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July 24, 1997 Revision 3 July 29, 2004 747-78A2166 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 1o f2 6 Commercial Airplane Group 747 Service Bulletin Number: 747-78A2166 Date: July 24, 1997 Revision 3 July 29, 2004 ATA System: 7830 SUBJECT: EXHAUST (CF6-80C2 Engines) - Thrust Reverser - Thrust Reverser Control System - Center Drive Unit (CDU) Cone Brake Integrity Test
BOEING PROPRIETARY, CONFIDENTIAL, AND/OR TRADE SECRET Copyright © 1997 The Boeing Company Unpublished Work - All Rights Reserved Boeing claims copyright in each page of this document only to the extent that the page contains copyrightable subject matter.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, BBJ, DC-8, DC-9, DC-10, MD-10, MD-11, MD-80, MD-88, MD-90, and the red-white-and-blue 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.
BLANK PAGE July 24, 1997 Revision 3 July 29, 2004 747-78A2166 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 2o f2 6 BOEING SERVICE BULLETIN 747-78A2166
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Table of Contents July 24, 1997 Revision 3 July 29, 2004 747-78A2166 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 3o f2 6 BOEING SERVICE BULLETIN 747-78A2166 Table of Contents
R e v i s i o n T r a n s m i t t a l S h e e t5
S u m m a r y7
1 . P L A N N I N G I N F O R M A T I O N ..................................... 1 1 A . E f f e c t i v i t y ............................................ 1 1 1 . A i r p l a n e s ......................................... 1 1 2 . S p a r e s A f f e c t e d ...................................... 1 6 B . C o n c u r r e n t R e q u i r e m e n t s................................... 1 6 C . R e a s o n ............................................ 1 6 D . D e s c r i p t i o n ........................................... 1 7 E . C o m p l i a n c e ........................................... 1 7 F . A p p r o v a l............................................ 1 8 G . M a n p o w e r ........................................... 1 8 H . W e i g h t a n d B a l a n c e C h a n g e s................................. 1 8 I . E l e c t r i c a l L o a d D a t a...................................... 1 8 J . R e f e r e n c e s ........................................... 1 8 1 . E x i s t i n g D a t a : ....................................... 1 8
2. Data supplied with this Service Bulletin:19
3. Installation Drawings Used in the Preparation of this Service Bulletin:19
K . P u b l i c a t i o n s A f f e c t e d ...................................... 1 9 L . I n t e r c h a n g e a b i l i t y a n d I n t e r m i x a b i l i t y o f P a r t s......................... 1 9 2 . M A T E R I A L I N F O R M A T I O N ..................................... 2 1 A . M a t e r i a l - P r i c e a n d A v a i l a b i l i t y ................................. 2 1 B . I n d u s t r y S u p p o r t I n f o r m a t i o n .................................. 2 1 C . P a r t s N e c e s s a r y F o r E a c h A i r p l a n e.............................. 2 1 1 . K i t s / P a r t s : ......................................... 2 1 2 . P a r t s a n d M a t e r i a l s S u p p l i e d b y t h e O p e r a t o r :...................... 2 1 3 . P a r t s M o d i f i e d a n d R e i d e n t i f i e d : ............................. 2 1 4 . P a r t s R e m o v e d a n d N o t R e p l a c e d : ............................ 2 1 D . P a r t s N e c e s s a r y t o C h a n g e S p a r e s.............................. 2 1 E . S p e c i a l T o o l i n g - P r i c e a n d A v a i l a b i l i t y ............................. 2 1 F . S p e c i a l T o o l i n g N e c e s s a r y t o d o t h i s S e r v i c e B u l l e t i n ..................... 2 1 3 . A C C O M P L I S H M E N T I N S T R U C T I O N S ............................... 2 3 A . G E N E R A L I N F O R M A T I O N .................................. 2 3
B. WORK INSTRUCTIONS23
FIGURE 1: CDU MANUAL BRAKE RELEASE LEVER, LOCKOUT PLATE AND DRIVE PAD LOCATIONS 26
Table of Contents July 24, 1997 Revision 3 July 29, 2004 747-78A2166 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 4o f2 6 BOEING SERVICE BULLETIN 747-78A2166
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July 24, 1997 Revision 3 July 29, 2004 747-78A2166 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 5o f2 6 Commercial Airplane Group 747 Service Bulletin Number: 747-78A2166 Revision Transmittal Sheet Date: July 24, 1997 Revision 3 July 29, 2004 ATA System: 7830 SUBJECT: EXHAUST (CF6-80C2 Engines) - Thrust Reverser - Thrust Reverser Control System - Center Drive Unit (CDU) Cone Brake Integrity Test This revision includes all pages of the service bulletin.
