## Middle River Aircraft Systems 

# CF6-80C2B SERVICE BULLETIN

EXHAUST - Fan Reverser – Thrust Reverser Actu ation System (TRAS) Lock Flexible Drive Cables Part Numbers 491B1200036-001 (Left-Hand) and 491B1200036-002 (Right-Hand) - Introduction

17 August 2010 CF6-80C2B S/B 78-1168 Revision 2, 19 April 2011 Page 1 of 17 MRAS PROPRIETARY INFORMATION

The information contained in this document is Middl e River Aircraft Systems proprietary information and is disclosed in confidence. It is the property of Middle River Aircraft Systems and shall not be used, disclosed to others or reproduced wit hout the express written consent of Middle River Aircraft Systems, including, but without limitation, it is not to be used in the creation, manufacture, development, or derivation of any repairs, modifica tions, spare parts, designs , or configuration changes or to obtain FAA or any other government or regulator y approval to do so. If consent is given for reproduction in whole or in part, this notice and the notice set forth on eac h page of this document shall appear in any such reproduction in whole or in part.

This technical data is considered EAR controll ed pursuant to 15 CFR Parts 730-774 respectively. Transfer of this data by any means to a Non-US Pers on, whether in the United States or abroad, without the proper U.S. Government authorization (e.g., License, exemption, NLR, etc.), is strictly prohibited.

All technical documentation and information contained her ein, with respect to assembly and disassembly, cleaning, inspection methods and limits, repair methods and limits, operational lim its, life limits and the like, have been developed and approved for use with fan reversers and parts that have been manufactured and/or approved by Middle River Ai rcraft Systems and that have been maintained in accordance with Middle River Aircraft Systems te chnical documentation and recommendations. Middle River Aircraft Systems has no contractual or legal obligation for, nor knowledge of, non-MRAS-approved parts and repairs. Accordingly, this document is not intended to apply to non-MRAS-approved parts and repairs.

MRAS authorizes the Federal Aviation Administration to incorporate this document by reference in an

Airworthiness Directive.

Copyright (2011) Middle River Aircraft Systems, MRA Systems Inc. – A Subsidiary of GE

TRANSMITTAL INFORMATION

REVISION 2 - SERVICE BULLETIN 78-1168

Revision 2 of Service Bulletin (SB) 78-1168 incorporates operator comments and adds optional Installation Record & Operator Torque Checks Feedback Forms. MRAS requests operators who have incorporated Revision 1 of SB 78-1168 to complete the Installation Record & Operator Torque Checks Feedback Forms in this Revision 2 (refer to Figures 2 and 3 herein) and to return the Installation Record & Operator Torque Checks Feedback Forms to MRAS (refer to the fax number and the e-mail address at the bottom of Figures 2 and 3).

1.A., Effectivity, is revised to add TRAS Lock Fl exible Drive Cables Part Numbers (PNs) 1806M47P01

and 1806M47P02.

1.C., Description, is revised to add TRAS Lock Flexible Drive Cables PNs 1806M47P01 and 1806M47P02 and to request completion of optional flex drive cables installation records/operator torque checks feedback forms.

# CF6-80C2B SERVICE BULLETIN

EXHAUST - Fan Reverser – Thrust Reverser Actu ation System (TRAS) Lock Flexible Drive Cables Part Numbers 491B1200036-001 (Left-Hand) and 491B1200036-002 (Right-Hand) - Introduction

17 August 2010 CF6-80C2B S/B 78-1168 Revision 2, 19 April 2011 Page 2

MRAS PROPRIETARY INFORMATION – Subject to the restrictions on the first page. TRANSMITTAL INFORMATION

REVISION 2 – SERVICE BULLETIN 78-1168 (Continued)

1.D., Compliance, is revised to agree with the comp liance statements in Boeing cover Service Bulletins

747-78A2185 and 767-78A0100.

1.I., References, is revis ed to add six references.

1.K., Interchangeability, is revised to add TRAS Lock Flexible Drive Cables PNs 1806M47P01 and 1806M47P02 and to correct a part number.

