating piston assembly in the rudder PCM. The secondary retention engages an existing window in the sleeve of the yaw damper modulating piston assembly.

This restricts the yaw damper modulating piston assembly from significantly shifting and causing considerable uncommanded input to the Rudder PCM main control valve in an event where the primary retention endcap is detached or compromised. Uncommanded input to the Rudder PCM main control valve may create a hard-over condition. A hard-over condition can result in a high speed runway excursion after touchdown in a landing.

Boeing Service Related Problem (SRP) 747-SRP-27-0193 is related to this service bulletin.

Original Issue: September 30, 2010 747-27A2497 10 of 24 BOEING SERVICE BULLETIN 747-27A2497

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D. Description Open access to the upper and the lower rudder PCM. Replace each rudder PCM. As an alternative, you can make the change to each PCM as given in Parker service bulletin 241700-27-333. Do the operational tests. Close access. Put the airplane back to a serviceable condition.

The work in this service bulletin is done in the maintenance zone(s) given below.

Affected Maintenance Zones ZoneModel 325, 326747SP E. Compliance The Federal Aviation Administration (FAA) will possibly release an Airworthiness Directive related to this service bulletin. The Airworthiness Directive will make the compliance tasks and times given in this service bulletin mandatory.

Boeing recommends that the change given in this service bulletin be done within 24 months or 8,400 flight hours after the original issue date on this service bulletin, whichever occurs first.

F. Approval This service bulletin was examined by the Federal Aviation Administration (FAA). The changes specified in this service bulletin comply with the applicable regulations and are FAA approved, as well as European Aviation Safety Agency (EASA)/Joint Aviation Authorities (JAA) approved for all EASA/JAA approved airplanes listed in the service bulletin effectivity. This service bulletin and its approval were based on the airplane in its original Boeing delivery configuration or as modified by other approved Boeing changes.

If an airplane has a non-Boeing modification or repair that affects a component or system also affected by this service bulletin, the operator is responsible for obtaining appropriate regulatory agency approval before incorporating this service bulletin.

G. Manpower Work Package 1, Option 1: Replace the Upper Rudder Power Control Module (PCM) Elapsed HoursTask-HoursNumber of Persons Task

1.503.002Open Access

2.004.002Figure 1

0.501.002Test

1.503.002Close Access

5.5011.00Total per airplane

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Work Package 1, Option 2: Change the Upper Rudder Power Control Module (PCM) Elapsed HoursTask-HoursNumber of Persons Task

0.501.002Open Access

0.750.751Test

0.501.002Close Access

1.752.75Total per airplane Work Package 2, Option 1: Replace the Lower Rudder Power Control Module (PCM) Elapsed HoursTask-HoursNumber of Persons Task

1.503.002Open Access

2.004.002Figure 2

0.501.002Test

1.503.002Close Access

5.5011.00Total per airplane Work Package 2, Option 2: Change the Lower Rudder Power Control Module (PCM) Elapsed HoursTask-HoursNumber of Persons Task

0.501.002Open Access

0.750.751Test

0.501.002Close Access

1.752.75Total per airplane Work Package Number 1 can be done at the same time as Work Package Number 2.

H. Weight and Balance Changes None.

I. Electrical Load Data Not changed.

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