Commercial 

Airplanes 747

Service Bulletin

SPECIAL ATTENTION

Number: 747-78-2183

Original Issue: January 12, 2010

Revision 1: December 23, 2010

ATA System: 7834

SUBJECT: EXHAUST (GE CF6-80 Series Engines) - Thrust Reverser Control System - Automatic

Leading Edge Flap Retraction System Wiring Change

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5.0
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BLANK PAGE
Table of Contents

Revision Transmittal Sheet ............................................ 5

Summary ...................................................... 7

1. PLANNING INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

A. Effectivity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

1. Airplanes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

2. Spares Affected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

B. Concurrent Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

C. Reason . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

D. Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

E. Compliance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

F. Approval . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

G. Manpower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

H. Weight and Balance Changes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

I. Electrical Load Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

J. References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

1. Existing Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

2. Data supplied with this Service Bulletin . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

3. Installation Drawings Used in the Preparation of this Service Bulletin . . . . . . . . . . . . 18

K. Publications Affected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

L. Interchangeability and Intermixability of Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

2. MATERIAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

A. Material - Price and Availability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

B. Industry Support Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

C. Parts Necessary For Each Airplane . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

1. Kits/Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

2. Parts and Materials Supplied by the Operator . . . . . . . . . . . . . . . . . . . . . . . . 19

3. Parts Modified and Reidentified . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

4. Parts Removed and Not Replaced . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

D. Parts Necessary to Change Spares . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

E. Special Tooling - Price and Availability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

F. Special Tooling Necessary to do this Service Bulletin . . . . . . . . . . . . . . . . . . . . . . . 20

3. ACCOMPLISHMENT INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

A. GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

B. WORK INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

FIGURE 1: NO.1 AND NO.2 ENGINE THRUST REVERSER CONTROL WIRING - P414 PANEL ROUTING

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

FIGURE 2: NO.1 AND NO.2 ENGINE THRUST REVERSER CONTROL WIRING, P414 PANEL - CHANGE

[Group 1] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

FIGURE 3: NO.3 AND NO.4 ENGINE THRUST REVERSER CONTROL WIRING - P415 PANEL ROUTING

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

FIGURE 4: NO.3 AND NO.4 ENGINE THRUST REVERSER CONTROL WIRING, P415 PANEL - CHANGE

[Group 1] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

FIGURE 5: NO.1 AND NO.2 ENGINE THRUST REVERSER CONTROL WIRING, P414 PANEL - CHANGE

[Group 2] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

FIGURE 6: NO.3 AND NO.4 ENGINE THRUST REVERSER CONTROL WIRING, P415 PANEL - CHANGE

[Group 2] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

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BOEING SERVICE BULLETIN 747-78-2183

BLANK PAGE
Commercial 

Airplanes 747

Service Bulletin

SPECIAL ATTENTION

Revision Transmittal Sheet Number: 747-78-2183

Original Issue: January 12, 2010

Revision 1: December 23, 2010

ATA System: 7834

SUBJECT: EXHAUST (GE CF6-80 Series Engines) - Thrust Reverser Control System - Automatic

Leading Edge Flap Retraction System Wiring Change

This revision includes all pages of the service bulletin.

COMPLIANCE INFORMATION RELATED TO THIS REVISION

Federal Aviation Administration (FAA) Notice of Proposed Rule Making NPRM 2010-NM-064-AD is related to

this service bulletin.

Airplanes RT001 thru RT005, RT021 and RT022, RT041 thru RT044, RT431 thru RT436, RT531 thru RT533,

RT591, RT641 thru RT650, RT691 and RT692, RT701, RT741, RT751 and RT752 are moved from Group 1 to

new Group 2.

No more work is necessary on airplanes changed in accordance with the original issue of this service bulletin.

REASON FOR REVISION

This revision is sent to change the functional test in the work instructions to give a better sequence and to better

describe the use of pneumatic and electrical power during its accomplishment. Also, new airplane Group 2 is

added for wiring configuration differences in the P414 and P415 panels.

These sections are changed:

– Summary Manpower and Paragraph 1.G., Manpower; Changed to show adjusted functional test hours. A

table is added for Group 2 airplanes.

– Summary Compliance and Paragraph 1.E., Compliance; Changed to add FAA NPRM.

– Paragraph 1.J.1., Existing Data; SWPM, AMM and FAA NPRM references added, one SWPM reference

deleted.

– Paragraph 2.C.2., Parts and Material Supplied by the Operator; Reference for supplier information changed.

– Paragraph 3.B., Work Instructions; Functional test tasks are added and the sequence changed for all Groups.

Instructions are added for Group 2 airplanes.

– Figure 1 and 3; Terminal block TD435 is added and the views of TD294 and TD295 are changed to be

more accurate, where applicable.

– Figure 2 and 4; Applicability is changed to Group 1 airplanes and SWPM references added for the

disassembly of equipment related to the change.

– Figure 5 and 6; Added for Group 2 airplanes to show wiring differences in the P414 and P415 panels related

to this change.

The data given in Information Notice 747-78-2183 IN 01 is included in this revision.

