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Commercial Airplane Group 767 Service Bulletin ALERT Number: 767-78A0081 Revision Transmittal SheetDate: July 24, 1997 Revision 2: April 19, 2001 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) 2000-09-04, Amendment 39-11712, is related to this service bulletin.
More work is necessary on airplanes changed as shown in the Revision 1 of this service bulletin.
Airplanes were added to Group 2 of the service bulletin effectivity.
REASON FOR REVISION This revision adds the inspection interval of the Electro-Mechanical brake and CDU cone brake for airplanes equipped with thrust reversers that have been modified in accordance with Boeing Service Bulletin 767-78-0063 or after the equivalent modification (Production Revision Record B11481-90) incorporating in production. Revise the service bulletin effectivity to add Group 2 airplanes which is included all 767-200, -300 and -300F airplanes (including future 767-200, -300 and -300F airplanes) with CF6-80C2 engines from production control line 475. Also, the Industry Support Information statement has been changed.
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: April 19, 2001 767-78A0081 Revision Transmittal Page 1 of 1
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Commercial Airplane Group 767 Service Bulletin ALERT Number: 767-78A0081 SummaryDate: July 24, 1997 Revision 2: April 19, 2001 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 and the Thrust Reverser Actuation System (TRAS) brake have the holding torque required to prevent any uncommanded thrust reverser sleeve movement.
The CDU cone brake and the TRAS brake are primary safety devices required to prevent inadvertent thrust reverser sleeve movement. To meet the system reliability requirements, periodic torque checks are required to ensure the integrity of these locking devices. A failure of either of these locks is not detected during normal operation. The torque check intervals have been determined through industry-wide accepted probability and reliability methods.
The TRAS lock is a solenoid activated disk brake this is connected to the upper angle gearbox by a flexible drive shaft. The brake is released when 28 VDC is applied from the control circuit and is locked at all other times. Low torque can be the result of a brake or flexible shaft failure.
The CDU cone brake is a spring load, unidirectional device that prevent rotation of the air motor in the deploy direction. The cone brake always allows the air motor to rotate in the stow direction. The brake is disengaged when the directional control valve actuator piston is commanded to the deploy position from the control circuit.
Boeing Service Related Problem (SRP) 767-SRP-78-0036 is related to this service bulletin.
ACTION For Group 1 airplanes that have not incorporated Boeing Service Bulletin 767-78-0063, on each thrust reverser half, do a functional test on the CDU cone brake to verify the holding torque.
For Group 1 airplanes that have incorporated Boeing Service Bulletin 767-78-0063 and Group 2 airplanes, on each thrust reverser half, do a functional test of the Electro-Mechanical brake and CDU cone brake to verify the holding torque.
EFFECTIVITY All 767-200, -300 and -300F 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 767-78-0063, Boeing recommends the operators repeat CDU cone brake test every 650 flight hours.
For Group 1 airplanes on which Boeing Service Bulletin 767-78-0063 has been incorporated and on Group 2 airplanes, Boeing recommends the operators repeat the Electro-Mechanical brake and CDU cone brake tests every 1,000 flight hours.
Federal Aviation Administration (FAA) Airworthiness Directive (AD) 2000-09-04, Amendment 39-11712, is related to this service bulletin.
767-78A0081 Summary Page 1 of 2
ALERT BOEING SERVICE BULLETIN 767-78A0081 ALERT
INDUSTRY SUPPORT INFORMATION Boeing warranty remedies are not available for the inspection given in this service bulletin.
MANPOWER Total Man-hours - 6 for each airplane Elapsed Time - 3 Hours
MATERIAL INFORMATION None ELECTRO−MECHANICAL BRAKE
DO A FUNCTIONAL TEST ON THE FOR EACH THRUST REVERSER HALF:
DO A FUNCTIONAL TEST ON THE FOR EACH THRUST REVERSER HALF:
CENTER DRIVE UNIT (CDU) CONE BRAKE
RIGHT SIDE OPPOSITE
LEFT SIDE SHOWN, S13036 July 24, 1997 767-78A0081 Revision 2: April 19, 2001 Summary Page 2 of 2
Commercial Airplane Group 767 Service Bulletin ALERT Number: 767-78A0081 Date: July 24, 1997 Revision 2: April 19, 2001 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 NOTE:* THIS EFFECTIVITY INCLUDES ALL FUTURE 767-200, -300 AND -300F AIRPLANES WITH CF6-80C2 ENGINES FROM PRODUCTION LINE NUMBER 475, EVEN IF THEY ARE NOT LISTED IN THIS SECTION.