2.A., Material – Price and Availability, is updated.

2.B., Industry Support Information, is revised to incorporate Addendum No. 1 for CF6-80C2 SB 78-1168

Revision 1.

2.D., Parts Disposition, is revised to give operators the option to quarantine, to scrap or to retain removed flexible drive cables and to provide a refe rence to the flexible drive cable component

maintenance manual.

3.A.(1), ACCOMPLISHMENT INSTRUCTIONS, is revi sed to add “fan reverser” prior to “PRSOV.”

3.B.(5), ACCOMPLISHMENT INSTRUCTIONS, is revis ed to remove the instruction to inspect and to

retain the removed flexible drive cable.

3.C., ACCOMPLISHMENT INSTRUCTIONS, is revised to arrange steps to match the sequence in the Boeing Aircraft Maintenance Manual (AMM).

3.E., ACCOMPLISHMENT INSTRUCTIONS, is revised to allow use of an equivalent approved TRAS lock holding torque check procedure.

3.F., ACCOMPLISHMENT INSTRUCTIONS, is added to request completion of the optional Installation Record & Operator Torque Checks Feedback Form and return of the Installation Record & Operator Torque Checks Feedback Form to MRAS.

4., DOCUMENT PERIODIC POST-SB 78-1168 TRAS LOCK HOLDING TORQUE CHECK RESULTS (OPTIONAL) is added.

Legend for Figure 1 is revised to add TRAS Lock Flexible Drive Cables PNs 1806M47P01 and

1806M47P02.

Figures 2 and 3, Installation Record & Operator Torque Checks Feedback Form, are added.

Revision 1 was issued 26 August 2010. The original was issued 17 August 2010. The original was not distributed because Boeing cover se rvice bulletins were pending.

Revision bars in the left margin identify Revision 2 changes.

# CF6-80C2B SERVICE BULLETIN

EXHAUST - Fan Reverser – Thrust Reverser Actu ation System (TRAS) Lock Flexible Drive Cables Part Numbers 491B1200036-001 (Left-Hand) and 491B1200036-002 (Right-Hand) - Introduction

17 August 2010 CF6-80C2B S/B 78-1168 Revision 2, 19 April 2011 Page 3

MRAS PROPRIETARY INFORMATION – Subject to the restrictions on the first page. 1. PLANNING INFORMATION

A. Effectivity

CF6-80C2B1/B2/B4/B6/B1F/B2F/B4F/B5F/B6F/B6FA/B7F/B8F

(1) TRAS Lock Flexible Drive Cable Part Numbers (PNs) 1806M47P01, 1806M47P02 and 1806M47P05 (Vendor Item Numbers (VINs) 3278500-1/-4, 3278500-2/-5 and 3278500-7, respectively) installed on CF6-80C2B fan reversers are affected.

(2) Left-Hand (LH) TRAS Lock Flexible Drive Cable PN 491B1200036-001 and Right-Hand (RH) TRAS Lock Flexible Drive C able PN 491B1200036-002 will be introduced in production on the fan reversers listed below.

(Boeing) R647/648-2022 and up, R649/650-457 and up, R651/652-064 and up (Boeing B6FA) R563/564-011 and up

(3) These serial numbers are the best available numbers.

B. Concurrent Requirements

None

C. Description

This service bulletin provides instructions fo r replacing TRAS Lock Flexible Drive Cable PN

1806M47P02 or 1806M47P05 with TRAS Lock Flexible Drive Cable PN 491B1200036-001 on

the left-hand fan reverser half. This service bulle tin provides instructions for replacing TRAS Lock Flexible Drive Cable PN 1806M47P01, 1806M47P02 or 1806M47P05 with TRAS Lock Flexible Drive Cable PN 491B1200036-002 on the right-hand fan reverser half.

Following installation of TRAS Lock Flexible Drive Cables PN 491B1200036-001 and PN 491B1200036-002 on a fan reverser, the operator is requested to complete the optional Installation Record & Operator Torque Checks Feedback Form (refer to Figures 2 and 3) and to return the Installation Record & Operator Torque Checks Feedback Form to MRAS.

