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Commercial Airplanes 767 Service Bulletin ALERT Number: 767-78A0100 Original Issue: October 26, 2010 ATA System: 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BOEING PROPRIETARY, CONFIDENTIAL, AND/OR TRADE SECRET Copyright © 2010 The Boeing Company Unpublished Work - All Rights Reserved Boeing claims copyright in each page of this document only to the extent that the page contains copyrightable subject matter.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.
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Original Issue: October 26, 2010 767-78A0100 1 of 26
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Table of Contents
Summary5
1. PLANNING INFORMATION9
A. Effectivity9
1. Airplanes9
2. Spares Affected ........................................ 1 3 B. Concurrent Requirements ...................................... 1 3 C. Reason ................................................ 1 3 D. Description .............................................. 1 3 E. Compliance .............................................. 1 4 F. Approval ............................................... 1 4 G. Manpower .............................................. 1 4 H. Weight and Balance Changes .................................... 1 5 I. Electrical Load Data ......................................... 1 5 J. References .............................................. 1 5
1. Existing Data .......................................... 1 5
2. Data supplied with this Service Bulletin ............................ 1 6
3. Installation Drawings Used in the Preparation of this Service Bulletin ............ 1 6 K. Publications Affected ........................................ 1 6 L. Interchangeability and Intermixability of Parts ........................... 1 6
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 767 Service Bulletin ALERT SummaryNumber: 767-78A0100Original Issue: October 26, 2010 ATA System: 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 767-78A0097 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 767-78A0097 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 767-78A0097, 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 767-78A0097.
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 (SRP) 767-SRP-78-0061 is related to this service bulletin.
Boeing Fleet Team Digest (FTD) 767 FTD 78-07001 is related to this service bulletin.
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Original Issue: October 26, 2010 767-78A0100 5 of 26
ACTION (PRR B12901-100S) 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 767-200/300/300F/400ER Airplanes powered by GE 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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BOEING SERVICE BULLETIN 767-78A0100
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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.
HRUST REVERSER (T/F 1994538 _EFT HALF SHOWN, RIGHT HALF ÓPPOSITE Original Issue: October 26, 2010 767-78A0100
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Commercial Airplanes 767 Service Bulletin ALERT Number: 767-78A0100 Original Issue: October 26, 2010 ATA System: 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 D624T001 Part 3 for Airplane Variable Number, Line Number, and Serial Number data.
This service bulletin is for the airplanes shown below. An equivalent change is on subsequent production airplanes. Refer to PRR B12901-100S for data about this change.
DESCRIPTIONCONFIGURATIONGROUP 767-200/300/300F/400ER airplanes powered by General Electric (GE) CF6-80C2 engines -1 Airplane Models:
767-200, 767-300, 767-300F, 767-400ER GroupVariable Number 1VB331 - VB332 1VB441 - VB444 1VE121 - VE126 1VE141 - VE149 1VE151 - VE152
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GroupVariable Number 1VF001 - VF002 1VF041 - VF042 1VF051 1VF171 - VF172 1VF180 - VF184 1VF251 1VK012 - VK016 1VK081 - VK082 1VK084 - VK113 1VK131 - VK133 1VK141 - VK148 1VK181 1VK186 1VL001 - VL006 1VL701 - VL703 1VL751 - VL755 1VL891 - VL900 1VL911 - VL914 1VL941 1VN001 - VN041 1VN051 - VN064 1VN081 - VN099 1VN191 - VN198 1VN231 - VN234 1VN291 - VN293 1VN301 - VN314 1VN421 - VN427 1VN436 1VN471 - VN472 1VN546 - VN547 1VN634 - VN638 1VN651 - VN658 1VN676
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GroupVariable Number 1VN731 - VN732 1VN751 - VN753 1VN791 - VN792 1VN811 - VN813 1VN921 - VN922 1VN951 - VN953 1VN968 - VN970 1VQ001 - VQ021 1VQ071 - VQ086 1VQ111 1VR051 - VR060 1VR081 1VR084 1VR086 - VR089 1VR106 - VR109 1VR201 - VR211 1VR251 1VR256 - VR260 1VR266 - VR272 1VR401 1VR426 1VR441 1VR461 1VS051 - VS056 1VS073 - VS078 1VS111 - VS113 1VS131 - VS133 1VS136 - VS137 1VS176 - VS177 1VS186 - VS187 1VS196 - VS203 1VS216 - VS217 1VS231
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GroupVariable Number 1VS261 - VS263 1VS266 - VS274 1VS291 - VS293 1VS316 1VS321 - VS324 1VS331 - VS333 1VS336 - VS337 1VS366 - VS367 1VS381 - VS382 1VS391 - VS392 1VS401 1VS466 - VS472 1VS486 1VS526 1VS546 - VS549 1VS701 - VS736 1VS751 - VS759 1VS861 1VS891 1VS901 - VS910 1VS921 - VS925 1VS931 - VS933 1VS941 1VS951 - VS952 1VS961 - VS962 1VT501 1VT511 - VT513 1VT521 - VT523 1VT531 - VT533 1VT541 - VT543 1VV001 1VW701 - VW721 1VW851
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