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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

Original Issue: January 12, 2010

Revision 1: December 23, 2010

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BOEING SERVICE BULLETIN 747-78-2183
Commercial 

Airplanes 747

Service Bulletin

SPECIAL ATTENTION

Summary Number: 747-78-2183

Original Issue: January 12, 2010

Revision 1: December 23, 2010

ATA System: 7834

SUBJECT: EXHAUST (GE CF6-80 Series Engines) - Thrust Reverser Control System - Automatic

Leading Edge Flap Retraction System Wiring Change

BOEING RECOMMENDS THAT EACH OPERATOR EXAMINE THIS SERVICE BULLETIN IMMEDIATELY.

CONCURRENT REQUIREMENTS

None.

BACKGROUND

This service bulletin is sent to prevent the Group A Leading Edge (LE) flaps from automatically retracting if the

Flap Control Unit (FCU) receives dual cowl unstowed indications from the thrust reversers. If this service bulletin

is not done, the Group A LE flaps can automatically retract if the FCU gets dual cowl unstowed indications from

the thrust reverser which could result in decreased climb performance of the airplane during takeoff.

During takeoff roll, an operator of a Rolls-Royce RB211 powered 747-400 airplane had a REV Amber indication

occurrence on the No.3 engine thrust reverser. This was followed thirteen seconds later by a REV Amber

indication on the No.2 engine thrust reverser. At the time of the second REV amber, the aircraft was beyond

V1. To prevent impingement from the thrust reversers, the FCU of the 747-400 is designed to automatically

retract the Group A LE flaps when a REV Amber signal is transmitted from the two inboard or the two outboard

thrust reversers and the aircraft is on the ground. The FCU performed as designed, and retracted the Group A

leading edge flaps. After takeoff, the air/ground logic took over and the Group A LE flaps re-deployed. During

the event, the flight crew reported buffeting and momentary stick shaker activation. The aircraft jettisoned fuel

and returned to the airport with a usual landing. All four thrust reversers deployed and stowed normally after

landing.

The automatic LE flap retraction logic for CF6-80C2 engines automatically retracts the Group A LE flaps during

reverse thrust operation. This is to prevent thrust reverser efflux air from impinging onto the Group A LE flaps

to improve the Group A LE flap panel’s structural life. This function is armed when the airplane is on the ground.

The Group A LE flaps retract when the FCU gets a signal from the LE Flap relay in the reverser circuitry on the

two inboard or the two outboard engines. The LE Flap relay is energized by the microswitch of the reverse thrust

lever or the unstow microswitch in the center drive unit (CDU).

The initial signal to the FCU comes from the microswitch in the aisle stand when thrust reverser deployment is

commanded. The signal to the FCU is kept after 'stow' is commanded by the CDU unstowed microswitches.

This signal is removed once the thrust reverser is stowed.

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The Group A LE flaps retract (or extend) in ten seconds. Once auto-retracted, there is a five second time delay

after the thrust reverser signal is removed from the FCU before the Group A LE flaps return to the commanded

position. The thrust reverser extends in two seconds and stows in three seconds. This time can slightly increase

during cold weather operation.

Accomplishment of this service bulletin will remove the thrust reverser unstow signal from the FCU. The timing

of the thrust reverser stow versus the time delay in the FCU accomplishes the original intent of the design. The

thrust reversers are fully stowed prior to the FCU time delay lapsing and Group A LE flap movement starting.

The signal from the thrust reverser lever will not be affected by this change, but the CMC message "ENG X

AUTO RESTOW EVENT" will be permanently inhibited. Instead, if there is an auto restow event on an airplane

the "ENG X PRESSURE SWITCH FAIL" message will be set.

Boeing Service Related Problem (SRP) 747-SRP-78-0070 is related to this service bulletin.

Boeing Fleet Team Digest (FTD) 747 FTD 78-09002 is related to this service bulletin.

ACTION (PRR 85665-R)

Get access to the P414 and P415 Power Distribution panels in the Electrical and Electronics Compartment.

Make wiring changes in the panels to the wires related to the thrust reverser control system of the No.1 thru

No.4 engines. Do tests of the thrust reverser control and the Group A Leading Edge (LE) flap systems.

EFFECTIVITY

747-400/400D/400F Airplanes powered by GE CF6-80C2 engines. Refer to Paragraph 1.A., Effectivity for the

list of affected airplanes.

COMPLIANCE

Federal Aviation Administration (FAA) Notice of Proposed Rule Making NPRM 2010-NM-064-AD is related to

this service bulletin.

Boeing recommends that the change given in this service bulletin be done within 36 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

Airplanes Total Task Hours Elapsed Hours

All Groups 11.30 6.80

MATERIAL INFORMATION

Operator Supplied Parts/Materials.