D. Compliance

Category 2

Do as soon as possible without effect on revenue service but no later than 26 October 2015.

# CF6-80C2B SERVICE BULLETIN

EXHAUST - Fan Reverser – Thrust Reverser Actu ation System (TRAS) Lock Flexible Drive Cables Part Numbers 491B1200036-001 (Left-Hand) and 491B1200036-002 (Right-Hand) - Introduction

17 August 2010 CF6-80C2B S/B 78-1168 Revision 2, 19 April 2011 Page 4

MRAS PROPRIETARY INFORMATION – Subject to the restrictions on the first page. 1. E. Reason

Objective:

Install improved TRAS lock flexible driv e cables on CF6-80C2B fan reversers.

Condition:

The current TRAS lock flexible drive cabl es can fail prematurely on CF6-80C2B fan

reversers.

Cause:

Engineering analysis and testing has determined t hat the torsional str ength and stiffness of

the current flexible shaft is not optimal for the operating environment.

Improvement:

TRAS Lock Flexible Drive Cables PN 491B1200036-001 and PN 491B1200036-002 have improved durability, improved ultimate torsional strength, and improved fatigue life. Reduced core stiffness results in lower torque at the end-of-travel impact. The improved design

reduces stress concentrations on the flex ible drive cable core and end fittings.

Substantiation:

Substantiation is by analysis and testing.

F. Approval

The FAA has approved the technical c ontent of this Service Bulletin.

G. Manpower

With access to the upper torque box of each f an reverser half, the estimate to replace two

TRAS lock flexible drive cables is 1.0 man-hour.

H. Weight and Balance

Weight and balance are not changed.

# CF6-80C2B SERVICE BULLETIN

EXHAUST - Fan Reverser – Thrust Reverser Actu ation System (TRAS) Lock Flexible Drive Cables Part Numbers 491B1200036-001 (Left-Hand) and 491B1200036-002 (Right-Hand) - Introduction

17 August 2010 CF6-80C2B S/B 78-1168 Revision 2, 19 April 2011 Page 5

MRAS PROPRIETARY INFORMATION – Subject to the restrictions on the first page. 1. I. References

Boeing 747 Aircraft Maintenance Manual (AMM) Boeing 747-400 Aircraft Maintenance Manual (AMM) Boeing 767 Aircraft Maintenance Manual (AMM) Boeing Service Bulletin 747-78A2185 entitled “EXHAUST (GE CF6-80 Series Engines) – Thrust Reverser Control System – S hort Flexible Drive Shaft Replacement” Boeing Service Bulletin 767-78A0100 entitled “EXHAUST (GE CF6-80 Series Engines) – Thrust Reverser Control System – S hort Flexible Drive Shaft Replacement” GE Commercial Engine Standard Practices Manual, GEK 9250 (CD GEK 108792) Component Maintenance Manual (CMM) G EK 103024 (ATA 78-32-57), Flexible Shaft Assembly

CF6-80C2 Service Bulletin 78-1133 entitled “EXHAU ST - Fan Reverser – Identification Plate for Recording Service Bulletin Accomplishment”

FAA AD 2000-09-04

FAA AD 2000-15-04

FAA AD 2003-16-16

For MRAS internal use: ECS 10-00709

J. Publications Affected

CF6-80C2 Fan Reverser Illustrated Parts Catalog (IPC), MR 92464

K. Interchangeability

TRAS Lock Flexible Drive Cable PN 1806M47P02 or PN 1806M47P05 and TRAS Lock Flexible Drive Cable PN 491B1200036-001 (LH) are one-way interchangeable. TRAS Lock Flexible Drive Cable PN 1806M47P01, 1806M 47P02 or 1806M47P05 and TRAS Lock Flexible Drive Cable PN 491B1200036-002 (RH) are one- way interchangeable. (1806M47P01/P02/P05 may be used as a replacement only where 1806M47P01/ P02/P05 is installed. On the LH fan reverser half, 491B1200036-001 is an acceptabl e replacement for 1806M47P02, 1806M47P05 or 491B1200036-001. On the RH fan reverser half, 491B1200036-002 is an acceptable replacement for 1806M47P01, 1806M 47P02, 1806M47P05 or 491B1200036-002.)