COMPLIANCE INFORMATION RELATED TO THIS REVISION Federal Aviation Administration (FAA) Airworthiness Directive (AD) 2003-16-16, Amendment 39-13269, is related to this service bulletin revision. AD 2003-16-16, Amendment 39-13269 supersedes AD 2000-09-03.
No airplanes were added to this service bulletin effectivity.
No more work is necessary on airplanes changed as shown in the Revision 2 of this service bulletin.
REASON FOR REVISION This revision is sent to remove reference "767" and add reference "747/747-400" in Paragraph 3.B.1.a, Accomplishment Instructions.
Paragraph 1.A., Effectivity, shows changes of airplane operators. Each operator should examine the Effectivity paragraph for changes.
Vertical lines are put on the left edge of each page, except in Paragraph 1.A., Effectivity, to show the location of important changes.
Pages with no vertical lines have no important changes.
REVISION HISTORY Initial Release: July 24, 1997 Revision 1: October 9, 1997 Revision 2: March 15, 2001 Revision 3: July 29, 2004
July 24, 1997 Revision 3 July 29, 2004 747-78A2166 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 6o f2 6 BOEING SERVICE BULLETIN 747-78A2166
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July 24, 1997 Revision 3 July 29, 2004 747-78A2166 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 7o f2 6 Commercial Airplane Group 747 Service Bulletin Number: 747-78A2166 Summary Date: July 24, 1997 Revision 3 July 29, 2004 ATA System: 7830 SUBJECT: EXHAUST (CF6-80C2 Engines) - Thrust Reverser - Thrust Reverser Control System - Center Drive Unit (CDU) Cone Brake Integrity Test
CONCURRENT REQUIREMENTS None
BACKGROUND This inspection will make sure that the center drive unit (CDU) cone brake continues to provide holding torque against an in-flight thrust reverser deployment.
Two operators have returned five CDU's to the vendor AlliedSignal because of low holding torque. The CDU's had accumulated between 3,400 and 3600 flight hours. AlliedSignal is currently analyzing the returned units to determine the cause of low holding torque.
The cone brake consists of a semi-stationary, spring loaded, friction cone and its rotating mating cone mounted on the CDU, air motor shaft. The brake is disengaged by a pivoted lever, actuated by the translation of the directional control valve (DCV), actuator piston. While the brake is released, it will allow free rotation of the air motor in the direction to stow and deploy the reverser. The cone brake ensures against rotation of the CDU air motor to deploy the reverser when it is engaged by the translation of the DCV actuation piston.
Currently, the CDU cone brake is required to be inspected at 1,000 flight hour intervals. Reducing the inspection interval for the CDU, cone brake from 1,000 to 650 flight hours will make sure that the CDU cone brake continues to provide holding torque against an in-flight, thrust reverser deployment.
Boeing Service Related Problem (SRP) 747-SRP-78-0036 is related to this service bulletin.
ACTION For Group 1 airplanes that have incorporated Boeing Service Bulletin 747-78-2151 or 747-78-2144, and on Group 2 airplanes, on each thrust reverser half, do a functional test on the Electro-Mechanical brake and CDU cone brake to verify the holding torque. Repeat this test every 1,000 flight hours.
For Group 1 airplanes that have not incorporated Boeing Service Bulletin 747-78-2151 or 747-78-2144, on each thrust reverser half, do a functional test on the CDU cone brake to verify the holding torque. Repeat this test every 650 flight hours.
July 24, 1997 Revision 3 July 29, 2004 747-78A2166 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 8o f2 6 BOEING SERVICE BULLETIN 747-78A2166
EFFECTIVITY All 747/747-400 airplanes powered by CF6-80C2 engines.
COMPLIANCE Boeing recommends the operators do this service bulletin within 650 flight hours after receipt of this service bulletin.
For Group 1 airplanes that have not incorporated Boeing Service Bulletin 747-78-2151 or 747-78-2144, Boeing recommends the operators repeat the CDU cone brake tests every 650 flight hours.
For Group 1 airplanes on which Boeing Service Bulletin 747-78-2151 or 747-78-2144 have been incorporated, and on Group 2 airplanes, Boeing recommends the operators repeat the Electro-Mechanical brake and the CDU cone brake tests every 1,000 flight hours.