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

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BOEING SERVICE BULLETIN 747-78-2183

BLANK PAGE
Commercial 

Airplanes 747

Service Bulletin

SPECIAL ATTENTION

Number: 747-78-2183

Original Issue: January 12, 2010

Revision 1: December 23, 2010

ATA System: 7834

SUBJECT: EXHAUST (GE CF6-80 Series Engines) - Thrust Reverser Control System - Automatic

Leading Edge Flap Retraction System Wiring Change

BOEING RECOMMENDS THAT EACH OPERATOR EXAMINE THIS SERVICE BULLETIN IMMEDIATELY.

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 85665-R for data about this

change.

GROUP CONFIGURATION DESCRIPTION

747-400/400D/400F airplanes with General Electric (GE) CF6-80C2

engines that have wiring differences

1 -

747-400 airplanes with General Electric (GE) CF6-80C2 engines that

have wiring differences

2 -

Airplane Models:

747-400, 747-400D, 747-400F

Variable Number Group

RF001 - RF006 1

RL401 - RL403 1

RL411 - RL430 1

RL461 - RL462 1

RL471 - RL481 1

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Variable Number Group

RL511 - RL516 1

RL521 - RL522 1

RL531 - RL534 1

RL561 - RL568 1

RL571 - RL572 1

RL576 - RL577 1

RL579 1

RL651 - RL655 1

RL671 - RL675 1

RL681 - RL684 1

RM001 - RM007 1

RM010 1

RM026 - RM030 1

RM051 - RM053 1

RM071 1

RM081 - RM084 1

RM116 - RM117 1

RM126 - RM132 1

RM156 - RM158 1

RM191 - RM192 1

RM231 - RM233 1

RM316 - RM318 1

RM351 - RM355 1

RM401 - RM403 1

RM426 1

RM431 1

RM441 - RM443 1

RM445 1

RM801 - RM803 1

RM861 - RM863 1

RM891 - RM899 1

RM901 - RM906 1

RM911 1

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BOEING SERVICE BULLETIN 747-78-2183
Variable Number Group

RR701 1

RR721 - RR724 1

RR746 - RR748 1

RT001 - RT005 2

RT006 - RT014 1

RT021 - RT022 2

RT041 - RT044 2

RT045 - RT047 1

RT071 - RT075 1

RT121 1

RT131 - RT137 1

RT151 - RT152 1

RT161 - RT168 1

RT431 - RT436 2

RT437 - RT447 1

RT531 - RT533 2

RT534 - RT535 1

RT591 2

RT641 - RT650 2

RT651 - RT657 1

RT681 - RT682 1

RT691 - RT692 2

RT693 - RT699 1

RT701 2

RT702 - RT704 1

RT711 - RT717 1

RT741 2

RT742 1

RT751 - RT752 2

RT753 - RT757 1

RT776 - RT777 1

RT801 - RT803 1

RT861 - RT864 1

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BOEING SERVICE BULLETIN 747-78-2183
Variable Number Group

RT931 - RT932 1

RT945 - RT949 1

RT951 - RT955 1

RT966 - RT967 1

RU031 - RU032 1

RU051 - RU052 1

RU059 - RU062 1

RU101 - RU102 1

RU801 - RU809 1

RU831 - RU841 1

2. Spares Affected

None.

B. Concurrent Requirements

None.

C. Reason

This service bulletin is sent to prevent the Group A Leading Edge (LE) flaps from automatically retracting

if the Flap Control Unit (FCU) receives dual cowl unstowed indications from the thrust reversers. If this

service bulletin is not done, the Group A LE flaps can automatically retract if the FCU gets dual cowl

unstowed indications from the thrust reverser which could result in decreased climb performance of

the airplane during takeoff.

During takeoff roll, an operator of a Rolls-Royce RB211 powered 747-400 airplane had a REV Amber

indication occurrence on the No.3 engine thrust reverser. This was followed thirteen seconds later by

a REV Amber indication on the No.2 engine thrust reverser. At the time of the second REV amber, the

aircraft was beyond V1. To prevent impingement from the thrust reversers, the FCU of the 747-400 is

designed to automatically retract the Group A LE flaps when a REV Amber signal is transmitted from

the two inboard or the two outboard thrust reversers and the aircraft is on the ground. The FCU performed

as designed, and retracted the Group A leading edge flaps. After takeoff, the air/ground logic took over

and the Group A LE flaps re-deployed. During the event, the flight crew reported buffeting and momentary

stick shaker activation. The aircraft jettisoned fuel and returned to the airport with a usual landing. All

four thrust reversers deployed and stowed normally after landing.

The automatic LE flap retraction logic for CF6-80C2 engines automatically retracts the Group A LE

flaps during reverse thrust operation. This is to prevent thrust reverser efflux air from impinging onto

the Group A LE flaps to improve the Group A LE flap panel’s structural life. This function is armed when

the airplane is on the ground. The Group A LE flaps retract when the FCU gets a signal from the LE

Flap relay in the reverser circuitry on the two inboard or the two outboard engines. The LE Flap relay

is energized by the microswitch of the reverse thrust lever or the unstow microswitch in the center drive

unit (CDU). The FCU auto-logic is inhibited at any phase of flight.