1. Airplanes Refer to Service Bulletin Index Document D624T001, Part 3 for Airplane Variable Number, Line Number, and Serial Number data.
Airplane Models:
767-200 767-300 767-300F
IDENTIFICATION BY CUSTOMER, CUSTOMER CODE, GROUP AND VARIABLE NUMBER
AEROFLOT (ARO) 2 VS321-VS324
AIR ALGERIE (ALG) 1 VK131-VK133
AIR CANADA (ACN) 1 VN052 VN054 VN057 VN731 2 VS546-VS548
AIR DO (HIA) 2 VS176
AIR EUROPA (ARE) 2 VS291-VS292
AIR EUROPE ITALY (EIY) 1 VN811-VN812
AIR FRANCE (AFA) 2 VN634-VN635 July 24, 1997 767-78A0081 Revision 2: April 19, 2001 Page 1 of 14
ALERT BOEING SERVICE BULLETIN 767-78A0081 ALERT
AIR MADAGASCAR (MAD) 2 VS316
AIR MAURITIUS (MAU) 1 VF001-VF002
AIR NEW ZEALAND (ANZ) 1 VN651-VN652 2 VN653-VN658 VS112-VS113
AIR PACIFIC (APC) 2 VN676
AIR SEYCHELLES (ASY) 1 VF051 2 VL941 VS526 AIR 2000 (ATZ) 2 VN921-VN922 VS216-VS217
AIRTOURS INT'L AIRWAYS (GUE) 2 VN951-VN953
ALITALIA (ALI) 2 VL701-VL702 VN422-VN427 VS366-VS367 VS401
ALL NIPPON AIRWAYS (ANA) 1 VK081-VK102 VN191-VN195 2 VK103-VK113 VN196-VN198 VR401
AMERICAN AIRLINES (AAL) 1 VN001-VN028 2 VN029-VN041 VS196-VS203
AMIRI FLIGHT (ABD) 2 VS391
ANSETT AUSTRALIA (ANS) 2 VL755
ASIANA AIRLINES (AAR) 1 VK141-VK142 VN753 2 VK143-VK148 VL703 VR426 VS231 VW851
BOEING (TBC) 2 VY999
BRITANNIA AIRWAYS (BRI) 1 VB331-VB332 2 VL911-VL913 VS051-VS056
BRITANNIA AIRWAYS AB (TNS) 2 VL914
CANADIAN AIRLINES (CDI) 1 VN051 VN053 VN058-VN062 VN751-VN752 VN813 2 VN732 VS381-VS382 July 24, 1997 767-78A0081 Revision 2: April 19, 2001 2
ALERT BOEING SERVICE BULLETIN 767-78A0081 ALERT
CHINA UNITED AIRLINES (CUL) 2 VS274
CITY BIRD (CBD) 2 VN436 VS177
CONTINENTAL AIRLINES (CAL) 2 VR051-VR058
DELTA AIR LINES (DAL) 1 VN301-VN306 2 VL753 VS073-VS078 VS266-VS273 VS466-VS471
EUROFLY (EUY) 2 VS392
EVA AIR (EVA) 1 VN471-VN472 VN791-VN792 2 VB441-VB444
GULF AIR (GUL) 1 VL004-VL006 VN307-VN308 2 VN309-VN310 VN313-VN314 H.M.S.F. AND AMEDEO CORP. (BWN) 2 VF180
IBERIA AIRLINES (IBE) 2 VN546-VN547
ITOCHU CORPORATION (CIT) 2 VF181-VF184
JAPAN AIRLINES (JAL) 2 VK012-VK016 VK181 VK186 VR441 VR461 K.B.A. FOUNDATION (KBA) 2 VN312
KALAIR USA CORP (KLA) 2 VN311
KENYA AIRWAYS (KEN) 2 VS331
KLM - ROYAL DUTCH AIRLINES (KLM) 2 VL891-VL900 VS136-VS137
LANCHILE AIRLINES (LAN) 1 VN063-VN064 2 VN968-VN970 VR251 VR256-VR257 VS131-VS133
LAPA ARGENTINA (LAZ) 2 VS111
LOT POLISH AIRLINES (LOT) 1 VF041-VF042 VN291 2 VN292-VN293 July 24, 1997 767-78A0081 Revision 2: April 19, 2001 3
ALERT BOEING SERVICE BULLETIN 767-78A0081 ALERT
MALEV HUNGARIAN AIRLINES (HGA) 1 VL003 2 VF171-VF172
MID EAST JET (SKL) 2 VF251
QANTAS (QAN) 1 VN081-VN093 2 VN094-VN099 VS186-VS187 VS486
ROYAL BRUNEI AIRLINES (RBA) 2 VN637-VN638
SKYMARK AIRLINES (SKM) 2 VS261-VS262
SOBELAIR (SBL) 2 VN421 VN636