# CF6-80C2B SERVICE BULLETIN

EXHAUST - Fan Reverser – Thrust Reverser Actu ation System (TRAS) Lock Flexible Drive Cables Part Numbers 491B1200036-001 (Left-Hand) and 491B1200036-002 (Right-Hand) - Introduction

17 August 2010 CF6-80C2B S/B 78-1168 Revision 2, 19 April 2011 Page 6

MRAS PROPRIETARY INFORMATION – Subject to the restrictions on the first page. 2. MATERIAL INFORMATION

A. Material – Price and Availability

(1) Parts necessary to do this service bulletin:

Part Number Quantity per Fan

Reverser Part Name 2011

Unit Price ($) Pkg Qty Lead Time (Days)

491B1200036-001 1 Flexible Drive Cable (LH) 3,811.20 * 1 30

491B1200036-002 1 Flexible Drive Cable (RH) 3,811.20 * 1 30

NOTE: Price and lead time are subject to change.

* Discount is available until 15 November 2012. See Section 2.B., Industry Support

Information.

(2) Consumables:

NOTE: Middle River Aircraft Systems does not supply consumables. Refer to GE Aircraft Engines Commercial Standard Practices Manual (SPM), GEK 9250, for sources of supply.

Code Number Description

C02-032 Loctite C5-A ® or equivalent anti-seize thread compound

# CF6-80C2B SERVICE BULLETIN

EXHAUST - Fan Reverser – Thrust Reverser Actu ation System (TRAS) Lock Flexible Drive Cables Part Numbers 491B1200036-001 (Left-Hand) and 491B1200036-002 (Right-Hand) - Introduction

17 August 2010 CF6-80C2B S/B 78-1168 Revision 2, 19 April 2011 Page 7

MRAS PROPRIETARY INFORMATION – Subject to the restrictions on the first page. 2. B. Industry Support Information

Middle River Aircraft Systems (MRAS) will supply Flexible Drive Cables PN 491B1200036-001 and PN 491B1200036-002. Refer to Paragraph 2.A., Material – Price and Availability, for quantities and prices. Send a Charge Purchase Order (the Purchase Order must include the flexible drive cables part numbers and the number of this Service Bulletin) to:

Middle River Aircraft Systems ATTN: Commercial Spares Support

Mail Point 46 103 Chesapeake Park Plaza Baltimore, MD 21220 U.S.A.

Fax: 410.682.0090

SITA: BWIMS7X E-mail: spares_support@mras-usa.com

MRAS will provide a 50% up-front price disc ount for Flexible Drive Cables PN 491B1200036-

001 and PN 491B1200036-002 until 15 November 2012.

The discounted price for Flexible Dr ive Cables PN 491B1200036-001 and PN 491B1200036- 002 ordered through 30 June 2011 is $1,830.00 each. (This is a 67% discount of the current Honeywell spare parts catalog list price for Fl exible Drive Cable PN 3278500-7; therefore, the discounted price includes the installation labor allowance.)

The discounted price for Flexible Dr ive Cables PN 491B1200036-001 and PN 491B1200036- 002 ordered from 1 July 2011 through 31 December 2011 will be $1,905.60 each.

The discounted price for Flexible Dr ive Cables PN 491B1200036-001 and PN 491B1200036- 002 ordered from 1 January 2012 through 15 No vember 2012 will be 50% of the 2012 MRAS CF6 Thrust Reverser Spare Parts Catalog list price.