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BOEING SERVICE BULLETIN 747-78-2183
The initial signal to the FCU comes from the microswitch in the aisle stand when thrust reverser

deployment is commanded. The signal to the FCU is kept after stow is commanded by the CDU

unstowed microswitches. This signal is removed once the thrust reverser is stowed.

The Group A LE flaps retract (or extend) in ten seconds. Once auto-retracted, there is a five second

time delay after the thrust reverser signal is removed from the FCU before the Group A LE flaps return

to the commanded position. The thrust reverser extends in two seconds and stows in three seconds.

This time can slightly increase during cold weather operation.

Accomplishment of this service bulletin will remove the thrust reverser unstow signal from the FCU.

The timing of the thrust reverser stow versus the time delay in the FCU accomplishes the original intent

of the design. The thrust reversers are fully stowed prior to the FCU time delay lapsing and Group A

LE flap movement starting. The signal from the thrust reverser lever will not be affected by this change,

but the CMC message "ENG X AUTO RESTOW EVENT" will be permanently inhibited. Instead, if there

is an auto restow event on an airplane the "ENG X PRESSURE SWITCH FAIL" message will be set.

Boeing Service Related Problem (SRP) 747-SRP-78-0070 is related to this service bulletin.

Boeing Fleet Team Digest (FTD) 747 FTD 78-09002 is related to this service bulletin.

Revision 1 is sent to change the functional test in the work instructions to give a better sequence and

to better describe the use of pneumatic and electrical power during its accomplishment. Also, new

airplane Group 2 is added for wiring configuration differences in the P414 and P415 panels.

The data given in Information Notice 747-78-2183 IN 01 is included in Revision 1.

D. Description

Get access to the P414 and P415 Power Distribution panels in the Electrical and Electronics

Compartment. Make wiring changes in the panels to the wires related to the thrust reverser control

system of the No.1 thru No.4 engines. Do tests of the thrust reverser control and the Group A Leading

Edge (LE) flap systems.

Revision 1 - No more work is necessary on airplanes 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.

Group 1:

Affected Maintenance Zones

Model Zone

747-400, 747-400D, 747-400F 117, 118

Group 2:

Affected Maintenance Zones

Model Zone

747-400 117, 118

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BOEING SERVICE BULLETIN 747-78-2183
E. Compliance

Federal Aviation Administration (FAA) Notice of Proposed Rule Making NPRM 2010-NM-064-AD is

related to this service bulletin.

Boeing recommends that the change given in this service bulletin be done within 36 months after the

original issue date of 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.

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 inspect the work

• Time to cure the materials

• Time to make the parts

• Time to find the tools.

Group 1:

Task Number of Persons Task Hours Elapsed Hours

Open Access 1 0.75 0.75

FIGURE 1 (Wire -

Routing Only)

FIGURE 2 1 0.40 0.40

FIGURE 3 (Wire -

Routing Only)

FIGURE 4 1 0.40 0.40

Close Access 1 0.75 0.75

Test 2 9.00 4.50

TOTAL FOR EACH AIRPLANE 11.30 6.80

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Group 2:

Task Number of Persons Task Hours Elapsed Hours

Open Access 1 0.75 0.75

FIGURE 1 (Wire -

Routing Only)

FIGURE 5 1 0.40 0.40

FIGURE 3 (Wire -

Routing Only)

FIGURE 6 1 0.40 0.40

Close Access 1 0.75 0.75

Test 2 9.00 4.50

TOTAL FOR EACH AIRPLANE 11.30 6.80

H. Weight and Balance Changes

None.

I. Electrical Load Data

None.

J. References

1. Existing Data

a. Engineering Change Memo PRR 85665-R.

b. Boeing Service Related Problem (SRP) 747-SRP-78-0070.

c. Boeing Standard Wiring Practices Manual (SWPM) 20-10-11, 20-10-12, 20-10-19, 20-30-16,

20-81-12, 20-90-11.

d. Federal Aviation Administration (FAA) Notice of Proposed Rule Making (NPRM)

2010-NM-064-AD.

e. 747 Fleet Team Digest (FTD) 747 FTD 78-09002.

f. 747-400 Aircraft Maintenance Manual (AMM) 24-22-00, 27-62-00, 27-81-00, 36-00-00,

54-62-00, 71-11-04, 78-31-00, 78-34-05.

g. 747-400 Wiring Diagram Manual (WDM) 78-34-11, 78-34-21, 78-34-31, 78-34-41.

2. Data supplied with this Service Bulletin

None.

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3. Installation Drawings Used in the Preparation of this Service Bulletin

None.

K. Publications Affected

1. Publications:

Publication Chapter-Section

747 Wiring Diagram Manual 78-34

747 Fault Isolation Manual 71-00

2. Damage Tolerance Based Structural Inspections:

Boeing has evaluated the repairs and/or changes in this service bulletin for effects on Fatigue

Critical Structure (FCS) and for changes to Damage Tolerance Inspections (DTI) required in the

Maintenance Program. This service bulletin does not affect FCS, therefore DTIs are not necessary.

L. Interchangeability and Intermixability of Parts

Accomplishment of this service bulletin does not affect interchangeability or intermixability of parts.