Federal Aviation Administration (FAA) Airworthiness Directive (AD) 2003-16-16, Amendment 39-13269, is related to this service bulletin. AD 2003-16-16, Amendment 39-13269 supersedes AD 2000-09-03.
INDUSTRY SUPPORT INFORMATION Boeing warranty remedies are not available for the inspection given in this service bulletin.
MANPOWER
MATERIAL INFORMATION None Total Task Hours Elapsed Hours 12 6
July 24, 1997 Revision 3 July 29, 2004 747-78A2166 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 9o f2 6 BOEING SERVICE BULLETIN 747-78A2166 FOR EACH THRUST REVERSER HALF:
DO A FUNCTIONAL TEST ON THE
CENTER DRIVE UNIT (CDU) CONE BRAKE
ELECTRO-MECHANICAL BRAKE
DO A FUNCTIONAL TEST ON THE FOR EACH THRUST REVERSER HALF:
LEFT SIDE SHOWN,
RIGHT SIDE OPPOSITE S11892
July 24, 1997 Revision 3 July 29, 2004 747-78A2166 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 10 of 26 BOEING SERVICE BULLETIN 747-78A2166
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July 24, 1997 Revision 3 July 29, 2004 747-78A2166 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 11 of 26 Commercial Airplane Group 747 Service Bulletin Number: 747-78A2166 Date: July 24, 1997 Revision 3 July 29, 2004 ATA System: 7830 SUBJECT: EXHAUST (CF6-80C2 Engines) - Thrust Reverser - Thrust Reverser Control System - Center Drive Unit (CDU) Cone Brake Integrity Test
1. PLANNING INFORMATION A. Effectivity
1. Airplanes Note: This service bulletin is for airplanes indentified below. The effectivity list shown below is complete for airplanes through line number 1348. However, airplanes after line number 1348 are also affected by this service bulletin.
Refer to Service Bulletin Index Document D6-30300, Part 3 for Airplane Variable Number, Line Number, and Serial Number data.
This service bulletin is for the airplanes shown below.
GROUP CONDITION DESCRIPTION 1 - 747-200/300/400 airplanes with CF6-80C2 engines.
1 747-200/300/400 airplanes with CF6-80C2 engines that have been modified in accordance with Boeing Service Bulletin 747-78-2151 or 747-78-2144 or equivalent modification (Production Revision Record PRR 80452-101R and -102) incorporated in production.
2 747-200/300/400 airplanes with CF6-80C2 engines that have not been modified in accordance with Boeing Service Bulletin 747-78-2151 or 747-78-2144 or equivalent modification (Production Revision Record PRR 80452-101R and -102) incorporated in production.
2 - 747-400 airplanes with CF6-80C2 engines production line number 1064 through 1348.
July 24, 1997 Revision 3 July 29, 2004 747-78A2166 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 12 of 26 BOEING SERVICE BULLETIN 747-78A2166 Airplane models:
747-200B 747-300 747-400 747-400D 747-400F
IDENTIFICATION BY CUSTOMER, CUSTOMER CODE, GROUP AND VARIABLE NUMBER
AEROLINEAS ARGENTINAS (ARG) 1 RT704
AIR ATLANTA ICELANDIC (AID) 1 RS332–RS333
AIR CANADA (ACN) 1 RT701
AIR FRANCE (AFA) 1 RT071–RT075 RT121 RT591 RT711–RT716 2 RL671–RL674 RM401–RM403
AIR INDIA (AIN) 1 RS781–RS782
AIR NAMIBIA (NAM) 2 RT137
AIR NEW ZEALAND (ANZ) 1 RT703 RT932 2 RM082 RM191–RM192
AIR PULLMANTUR (PUL) 1R S 3 3 1
ALL NIPPON AIRWAYS (ANA) 1 RT751–RT755 RT776–RT777 RU831–RU840 2 RM231–RM233 RT756–RT757 RU841
AMIRI FLIGHT (ABD) 2R M 0 8 4
ASIANA AIRLINES (AAR) 1 RR746 RT131–RT134 RU032 2 RM071 RM861–RM862 RR747–RR748 RT135–RT136
ATLAS AIR (TLS) 2 RM891–RM899 RM901–RM906
BAHRAIN ROYAL FLIGHT (BHR) 2R M 4 2 6
BOEING (TBC) 1 RT021–RT022