Operators with CF6-80C2 fan reversers not having Flexible Drive Cables PN 491B1200036- 001 and PN 491B1200036-002 installed and having less than 3,500 Flight Hours Since New may submit a No-Charge Purchase Order to MRAS for Flexible Drive Cables PN 491B1200036-001 and PN 491B1200036-002. The No-Charge Purchase Order must include

the serial numbers of the fan reverser halve s and the number of fan reverser flight hours

accumulated since new. Without this info rmation, MRAS will not accept the No-Charge

Purchase Order.

After 15 November 2012, MRAS will not provide a discount for Flexible Drive Cables PN

491B1200036-001 and PN 491B1200036-002.

# CF6-80C2B SERVICE BULLETIN

EXHAUST - Fan Reverser – Thrust Reverser Actu ation System (TRAS) Lock Flexible Drive Cables Part Numbers 491B1200036-001 (Left-Hand) and 491B1200036-002 (Right-Hand) - Introduction

17 August 2010 CF6-80C2B S/B 78-1168 Revision 2, 19 April 2011 Page 8

MRAS PROPRIETARY INFORMATION – Subject to the restrictions on the first page. 2. C. Configuration Chart

*** CF6-80C2B1/B2/B4/B6/B1F/B2F /B4F/B5F/B6F/B6FA/B7F/B8F ***

New Part Number Qty /

F/R Part Name Old Part Number /

IPC Location Qty /

F/R Op

Code Chg / Sprt

Code
(Production)

683L307G19 (1) Kit – TRAS Lock (LH) (767 / 747) (Pos 1 / Pos 1 & 2) (Pos 2 / Pos 3 & 4) 683L307G14 (VIN 3283094-14)

78-32-00-6-050

78-32-00-16-050 (1) RE 1 / A

683L307G20 (1) Kit – TRAS Lock (RH) (767 / 747) (Pos 1 / Pos 1 & 2) (Pos 2 / Pos 3 & 4) 683L307G15 (VIN 3283094-15)

78-32-00-11-050

78-32-00-21-050 (1) RE 1 / A

(Production / Field)

.491B1200036-001

.491B1200036-002 (1)

(1) Flexible Drive Cable (LH)

Flexible Drive Cable (RH) .1806M47P05 (VIN 3278500-7)

78-36-10-1-020

78-36-10-1-030

78-36-10-1A-020

78-36-10-1B-020 (2) RE 1 / A

Operation Code Change Code Spare Parts Support Code RE = Replace 1 = One-way interchangeable A = Old parts will no longer be supplied.

D. Parts Disposition

At the operator’s option, quarantine, scrap or retain TRAS Lock Flexible Drive Cables PN 1806M47P01/P02/P05. To determine serviceability of TRAS Lock Flexible Drive Cables PN 1806M47P01/P02/P05, refer to Flexible S haft Assembly Component Maintenance Manual (CMM) GEK 103024 (ATA 78-32-57), Section 2, Testing and Fault Isolation.

E. Tooling

Mechanic’s hand tools

# CF6-80C2B SERVICE BULLETIN

EXHAUST - Fan Reverser – Thrust Reverser Actu ation System (TRAS) Lock Flexible Drive Cables Part Numbers 491B1200036-001 (Left-Hand) and 491B1200036-002 (Right-Hand) - Introduction

17 August 2010 CF6-80C2B S/B 78-1168 Revision 2, 19 April 2011 Page 9

MRAS PROPRIETARY INFORMATION – Subject to the restrictions on the first page. 3. ACCOMPLISHMENT INSTRUCTIONS

NOTE: The following Accomplishment Instructi ons are for both left and right hand fan reverser halves. Figure 1 in this Service Bulletin s hows the right-hand fan reverser half only. The left-hand fan reverser half is a mirror image of the right-hand fan reverser half.

A. Job Set-up

WARNING: MAKE CERTAIN THAT CIRCUIT BREAKERS ARE OPEN, SAFETIED, AND

TAGGED BEFORE ATTEMPTING MA INTENANCE PROCEDURES.