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BOEING SERVICE BULLETIN 747-78-2183
2. MATERIAL INFORMATION

A. Material - Price and Availability

The operator can supply the parts and materials shown in Paragraph 2.C., Parts Necessary for Each

Airplane. As an alternative, operators can purchase the parts from Boeing Spares. This service bulletin

does not show the Boeing price and supply data.

The parts are subject to the terms and conditions of the Boeing standard purchase order

acknowledgment. Prices are in United States dollars. Terms: Net 30 days.

Reference this service bulletin and submit your purchase order by one of these methods:

1. Order on-line via ATA Spec 2000 or The Boeing Part Page

2. Fax to (206) 662-7145

B. Industry Support Information

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

C. Parts Necessary For Each Airplane

1. Kits/Parts

None.

2. Parts and Materials Supplied by the Operator

Part Number / QTY Name Notes

Specification

BACT63D2 8 End Cap (a)

(a) Refer to Paragraph 2.A., Material - Price and Availability for procurement information.

3. Parts Modified and Reidentified

None.

4. Parts Removed and Not Replaced

None.

D. Parts Necessary to Change Spares

None.

E. Special Tooling - Price and Availability

None.

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F. Special Tooling Necessary to do this Service Bulletin

None.

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BOEING SERVICE BULLETIN 747-78-2183
3. ACCOMPLISHMENT INSTRUCTIONS

A. GENERAL INFORMATION

CAUTION: KEEP THE WORK AREA, WIRES AND ELECTRICAL BUNDLES CLEAN OF METAL

PARTICLES OR CONTAMINATION WHEN YOU USE TOOLS. UNWANTED MATERIAL,

METAL PARTICLES OR CONTAMINATION CAUGHT IN WIRE BUNDLES CAN CAUSE

DAMAGE TO THE BUNDLES. DAMAGED WIRE BUNDLES CAN CAUSE SPARKS OR

OTHER ELECTRICAL DAMAGE.

NOTE: 1. The instructions identified in Paragraph 3.B., Work Instructions, and the Figure(s)

give the recommended sequence of steps. The sequence of steps to do this service

bulletin can be changed.

2. Manual titles are referred to by acronyms. Refer to Paragraph 1.J., References, for

definition of the acronyms.

3. Obey all of the warnings and cautions given in the specified manual sections.

4. Refer to the SWPM 20-10-11 and SWPM 20-10-12 for the wire installation procedures,

and SWPM 20-10-19 for the wire separation requirements, as accepted procedures.

5. These work instructions refer to procedures included in other Boeing documents.

When the words "refer to" are used and the operator has an accepted alternative

procedure, the accepted alternative procedure can be used. When the words "in

accordance with" are included in the instruction, the procedure in the Boeing document

must be used.

6. The instructions in Paragraph 3.B., Work Instructions and the figures can include

operation of tools or test equipment. Boeing Engineering Tool Drawings, the Illustrated

Tool and Equipment Manual, and the Special Tool and Ground Handling Drawing

Index contain data on versions of the tools or test equipment that you can use. It is

permitted to use replaced tools. It is not permitted to use superseded tools.

7. If it is necessary to remove more parts for access, you can remove those parts. If

you can get access without removing identified parts, it is not necessary to remove

all of the identified parts. Jacking and shoring limitations must be observed.

8. This service bulletin includes functional test procedures for the systems changed by

this service bulletin. More functional tests can possibly be necessary in accordance

with standard maintenance practices because of interruption to other airplane systems.

B. WORK INSTRUCTIONS

1. Remove electrical power from the airplane. Refer to 747-400 AMM 24-22-00 as an accepted

procedure.

2. Get access to the P414 and P415 Power Distribution panels in the Electrical and Electronics

Compartment.

3. Change the thrust reverser control wiring in the P414 and P415 Power Distribution panels for each

engine in accordance with:

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Group 1:

Engine Figure

No.1 and No.2 FIGURE 1 and FIGURE 2

No.3 and No.4 FIGURE 3 and FIGURE 4

Group 2:

Engine Figure

No.1 and No.2 FIGURE 1 and FIGURE 5

No.3 and No.4 FIGURE 3 and FIGURE 6

WARNING: MAKE SURE THAT PERSONS AND EQUIPMENT ARE CLEAR OF THE LEADING

EDGE (LE), TRAILING EDGE (TE) FLAPS AND FLAP DRIVE MECHANISMS BEFORE

THE FLAP CONTROL LEVER IS MOVED. WITH HYDRAULIC POWER REMOVED,

THE FLAPS WILL MOVE AUTOMATICALLY BY ELECTRICAL POWER WHEN THE

FLAP CONTROL LEVER IS MOVED. THIS CAN CAUSE INJURY TO PERSONS OR

DAMAGE TO EQUIPMENT.