TRANSBRASIL (TBL) 1 VL001-VL002
UPS (UPS) 2 VR201-VR209 VW701-VW721
US AIRWAYS (USA) 1 VE141-VE151 2 VE152
VARIG AIRLINES (VAR) 1 VE121-VE126 VN055-VN056 VN231-VN234
VIETNAM AIRLINES (VIE) 2 VL751-VL752 VL754
IDENTIFICATION BY VARIABLE NUMBER GROUP 1 VB331-VB332 VE121-VE126 VE141-VE151 VF001-VF002 VF041-VF042 VF051 VK081-VK102 VK131-VK133 VK141-VK142 VL001-VL006 VN001-VN028 VN051-VN064 VN081-VN093 VN191-VN195 VN231-VN234 VN291 VN301-VN308 VN471-VN472 VN651-VN652 VN731 VN751-VN753 VN791-VN792 VN811-VN813 GROUP 2 * VB441-VB444 VE152 VF171_VF172 VF180-VF184 VF251 VK012-VK016 VK103-VK113 VK143-VK148 VK181 VK186 VL701-VL703 VL751-VL755 VL891-VL900 VL911-VL914 VL941 VN029-VN041 VN094-VN099 VN196-VN198 VN292-VN293 VN309-VN314 VN421-VN427 VN436 VN546-VN547 VN634-VN638 VN653-VN658 VN676 VN732 VN921-VN922 VN951-VN953 VN968-VN970 VR051-VR058 VR201-VR209 VR251 VR256-VR257 VR401 VR426 VR441 VR461 VS051-VS056 VS073-VS078 VS111-VS113 VS131-VS133 VS136-VS137 VS176-VS177 VS186-VS187 VS196-VS203 VS216-VS217 VS231 VS261-VS262 VS266-VS274 VS291-VS292 VS316 VS321-VS324 VS331 VS366-VS367 VS381-VS382 VS391-VS392 VS401 VS466-VS471 VS486 VS526 VS546-VS548 VW701-VW721 VW851 VY999 July 24, 1997 767-78A0081 Revision 2: April 19, 2001 4
ALERT BOEING SERVICE BULLETIN 767-78A0081 ALERT
2. Spares None July 24, 1997 767-78A0081 Revision 2: April 19, 2001 5
ALERT BOEING SERVICE BULLETIN 767-78A0081 ALERT B. Concurrent Requirements None C. Reason This inspection will make sure that the center drive unit (CDU) cone brake and the Thrust Reverser Actuation System (TRAS) brake have the holding torque required to prevent any uncommanded thrust reverser sleeve movement.
The CDU cone brake and the TRAS brake are primary safety devices required to prevent inadvertent thrust reverser sleeve movement. To meet the system reliability requirements, periodic torque checks are required to ensure the integrity of these locking devices. A failure of either of these locks is not detected during normal operation. The torque check intervals have been determined through industry-wide accepted probability and reliability methods.
The TRAS lock is a solenoid activated disk brake this is connected to the upper angle gearbox by a flexible drive shaft. The brake is released when 28 VDC is applied from the control circuit and is locked at all other times. Low torque can be the result of a brake or flexible shaft failure.
The CDU cone brake is a spring load, unidirectional device that prevent rotation of the air motor in the deploy direction. The cone brake always allows the air motor to rotate in the stow direction. The brake is disengaged when the directional control valve actuator piston is commanded to the deploy position from the control circuit.