INADVERTENT ENGINE START OR FAN REVERSER OPERATION COULD

RESULT IN DEATH OR SERIOUS INJ URY TO PERSONNEL. MAKE CERTAIN THAT THROUGHOUT THE JOB SET-UP, THE AIRCRAFT PNEUMATIC

SYSTEM IS NOT PRESSURIZED BY PNEU MATIC GROUND POWER, APU, OR

ANOTHER ENGINE.

(1) Open, safety, and tag the appropriate circuit breakers (ensure that the fan reverser PRSOV circuit breaker is open to disable the fan reverser auto re-stow function), and open the fan cowl doors to the full open position and the fan reversers to the lower open position. Be

sure the fan cowl doors and the fan reversers ar e secured. Refer to the applicable Aircraft Maintenance Manual (AMM).

(2) Get access to the fan reverser half upper torque box area.

B. Remove the TRAS Lock Flexible Drive Cable from the Fan Reverser Half

(1) Refer to Figure 1. Disconnect the elec trical connector from the TRAS lock (Item 1).

(2) Remove the two bolts (Item 3) and the two wa shers (Item 4) that attach the flexible drive cable (Item 2) to the upper end actuator t op drive pad (Item 5). Retain the bolts and

washers.

(3) Remove the three bolts (Item 6) and the th ree washers (Item 7) that attach the TRAS lock (Item 1) to the bracket (Item 8) . Retain the bolts and washers.

(4) Remove the TRAS lock (Item 1) and the flexible drive cable (Item 2) from the bracket (Item 8).

(5) Disconnect the flexible drive cable (Item 2) from the TRAS lock (Item 1).

# CF6-80C2B SERVICE BULLETIN

EXHAUST - Fan Reverser – Thrust Reverser Actu ation System (TRAS) Lock Flexible Drive Cables Part Numbers 491B1200036-001 (Left-Hand) and 491B1200036-002 (Right-Hand) - Introduction

17 August 2010 CF6-80C2B S/B 78-1168 Revision 2, 19 April 2011 Page 10

MRAS PROPRIETARY INFORMATION – Subject to the restrictions on the first page. 3. C. Install Left-Hand TRAS Lock Flexible Drive Cable PN 491B1200036-001 or Right-Hand TRAS

Lock Flexible Drive Cable PN 491B1200036-002 on the Fan Reverser Half

(1) Obtain TRAS Lock Flexible Drive Cable PN 491B1200036-001 for the left-hand fan

reverser half or TRAS Lock Flexible Dr ive Cable PN 491B1200036-002 for the right-hand

fan reverser half.

NOTE: TRAS Lock Flexible Drive Cable PN 491B1200036-001 is labeled “LH ONLY” in two places. TRAS Lock Flexible Dr ive Cable PN 491B1200036-002 is labeled “RH ONLY” in two places.

(2) Refer to Figure 1. Slide the flexible drive cable (Item 2) into the TRAS lock (Item 1) until it
stops.

(3) Put the TRAS lock/flexible drive cable asse mbly (Items 1 & 2) on the bracket (Item 8). Slide the assembly into the upper end actuator top drive pad (Item 5) by inserting the square drive end of the flexible drive cable (Item 2).

(4) If it is necessary, pull up the manual rel ease handle of the TRAS lock (Item 1) from its retaining clip to disengage the TRAS lock (Item 1) and permit the flexible drive cable (Item 2)

to turn.

NOTE: This will allow alignment of the square drive end of the flexible drive cable with the top drive pad of the upper end actuator.

(5) Attach the flexible drive cable (Item 2) to the top drive pad of the upper end actuator (Item 5) with the two retained bolts (Item 3) and t he two retained washers (Item 4). Install the bolts (Item 3) wet with anti-seize compound (C02-032). Torque the bolts to 24-27 lb-in. (2,7-3,1 N.m).