4. Supply electrical power to the airplane. Refer to 747-400 AMM 24-22-00 as an accepted procedure.

5. Do the functional test as follows:

a. In the Flight Compartment, make sure the applicable engine START and ENGINE BLEED

switches, on the overhead panel, are in the OFF position.

b. In the Flight Compartment, make sure the reverse thrust lever is in the forward thrust position.

c. In the Flight Compartment, open the circuit breakers specified in the table below and attach

DO-NOT-CLOSE tags:

MAIN POWER DISTRIBUTION PANEL

Panel Number Location Name Number

P6 F11 T/R LOCK CONT ENG 1 C10934

P6 F13 T/R CONT ENG 1 C01703

P6 E11 T/R LOCK CONT ENG 2 C10935

P6 E13 T/R CONT ENG 2 or ENG 2, T/R CONT C01704

P6 D11 T/R LOCK CONT ENG 3 C10936

P6 D13 T/R CONT ENG 3 C01442

P6 C11 T/R LOCK CONT ENG 4 C10937

P6 C13 T/R CONT ENG 4 or ENG 4, T/R CONT C01441

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d. Remove the access doors to the Pressure Regulating and Shutoff Valve (PRSOV) on the

No.1 thru No.4 engine nacelle struts. Refer to 747-400 AMM 54-62-00 as an accepted

procedure.

e. Disconnect the electrical connectors, specified in the table below, from the PRSOV of the

No.1 thru No.4 engine. Refer to 747-400 AMM 78-34-05 for the location of the PRSOV and

the electrical connector.

Engine Equipment Number

No.1 DV360

No.2 DV361

No.3 DV362

No.4 DV363

NOTE: This will prevent the supply of pneumatic pressure to the thrust reverser system and

prevent auto-restow when the thrust reversers are manually deployed.

WARNING: MAKE SURE THAT PERSONS AND EQUIPMENT ARE CLEAR OF THE LE FLAPS

AND CONTROL SURFACES BEFORE PNEUMATIC POWER IS SUPPLIED. THIS

CAN CAUSE INJURY TO PERSONS AND DAMAGE EQUIPMENT.

f. Make sure the Leading Edge (LE) flaps are retracted. Refer to 747-400 AMM 27-81-00 as an

accepted procedure.

NOTE: If this task is accomplished by pneumatic power, it is not necessary to remove

pneumatics from the airplane at the end of the procedure.

g. Make sure pneumatic power is supplied to the airplane. Refer to 747-400 AMM 36-00-00 as

an acceptable procedure.

h. Open left or right fan cowl panels on the No.1 thru No.4 engines. Refer to 747-400 AMM

71-11-04 as an accepted procedure.

NOTE: Open and unlock the applicable sleeve. Only one sleeve on each engine is necessary

to be manually deployed to complete this functional test.

i. If installed, pull the manual release handle upwards to unlock the left or right electro-mechanical

brake of the No.1 thru No.4 engines. Refer to 747-400 AMM 78-31-00 for the location of the

manual release handle.

j. Release the left or right Center Drive Unit (CDU) brake. Refer to 747-400 AMM 78-31-00 for

the location of the CDU brake.

(1) Pull the brake handle out and away from the CDU until the detent is felt (approximately

60 degrees).

k. In the Flight Compartment, remove the DO-NOT-CLOSE tags and close the circuit breakers

specified in the table below:

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MAIN POWER DISTRIBUTION PANEL

Panel Number Location Name Number

P6 F11 T/R LOCK CONT ENG 1 C10934

P6 F13 T/R CONT ENG 1 C01703

P6 E11 T/R LOCK CONT ENG 2 C10935

P6 E13 T/R CONT ENG 2 or ENG 2, T/R CONT C01704

P6 D11 T/R LOCK CONT ENG 3 C10936

P6 D13 T/R CONT ENG 3 C01442

P6 C11 T/R LOCK CONT ENG 4 C10937

P6 C13 T/R CONT ENG 4 or ENG 4, T/R CONT C01441

l. In the Flight Compartment, make sure the circuit breakers specified in the table below are

closed:

OVERHEAD CIRCUIT BREAKER PANEL

Panel Number Location Name Number

P7 C10 FLT CONT ELEC 2L-AC C10263

P7 C11 FLT CONT ELEC 2L-DC C10264

P7 C12 FLT CONT ELEC 1L-AC C08782

P7 C13 FLT CONT ELEC 1L-DC C08783

P7 C14 FLT CONT ELEC 1R-AC C08784

P7 C15 FLT CONT ELEC 1R-DC C08785

P7 C16 FLT CONT ELEC 2R-AC C10265

P7 C17 FLT CONT ELEC 2R-DC C10266

m. Do the 'Automatic Speed Brake System Deactivation'. Refer to 747-400 AMM 27-62-00 as

an accepted procedure.

CAUTION: ONLY EXTEND OR RETRACT THE FLAPS ELECTRICALLY ONCE IN A FIVE

MINUTE PERIOD TO PREVENT OVERHEATING OF THE MOTOR.

n. In the Flight Compartment, move the flap control lever to the 1-unit detent to extend the LE

flaps.

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WARNING: MAKE SURE PERSONS AND EQUIPMENT ARE CLEAR OF THE LE FLAPS

BEFORE THE THRUST REVERSER SLEEVES ARE MOVED MANUALLY.

