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Commercial Airplanes 747 Service Bulletin ALERT Number: 747-78A2185 Original Issue: October 26, 2010 ATA System: 7831 7834 SUBJECT: EXHAUST (GE CF6-80 Series Engines) - Thrust Reverser Control System - Short Flexible Drive Shaft Replacement 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BOEING PROPRIETARY, CONFIDENTIAL, AND/OR TRADE SECRET Copyright © 2010 The Boeing Company Unpublished Work - All Rights Reserved Boeing claims copyright in each page of this document only to the extent that the page contains copyrightable subject matter.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.
BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: October 26, 2010 747-78A2185 1 of 26
2.0
BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: October 26, 2010 747-78A2185 2 of 26 BOEING SERVICE BULLETIN 747-78A2185
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Table of Contents
Summary5
1. PLANNING INFORMATION9
A. Effectivity9
1. Airplanes9
2. Spares Affected ........................................ 1 2 B. Concurrent Requirements ...................................... 1 2 C. Reason ................................................ 1 2 D. Description .............................................. 1 3 E. Compliance .............................................. 1 3 F. Approval ............................................... 1 3 G. Manpower .............................................. 1 3 H. Weight and Balance Changes .................................... 1 4 I. Electrical Load Data ......................................... 1 4 J. References .............................................. 1 5
1. Existing Data .......................................... 1 5
2. Data supplied with this Service Bulletin ............................ 1 5
3. Installation Drawings Used in the Preparation of this Service Bulletin ............ 1 5 K. Publications Affected ........................................ 1 5 L. Interchangeability and Intermixability of Parts ........................... 1 5
2. MATERIAL INFORMATION ........................................ 1 7 A. Material - Price and Availability ................................... 1 7 B. Industry Support Information .................................... 1 7 C. Parts Necessary For Each Airplane ................................. 1 7
1. Kits/Parts ............................................ 1 7
2. Parts and Materials Supplied by the Operator ........................ 1 7
3. Parts Modified and Reidentified ................................ 1 7
4. Parts Removed and Not Replaced .............................. 1 7 D. Parts Necessary to Change Spares ................................. 1 7 E. Special Tooling - Price and Availability ............................... 1 7 F. Special Tooling Necessary to do this Service Bulletin ....................... 1 7
3. ACCOMPLISHMENT INSTRUCTIONS .................................. 1 9 A. GENERAL INFORMATION ..................................... 1 9 B. WORK INSTRUCTIONS ....................................... 1 9 FIGURE 1: THRUST REVERSER LEFT HALF ELECTRO-MECHANICAL BRAKE - SHORT FLEXSHAFT REPLACEMENT ........................................ 2 1 FIGURE 2: THRUST REVERSER RIGHT HALF ELECTRO-MECHANICAL BRAKE - SHORT FLEXSHAFT REPLACEMENT ........................................ 2 4
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Commercial Airplanes 747 Service Bulletin ALERT SummaryNumber: 747-78A2185Original Issue: October 26, 2010 ATA System: 7831 7834 SUBJECT: EXHAUST (GE CF6-80 Series Engines) - Thrust Reverser Control System - Short Flexible Drive Shaft Replacement
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 will prevent damage and the possible breakage of the short flexshafts related to the electro-mechanical brake of General Electric (GE) CF6-80C2 engines. Flexshaft breakage removes the primary level of protection against an uncommanded thrust reverser deployment occurrence. Uncommanded T/R deployment could result in a loss of control of the airplane.
In 1998 operators first told Boeing of unserviceable short flexible drive shafts (also referred to as 'flexshafts') related to the electro-mechanical brake of the Thrust Reverser Actuation System (TRAS) on GE CF6-80C2 engines. Boeing released service bulletin 747-78A2179 to replace these short flexshafts individually when necessary. But since the release of that service bulletin, flexshaft damage and breakage has continued to occur.
The performance of the short flexshaft installed by service bulletin 747-78A2179 did not have the necessary reliability for the system. Since its installation on GE CF6-80C2 engines, short flexshaft part number 3278500-7 has had a number of unserviceable occurrences reported by operators. Similar to the reports described in Boeing service bulletin 747-78A2179, the unserviceable flexshafts were found to have cores that had become sheared and unbraided. The manufacturer of the engines, General Electric (GE), and Middle River Aircraft Systems (MRAS), the supplier of the T/R, have changed the design and supplier of the flexshafts. The flexshaft design change incorporates a better end fitting attachment, a larger core diameter with the core wound specifically for use on a left and right T/R half to increase its resistance to damage. The incorporation of this service bulletin is the recommended alternative to Boeing service bulletin 747-78A2179.
This service bulletin, together with MRAS service bulletin CF6-80C2 S/B 78-1168, gives instructions to replace the short flexible drive shaft of each T/R half of each engine. Left and right halves of each T/R will have a new flexshaft installed that is specific to each half.
Boeing Service Related Problem 747-SRP-78-0061 is related to this service bulletin.
Boeing Fleet Team Digest 747 FTD 78-07001 is related to this service bulletin.
BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: October 26, 2010 747-78A2185 5 of 26
ACTION (PRR 85901-106RS) Work Package 1 - Prepare the thrust reverser (T/R) and get access the short flexshaft between the electro-mechanical brake and the upper angle gearbox of each T/R left half. Replace the short flexshaft.
Work Package 2 - Prepare the thrust reverser (T/R) and get access the short flexshaft between the electro-mechanical brake and the upper angle gearbox of each T/R right half. Replace the short flexshaft.
EFFECTIVITY 747-200B/300/400/400D/400F airplanes powered by General Electric CF6-80C2 engines. Refer to Paragraph
1.A., Effectivity 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 60 months after the original issue date of this service bulletin.
