Boeing SB 747-78-2178: Revision 1, text

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Commercial Airplanes 747 Service Bulletin Number: 747-78-2178 Original Issue: January 22, 2009 Revision 1: August 04, 2011 ATA System: 7834 SUBJECT: EXHAUST - Thrust Reverser Control System - Rolls Royce RB211-524 Powered Uncommanded Thrust Reverser Unlock Event, 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BOEING PROPRIETARY, CONFIDENTIAL, AND/OR TRADE SECRET Copyright © 2009 The Boeing Company Unpublished Work - All Rights Reserved Boeing claims copyright in each page of this document only to the extent that the page contains copyrightable subject matter.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: January 22, 2009 747-78-2178Revision 1: August 04, 2011 1 of 52

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Original Issue: January 22, 2009 747-78-2178Revision 1: August 04, 2011 2 of 52 BOEING SERVICE BULLETIN 747-78-2178

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Table of Contents

Revision Transmittal Sheet5

Summary7

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 2 H. Weight and Balance Changes .................................... 1 2 I. Electrical Load Data ......................................... 1 3 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 4

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 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 ....................................... 2 0 FIGURE 1: P252 PANEL - THRUST REVERSER CONTROL - ENGINE 1 AND 2, RELAY CHANGE . 31 FIGURE 2: P252 PANEL - THRUST REVERSER CONTROL - ENGINE 1, W2281 WIRING CHANGE . 36 FIGURE 3: P252 PANEL - THRUST REVERSER CONTROL - ENGINE 2, W2283 WIRING CHANGE . 38 FIGURE 4: P252 PANEL - THRUST REVERSER CONTROL - ENGINE 1 AND ENGINE 2, RETURN ACCESS ............................................ 4 0 FIGURE 5: P253 PANEL - THRUST REVERSER CONTROL - ENGINE 3 AND 4, RELAY CHANGE . 42 FIGURE 6: P253 PANEL - THRUST REVERSER CONTROL - ENGINE 3, W2285 WIRING CHANGE . 47 FIGURE 7: P253 PANEL - THRUST REVERSER CONTROL - ENGINE 4, W2287 WIRING CHANGE . 49 FIGURE 8: P253 PANEL - THRUST REVERSER CONTROL - ENGINE 3 AND ENGINE 4, RETURN ACCESS ............................................ 5 1

Original Issue: January 22, 2009 747-78-2178Revision 1: August 04, 2011 3 of 52 BOEING SERVICE BULLETIN 747-78-2178

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Original Issue: January 22, 2009 747-78-2178Revision 1: August 04, 2011 4 of 52 BOEING SERVICE BULLETIN 747-78-2178

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Commercial Airplanes 747 Service Bulletin Revision Transmittal SheetNumber: 747-78-2178Original Issue: January 22, 2009 Revision 1: August 04, 2011 ATA System: 7834 SUBJECT: EXHAUST - Thrust Reverser Control System - Rolls Royce RB211-524 Powered Uncommanded Thrust Reverser Unlock Event, Change This revision includes all pages of the service bulletin.

COMPLIANCE INFORMATION RELATED TO THIS REVISION No more work is necessary on the airplane(s) changed in accordance with the original issue of this service bulletin.

REASON FOR REVISION As a part of a service bulletin validation program, this change was completed on airplane RD142 by Service Bulletin 747-78-2178 Original Issue before the release of Revision 1 of this service bulletin. The change completed on airplane RD142 by Service Bulletin 747-78-2178 Original Issue is equivalent to the release of Revision 1 of this service bulletin. Airplane RD142 has the configuration of a Group 1 airplane.

This service bulletin revision is sent to provide operators with the changed service bulletin after the incorporation of the validation findings. During the modification, findings during testing led to a partial rewrite of the functional test to change the voltage check locations. A maintenance zone table has been added to the service bulletin.

The Damage Tolerance Based Structural Inspections impact information was added.

These sections were changed:

1. Summary Background, Validation Information added.

2. Paragrapgh 1.C, Reason, Validation Information added.

3. Paragrapgh 1.D, Maintenance Zones table added.

4. Paragrapgh 1.K, Publication Affected The Damage Tolerance Based Structural Inspections impact information added.

5. Section 2.C, Parts Necessary for Each Airplane, replaced several kit parts.

6. Paragrapgh 3.A, General Information, added information about lightweight and heavyweight intermix.

7. Paragrapgh 3.B, Work Instructions, added missing steps and changed voltage check location.

8. FIGURE 2, P252 PANEL - THRUST REVERSER CONTROL - ENGINE 1, W2281 WIRING CHANGE, replaced kit parts with new parts.

Original Issue: January 22, 2009 747-78-2178Revision 1: August 04, 2011 5 of 52

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9. FIGURE 3, P252 PANEL - THRUST REVERSER CONTROL - ENGINE 2, W2283 WIRING CHANGE, replaced kit parts with new parts.