CAUTION: DO NOT OPEN THE THRUST REVERSER HALF MORE THAN 34 DEGREES IF

THE TRANSLATING COWL IS EXTENDED. DAMAGE TO THE TRANSLATING

COWL OR THE STRUT CAN OCCUR.

CAUTION: MAKE SURE THERE IS NO EQUIPMENT IN THE AREA BEHIND THE THRUST

REVERSER. DAMAGE CAN OCCUR IF THE THRUST REVERSER HITS THE

EQUIPMENT.

CAUTION: WHEN THE THRUST REVERSER IS MOVED MANUALLY, LOOK FOR THE TOP

AND THE BOTTOM BALLSCREW ACTUATORS TO TURN. IF YOU DO NOT SEE

THESE BALLSCREW ACTUATORS TURN, DO A CHECK FOR FLEXSHAFTS

THAT ARE BROKEN OR ARE NOT THERE.

o. Do the test as follows for the position of the Group A LE flaps during the reverse thrust operation

of the inboard engines:

(1) Remove the lockout plate on the left or right CDU of the No.2 and No.3 engine:

(a) Remove the two bolts that attach the lockout plate on the manual drive pad on the

bottom CDU. Refer to 747-400 AMM 78-31-00 for the location of lockout plate and

bolts.

(2) Manually extend the left or right translating cowl of the No.2 and No.3 engine thrust

reversers to between 0.5 and 2.0 inches. Refer to 747-400 AMM 78-31-00 for the manual

drive pad location.

(a) Use a 0.25 inch square drive on the CDU to extend the translating cowl. Do not apply

more than 10 inch-pounds (1.1 Nm) of torque.

(3) Make sure the LE flaps do not retract.

(4) Manually retract the left or right translating cowl of the No.2 and No.3 engine thrust

reversers to the stowed position and make sure the translating cowl is fully retracted,

CDU brake is engaged, CDU lockout plate is correctly installed and the electromechanical

brake is locked. Refer to 747-400 AMM 78-31-00 as an accepted procedure.

NOTE: Make sure the square drive is turned in the direction that retracts the thrust

reverser sleeve.

p. Do the test as follows for the position of the Group A LE flaps during the reverse thrust operation

of the outboard engines:

(1) Remove the lockout plate on the left or right CDU of the No.1 and No.4 engine:

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(a) Remove the two bolts that attach the lockout plate on the manual drive pad on the

bottom CDU. Refer to 747-400 AMM 78-31-00 for the location of lockout plate and

bolts.

(2) Manually extend the left or right translating cowl of the No.1 and No.4 engine thrust

reversers to between 0.5 and 2.0 inches. Refer to 747-400 AMM 78-31-00 for the manual

drive pad location.

(a) Use a 0.25 inch square drive on the CDU to extend the translating cowl. Do not apply

more than 10 inch-pounds (1.1 Nm) of torque.

(3) Make sure the LE flaps do not retract.

(4) Manually retract the left or right translating cowl of the No.1 and No.4 engine thrust

reversers to the stowed position and make sure the translating cowl is fully retracted,

CDU brake is engaged, CDU lockout plate is correctly installed and the electromechanical

brake is locked. Refer to 747-400 AMM 78-31-00 as an accepted procedure.

NOTE: Make sure the square drive is turned in the direction that retracts the thrust

reverser sleeve.

q. In the Flight Compartment, open the circuit breakers specified in the table below and attach

DO-NOT-CLOSE tags:

MAIN POWER DISTRIBUTION PANEL

Panel Number Location Name Number

P6 F11 T/R LOCK CONT ENG 1 C10934

P6 F13 T/R CONT ENG 1 C01703

P6 E11 T/R LOCK CONT ENG 2 C10935

P6 E13 T/R CONT ENG 2 or ENG 2, T/R CONT C01704

P6 D11 T/R LOCK CONT ENG 3 C10936

P6 D13 T/R CONT ENG 3 C01442

P6 C11 T/R LOCK CONT ENG 4 C10937

P6 C13 T/R CONT ENG 4 or ENG 4, T/R CONT C01441

r. Connect the electrical connectors, specified in the table below, back on the PRSOV of the

No.1 thru No.4 engines. Refer to 747-400 AMM 78-34-05 for the location of the PRSOV and

the electrical connector.

Engine Equipment Number

No.1 DV360

No.2 DV361

No.3 DV362

No.4 DV363

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s. In the Flight Compartment, remove the DO-NOT-CLOSE tags and close the circuit breakers

specified in the table below:

MAIN POWER DISTRIBUTION PANEL

Panel Number Location Name Number

P6 F11 T/R LOCK CONT ENG 1 C10934

P6 F13 T/R CONT ENG 1 C01703

P6 E11 T/R LOCK CONT ENG 2 C10935

P6 E13 T/R CONT ENG 2 or ENG 2, T/R CONT C01704

P6 D11 T/R LOCK CONT ENG 3 C10936

P6 D13 T/R CONT ENG 3 C01442

P6 C11 T/R LOCK CONT ENG 4 C10937

P6 C13 T/R CONT ENG 4 or ENG 4, T/R CONT C01441

t. Put the LE flaps back to the normal stowed position.

u. Do the 'Group A Leading Edge Flaps during Reverse Thrust Operation - Operational Test'.