INDUSTRY SUPPORT INFORMATION Boeing warranty remedies are not available for the configuration changes given in this service bulletin.
MANPOWER Refer to Paragraph 1.G., Manpower.
MATERIAL INFORMATION Operator Supplied Parts/Materials.
Refer to Paragraph 2.A., Material - Price and Availability.
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Original Issue: October 26, 2010 747-78A2185 6 of 26 BOEING SERVICE BULLETIN 747-78A2185
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BOEING SERVICE BULLETIN 747-78A2185
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REPLACE THE SHORT
FLEXSHAFT BETWEEN THE
ELECTRO-MECHANICAL
BRAKE AND THE UPPER
ANGLE GEARBOX ON EACH
T/R HALF OF EACH ENGINE.
_EFT HALF SHOWN, F F SHOWN, RIGHT HALF OPPOSITE 1994539 Original Issue: October 26, 2010 747-78A2185
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Commercial Airplanes 747 Service Bulletin ALERT Number: 747-78A2185 Original Issue: October 26, 2010 ATA System: 7831 7834 SUBJECT: EXHAUST (GE CF6-80 Series Engines) - Thrust Reverser Control System - Short Flexible Drive Shaft Replacement
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 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. Refer to PRR 85901-106RS for data about this change.
DESCRIPTIONCONFIGURATIONGROUP 747-200B/300/400/400D/400F airplanes powered by General Electric (GE) CF6-80C2 engines -1 Airplane Models:
747-200B, 747-300, 747-400, 747-400D, 747-400F GroupVariable Number 1RD166 - RD167 1RF001 - RF006 1RL401 - RL403 1RL411 - RL430 1RL461 - RL462
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GroupVariable Number 1RL471 - RL481 1RL511 - RL516 1RL521 - RL522 1RL531 - RL534 1RL561 - RL568 1RL571 - RL572 1RL576 - RL577 1RL579 1RL651 - RL655 1RL671 - RL675 1RL681 - RL684 1RM001 - RM007 1RM010 1RM026 - RM030 1RM051 - RM053 1RM071 1RM081 - RM084 1RM116 - RM117 1RM126 - RM132 1RM156 - RM158 1RM191 - RM192 1RM231 - RM233 1RM316 - RM318 1RM351 - RM355 1RM401 - RM403 1RM426 1RM431 1RM441 - RM443 1RM445 1RM801 - RM803 1RM861 - RM863 1RM891 - RM899 1RM901 - RM906
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GroupVariable Number 1RM911 1RR701 1RR721 - RR724 1RR746 - RR748 1RS331 - RS333 1RS341 - RS342 1RS781 - RS782 1RT001 - RT014 1RT021 - RT022 1RT041 - RT047 1RT071 - RT075 1RT121 1RT131 - RT137 1RT151 - RT152 1RT161 - RT168 1RT431 - RT447 1RT531 - RT535 1RT591 1RT641 - RT657 1RT681 - RT682 1RT691 - RT699 1RT701 - RT704 1RT711 - RT717 1RT741 - RT742 1RT751 - RT757 1RT776 - RT777 1RT801 - RT803 1RT861 - RT864 1RT931 - RT932 1RT945 - RT949 1RT951 - RT955 1RT966 - RT967 1RU031 - RU032
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Original Issue: October 26, 2010 747-78A2185 11 of 26 BOEING SERVICE BULLETIN 747-78A2185
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GroupVariable Number 1RU051 - RU052 1RU059 - RU062 1RU101 - RU102 1RU801 - RU809 1RU831 - RU841
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 will prevent damage and the possible breakage of the short flexshafts related to the electro-mechanical brake of General Electric (GE) CF6-80C2 engines. Flexshaft breakage removes the primary level of protection against an uncommanded thrust reverser deployment occurrence. Uncommanded T/R deployment could result in a loss of control of the airplane.
In 1998 operators first told Boeing of unserviceable short flexible drive shafts (also referred to as 'flexshafts') related to the electro-mechanical brake of the Thrust Reverser Actuation System (TRAS) on GE CF6-80C2 engines. Boeing released service bulletin 747-78A2179 to replace these short flexshafts individually when necessary. But since the release of that service bulletin, flexshaft damage and breakage has continued to occur. The performance of the short flexshaft installed by service bulletin 747-78A2179 did not have the necessary reliability for the system. Since its installation on GE CF6-80C2 engines, short flexshaft part number 3278500-7 has had a number of unserviceable occurrences reported by operators. Similar to the reports described in Boeing service bulletin 747-78A2179, the unserviceable flexshafts were found to have cores that had become sheared and unbraided. The manufacturer of the engines, General Electric (GE), and Middle River Aircraft Systems (MRAS), the supplier of the T/R, have changed the design and supplier of the flexshafts. The flexshaft design change incorporates a better end fitting attachment, a larger core diameter with the core wound specifically for use on a left and right T/R half to increase its resistance to damage. The incorporation of this service bulletin is the recommended alternative to Boeing service bulletin 747-78A2179.
This service bulletin, together with MRAS service bulletin CF6-80C2 S/B 78-1168, gives instructions to replace the short flexible drive shaft of each T/R half of each engine. Left and right halves of each T/R will have a new flexshaft installed that is specific to each half.
Boeing Service Related Problem 747-SRP-78-0061 is related to this service bulletin.
Boeing Fleet Team Digest 747 FTD 78-07001 is related to this service bulletin.
BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: October 26, 2010 747-78A2185 12 of 26 BOEING SERVICE BULLETIN 747-78A2185