10. FIGURE 6, P253 PANEL - THRUST REVERSER CONTROL - ENGINE 3, W2285 WIRING CHANGE, :

11. FIGURE 7, P253 PANEL - THRUST REVERSER CONTROL - ENGINE 4, W2287 WIRING CHANGE, :

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 January 22, 2009Original Issue:

August 04, 2011Revision 1:

Original Issue: January 22, 2009 747-78-2178Revision 1: August 04, 2011 6 of 52 BOEING SERVICE BULLETIN 747-78-2178

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Commercial Airplanes 747 Service Bulletin SummaryNumber: 747-78-2178Original Issue: January 22, 2009 Revision 1: August 04, 2011 ATA System: 7834 SUBJECT: EXHAUST - Thrust Reverser Control System - Rolls Royce RB211-524 Powered Uncommanded Thrust Reverser Unlock Event, Change

CONCURRENT REQUIREMENTS Refer to Paragraph 1.B., Concurrent Requirements.

BACKGROUND This service bulletin gives instructions to change the thrust reverser control logic in the P252 and the P253 panels. The change to the thrust reverser control logic will electrically isolate the number 2 and number 3 locking gear boxes from the air motor brake unlock proximity sensor. This change will prevent the gear box lock solenoids from receiving electrical power to unlock when the air motor brake proximity sensor senses an uncommanded brake disengagement. This is done by the removal of the air motor brake, release relay, from the thrust reverser control circuit. This change also installs a new unstow, time delay relay, for each engine. The position of the air motor brake, as sensed by the brake proximity sensor, will have no effect on the gear box unlock logic. If the change in this service bulletin is not done, then the number 2 locking gearbox can become unlocked with an associated air motor failure.

One operator reported that during takeoff roll on an RB211-524 powered 747-400 airplane, the flight crew received the ENG 4 REV LIMTD EICAS status message and the ENG 4 REVERSER advisory and status messages. During climb, the cabin crew saw sparks from the exhaust of the number 4 engine. As a precaution, the flight crew shutdown the number 4 engine and proceeded with an uneventful air turn-back and landing. The event was found to be caused by a failure of the o-rings in the air motor switcher or shutoff solenoid valves because of overheating. This let the air motor shutoff valve open, which released the air motor brake. This, in the ground mode, energized the number 2 and number 3 thrust reverser gear box unlock solenoids and thereby unlocking the number 2 and number 3, gear boxes.

As a part of a service bulletin validation program, this change was completed on airplane RD142 by Service Bulletin 747-78-2178 Original Issue before the release of Revision 1 of this service bulletin. The change completed on airplane RD142 by Service Bulletin 747-78-2178 Original Issue is equivalent to the release of Revision 1 of this service bulletin. Airplane RD142 has the configuration of a Group 1 airplane.

Boeing Service Related Problem (SRP) 747-SRP-72-0029 is related to this service bulletin.

ACTION (PRR 85901-75S) Remove power to the P252 and P253 panels and the thrust reverser systems. Get access to the P252 and P253 panels. Remove two existing relays and relay sockets from each panel. Add two new relays and relay sockets to each panel. Do the given wiring changes. Do continuity and voltage checks for each engine and the thrust reverser operational test. Return access.

Original Issue: January 22, 2009 747-78-2178Revision 1: August 04, 2011 7 of 52

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EFFECTIVITY 747-200B/-200F/-300/SP airplanes powered by Rolls Royce RB211-524 engines with the lightweight thrust reversers. 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.

Federal Aviation Administration (FAA) Airworthiness Directive 2000-01-05 is related to service bulletin 747-78-2156. Service bulletin 747-78-2156 is related to this service bulletin.

Boeing recommends that the change given in this service bulletin be done within 60 months after the date on this service bulletin.

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

MANPOWER Elapsed HoursTotal Task HoursAirplanes 2530Group 1

MATERIAL INFORMATION Boeing Supplied Kits/Parts.

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

Original Issue: January 22, 2009 747-78-2178Revision 1: August 04, 2011 8 of 52 BOEING SERVICE BULLETIN 747-78-2178

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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 85901-75S 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 747-200/-300/SP airplanes powered by Rolls Royce RB211-524 engines with the light weight thrust reversers.