Boeing Service Related Problem (SRP) 767-SRP-78-0036 is related to this service bulletin.
Revision 1 is sent to change the inspection interval for the CDU cone brake test from 600 to 650 flight hours to coincide with operators maintenance schedule.
Revision 2 adds the inspection interval of the Electro-Mechanical brake and CDU cone brake for airplanes equipped with thrust reversers that have been modified in accordance with Boeing Service Bulletin 767-78-0063 or after the equivalent modification (Production Revision Record B11481-90) incorporating in production. Revise the service bulletin effectivity to add Group 2 airplanes which is included all 767-200, -300 and -300F airplanes (including future 767-200, -300 and -300F airplanes) with CF6-80C2 engines from production control line 475. Also, the Industry Support Information statement has been changed.
D. Description For Group 1 airplanes that have not incorporated Boeing Service Bulletin 767-78-0063, on each thrust reverser half, do a functional test on the CDU cone brake to verify the holding torque.
For Group 1 airplanes that have incorporated Boeing Service Bulletin 767-78-0063 and Group 2 airplanes, on each thrust reverser half, do a functional test of the Electro-Mechanical brake and CDU cone brake to verify the holding torque.
Revision 1 - No more work is necessary on airplanes changed as shown in the initial release of this service bulletin.
Revision 2 - More work is necessary on airplanes changed as shown in the Revision 1 of this service bulletin.
An evaluation form is attached to this service bulletin. Please use this form to tell us what you think of the quality of this service bulletin.
July 24, 1997 767-78A0081 Revision 2: April 19, 2001 6
ALERT BOEING SERVICE BULLETIN 767-78A0081 ALERT E. 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 767-78-0063, Boeing recommends the operators repeat CDU cone brake test every 650 flight hours.
For Group 1 airplanes on which Boeing Service Bulletin 767-78-0063 has been incorporated and on Group 2 airplanes, Boeing recommends the operators repeat the Electro-Mechanical brake and CDU cone brake tests every 1,000 flight hours.
Federal Aviation Administration (FAA) Airworthiness Directive (AD) 2000-09-04, Amendment 39-11712, is related to this service bulletin.
F. Approval This service bulletin was examined by the Federal Aviation Administration (FAA). The changes specified in this service bulletin comply with the applicable Federal Aviation Regulations (FAR) and are FAA approved. This service bulletin and the FAA approval were based on the airplane in its original Boeing delivery configuration or as modified by other FAA 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.
This service bulletin has been approved by the FAA. In addition, the Manager of the FAA Seattle Aircraft Certification Office approves the inspection and tests defined in this service bulletin as an alternative method of compliance to the requirements of paragraphs (d)(2), (f) and (g) of AD 2000-09-04. All provisions of AD 2000-09-04 that are not specifically referenced in the above sentence remain fully applicable and must be complied with.
G. Manpower Approximately 6 man-hours and 2 persons are necessary to do this test for each airplane.
Time does not include CDU replacement.
This estimate is for direct labor only, done by an experienced crew. Adjust the estimate with operator man-hour data if necessary. The estimate does not include lost time. These are some examples of lost time:
- Time to adjust to the workplace
- Time to schedule the work
- Time to examine the work
- Time to cure the materials
- Time to make the parts
- Time to find the tools.
H. Weight and Balance Changes None I. Electrical Load Data Not changed July 24, 1997 767-78A0081 Revision 2: April 19, 2001 7
ALERT BOEING SERVICE BULLETIN 767-78A0081 ALERT J. References
1. Existing Data:
a. Service Related Problem (SRP) 767-SRP-78-0036
b. 767 Maintenance Manual (AMM) Subject 71-11-04, 78-31-21
c. Boeing Service Bulletin 767-78-0047, "Thrust Reverser (CF6-80C2 Engines) - Thrust Reverser Control System - Operational Test"
d. Boeing Service Bulletin 767-78-0063, "Exhaust (GE CF6-80C2 Engines) - Thrust Reverser - Lock Installation"
2. Data supplied with this service bulletin:
None
3. Installation Drawings:
None K. Publications Changed None L. Interchangeability and Intermixability of Parts Refer to Paragraph 2.E., Existing Parts Accountability, for interchangeability and intermixability information.
July 24, 1997 767-78A0081 Revision 2: April 19, 2001 8