Refer to 747-400 AMM 27-81-00 as an accepted procedure.

v. Do the 'Thrust Reverser Operational Test'. Refer to 747-400 AMM 78-31-00 as an accepted

procedure.

w. If not done, do the 'Automatic Speed Brake System Reactivation'. Refer to 747-400 AMM

27-62-00 as an accepted procedure.

6. Put the airplane back to a serviceable condition.

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BOEING SERVICE BULLETIN 747-78-2183
FIGURE 1: NO.1 AND NO.2 ENGINE THRUST REVERSER CONTROL WIRING - P414 PANEL ROUTING

(SHEET 1 OF 3)

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FIGURE 1: NO.1 AND NO.2 ENGINE THRUST REVERSER CONTROL WIRING - P414 PANEL ROUTING

(SHEET 2 OF 3)

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FIGURE 1: NO.1 AND NO.2 ENGINE THRUST REVERSER CONTROL WIRING - P414 PANEL ROUTING

(SHEET 3 OF 3)

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This Figure applies only to: Group 1.

REFERENCE: 747-400 WDM 78-34-11, 747-400 WDM 78-34-21.

The flag note numbers shown below agree with the numbers shown in the flag symbols in the figure.

NAME IDENTIFICATION QTY MORE DATA

FLAG

NOTE

Refer to SWPM 20-30-16 as an

accepted procedure. (a)

1 END CAP BACT63D2 4

(a) Refer to SWPM 20-81-12 as an accepted procedure for the disassembly of the DR7128 and DR7129 relay

sockets. Refer to SWPM 20-90-11 as an accepted procedure for the disassembly of the TD294 terminal

block.

FIGURE 2: NO.1 AND NO.2 ENGINE THRUST REVERSER CONTROL WIRING, P414 PANEL - CHANGE

(SHEET 1 OF 1)

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FIGURE 3: NO.3 AND NO.4 ENGINE THRUST REVERSER CONTROL WIRING - P415 PANEL ROUTING

(SHEET 1 OF 2)

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FIGURE 3: NO.3 AND NO.4 ENGINE THRUST REVERSER CONTROL WIRING - P415 PANEL ROUTING

(SHEET 2 OF 2)

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This Figure applies only to: Group 1.

REFERENCE: 747-400 WDM 78-34-31, 747-400 WDM 78-34-41.

The flag note numbers shown below agree with the numbers shown in the flag symbols in the figure.

NAME IDENTIFICATION QTY MORE DATA

FLAG

NOTE

Refer to SWPM 20-30-16 as an

accepted procedure. (a)

1 END CAP BACT63D2 4

(a) Refer to SWPM 20-81-12 as an accepted procedure for the disassembly of the DR7130 and DR7131 relay

sockets. Refer to SWPM 20-90-11 as an accepted procedure for the disassembly of the TD295 terminal

block.

FIGURE 4: NO.3 AND NO.4 ENGINE THRUST REVERSER CONTROL WIRING, P415 PANEL - CHANGE

(SHEET 1 OF 1)

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This Figure applies only to: Group 2.

REFERENCE: 747-400 WDM 78-34-11, 747-400 WDM 78-34-21.

The flag note numbers shown below agree with the numbers shown in the flag symbols in the figure.

NAME IDENTIFICATION QTY MORE DATA

FLAG

NOTE

Refer to SWPM 20-30-16 as an

accepted procedure. (a)

1 END CAP BACT63D2 4

(a) Refer to SWPM 20-81-12 as an accepted procedure for the disassembly of the DR7128 and DR7129 relay

sockets. Refer to SWPM 20-90-11 as an accepted procedure for the disassembly of the TD435 terminal

block.

FIGURE 5: NO.1 AND NO.2 ENGINE THRUST REVERSER CONTROL WIRING, P414 PANEL - CHANGE

(SHEET 1 OF 1)

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BOEING SERVICE BULLETIN 747-78-2183
This Figure applies only to: Group 2.

REFERENCE: 747-400 WDM 78-34-31, 747-400 WDM 78-34-41.

The flag note numbers shown below agree with the numbers shown in the flag symbols in the figure.

NAME IDENTIFICATION QTY MORE DATA

FLAG

NOTE

Refer to SWPM 20-30-16 as an

accepted procedure. (a)

1 END CAP BACT63D2 4

(a) Refer to SWPM 20-81-12 as an accepted procedure for the disassembly of the DR7130 and DR7131 relay

sockets. Refer to SWPM 20-90-11 as an accepted procedure for the disassembly of the TD295 terminal

block.

FIGURE 6: NO.3 AND NO.4 ENGINE THRUST REVERSER CONTROL WIRING, P415 PANEL - CHANGE

(SHEET 1 OF 1)

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BOEING SERVICE BULLETIN 747-78-2183