-1 Airplane Models:

747-200B, 747-200F, 747-300, 747SP GroupVariable Number 1RB411 - RB413 1RD131 - RD132 1RD135 - RD138 1RD141 - RD144 1RD311 1RD356 - RD358 1RD471 - RD475 1RH101 - RH102 1RR441 - RR442

Original Issue: January 22, 2009 747-78-2178Revision 1: August 04, 2011 9 of 52

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GroupVariable Number 1RR526 1RR531 1RS271 - RS276 1RS301 - RS306 1RS311 - RS320

2. Spares Affected None.

B. Concurrent Requirements The service bulletin listed below must be done before or at the same time as this service bulletin:

DescriptionService BulletinCompany Gives the instruction to install an additional locking system on the thrust reversers.

747-78-2156, Original Issue or Revision 1Boeing C. Reason This service bulletin gives instructions to change the thrust reverser control logic in the P252 and the P253 panels. The change to the thrust reverser control logic will electrically isolate the number 2 and number 3 locking gear boxes from the air motor brake, unlock proximity sensor. This change will prevent the gear box lock solenoids from receiving electrical power to unlock when the air motor brake proximity sensor senses an uncommanded brake disengagement. This is done by the removal of the air motor brake, release relay, from the thrust reverser control circuit. This change also installs a new unstow, time delay relay, for each engine. The position of the air motor brake, as sensed by the brake proximity sensor, will have no effect on the gear box unlock logic. If the change in this service bulletin is not done, then the number 2 locking gearbox can become unlocked with an associated air motor failure.

The change completed on airplane RD142 by Service Bulletin 747-78-2178 Original Issue is equivalent to the release of Revision 1 of this service bulletin. Airplane RD142 has the configuration of a Group 1 airplane.

Original Issue: January 22, 2009 747-78-2178Revision 1: August 04, 2011 10 of 52 BOEING SERVICE BULLETIN 747-78-2178

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Revision 1 is sent to provide operators with the changed service bulletin after the incorporation of the validation findings. During the modification, findings during testing led to a partial rewrite of the functional test to change the voltage check locations. A maintenance zone table has been added to the service bulletin. The Damage Tolerance Based Structural Inspections impact information was added.

Boeing Service Related Problem (SRP) 747-SRP-72-0029 is related to this service bulletin.

D. Description Remove power to the P252 and P253 panels and the thrust reverser systems. Get access to the P252 and P253 panels. Remove two existing relays and relay sockets from each panel. Add two new relays and relay sockets to each panel. Do the given wiring changes. Do continuity and voltage checks for each engine and the thrust reverser operational test. Return access.

No more work is necessary on the airplane(s) changed in accordance with the original issue of this service bulletin.

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

Affected Maintenance Zones ZoneModel 115, 116, 117, 118747-200B, 747-200F, 747-300, 747SP 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.

Federal Aviation Administration (FAA) Airworthiness Directive 2000-01-05 is related to service bulletin 747-78-2156. Service bulletin 747-78-2156 is related to this service bulletin.

Boeing recommends that the change given in this service bulletin be done within 60 months after the date on 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 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.

Original Issue: January 22, 2009 747-78-2178Revision 1: August 04, 2011 11 of 52 BOEING SERVICE BULLETIN 747-78-2178

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In addition, the Manager of the FAA Seattle Aircraft Certification Office approves the action (i.e. inspection or modification) defined in this service bulletin as an alternative method of compliance to the requirements of paragraph (c) of FAA AD 2000-01-05. All provisions of FAA AD 2000-01-05 that are not specifically referenced in the above statement remain fully applicable and must be complied with.

G. Manpower The table below shows an estimate of the task-hours necessary to do this change for each airplane.

This estimate is for direct labor only, done by an experienced crew. Adjust the estimate with operator task-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.

This estimate does not include the task-hour data given in the service bulletins in Paragraph 1.B., Concurrent Requirements.

Elapsed HoursTask-HoursNumber of Persons Task

0.250.251Open Access

1.01.01Figure 1

4.254.251Figure 2

4.254.251Figure 3

0.250.251Figure 4

1.01.01Figure 5

4.254.251Figure 6

4.254.251Figure 7

0.250.251Figure 8

0.250.251Close Access 5102Continuity Checks and Functional Tests 2530TOTAL FOR EACH AIRPLANE H. Weight and Balance Changes Change in Moment (Pound-Inches) Change in Weight (Pounds) Airplane +315.0+0.9747-200, 747-300 +495.0+0.9747 SP

Original Issue: January 22, 2009 747-78-2178Revision 1: August 04, 2011 12 of 52 BOEING SERVICE BULLETIN 747-78-2178

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