CAUTION: THERE ARE TWO ALTERNATE BOLT HOLE PATTERNS ON THE TRAS LOCK BRACKET (FIGURE 1, SHEET 2). U SE THE BOLT HOLE PATTERN THAT BEST

ALIGNS THE FLEXIBLE DRIVE CABLE (ITEM 2) TO THE UPPER END

ACTUATOR. DO NOT LET THE FL EXIBLE DRIVE CABLE MAKE AN S-TYPE

CURVE. THE FLEXIBLE DRIVE CABLE MUST BE STRAIGHT OR MAKE A CONTINUOUS ARC, OR THE FLEXIBLE DRIVE CABLE CAN BECOME

DAMAGED.

(6) Refer to Figure 1, Sheet 2. Align the TR AS lock (Item 1) with the bolt hole pattern of the bracket (Item 8) that gives the straightest conf iguration of the flexible drive cable (Item 2).

(7) Attach the TRAS lock (Item 1) to the bracke t (Item 8) with the three retained machine bolts (Item 6) and the three retained flat washers (Ite m 7). The machine bolts are installed from under the bracket (Item 8). Install the bolts (Item 6) wet with anti-seize compound (C02- 032). Torque the machine bolts to 55-70 lb-in. (6,2-7,9 N.m).

(8) Attach the electrical c onnector to the TRAS lock (Item 1).

# CF6-80C2B SERVICE BULLETIN

EXHAUST - Fan Reverser – Thrust Reverser Actu ation System (TRAS) Lock Flexible Drive Cables Part Numbers 491B1200036-001 (Left-Hand) and 491B1200036-002 (Right-Hand) - Introduction

17 August 2010 CF6-80C2B S/B 78-1168 Revision 2, 19 April 2011 Page 11

MRAS PROPRIETARY INFORMATION – Subject to the restrictions on the first page. 3. C. (Continued)

(9) Pull down the manual release handle of the TRAS lock (Item 1) until the handle fully engages its retaining clip.

D. Repeat Sections 3.B. and 3.C. for the Other Fan Reverser Half

E. Do the TRAS Lock Holding Torque Check per AMM 78-34-07/501 or an equivalent approved procedure.

F. Complete the Installation Record & Operator Torque Checks Feedback Form and Return to

MRAS (Optional)

.

Refer to Figures 2 and 3. Complete the appr opriate Installation Record & Operator Torque Checks Feedback Form (one form for 767; two forms for 747). Return the Installation Record & Operator Torque Checks Feedback Form to MRAS via fax or e-mail (refer to the fax number and the e-mail address at the bottom of the Installation Record).

G. Record Service Bulletin Accomplishment (Optional)

(1) If CF6-80C2 Service Bulletin 78-1133 has been accomplished, mark “S/B 78-1168” on

Identification Plate PN MS27253-2. Method of marking (e.g., metal stamp or vibropeen) is the operator’s choice.

NOTE: Step 3. G .(2) installs an identificat ion plate used to record Service Bulletin accomplishment. The operator may choose not to accomplish Step 3. G .(2).

(2) If CF6-80C2 Service Bulletin 78-1133 has not been accomplished, accomplish SB 78- 1133, then mark “S/B 78-1168” on Identific ation Plate PN MS27253-2. Method of marking (e.g., metal stamp or vi bropeen) is the operator’s choice.

H. Job Close-up

(1) Close the fan reverser halves and the fan cowl doors. Refer to the applicable AMM.

(2) Remove safety clips and tags and close prev iously opened circuit breakers. Refer to the applicable AMM.

# CF6-80C2B SERVICE BULLETIN

EXHAUST - Fan Reverser – Thrust Reverser Actu ation System (TRAS) Lock Flexible Drive Cables Part Numbers 491B1200036-001 (Left-Hand) and 491B1200036-002 (Right-Hand) - Introduction

17 August 2010 CF6-80C2B S/B 78-1168 Revision 2, 19 April 2011 Page 12

MRAS PROPRIETARY INFORMATION – Subject to the restrictions on the first page. 4. DOCUMENT PERIODIC POST-SB 78-1168 TRAS LOCK HOLDING TORQUE CHECK RESULTS (OPTIONAL)

.

Following installation of Flexible Dr ive Cables PN 491B1200036-001 and PN 491B1200036-002, TRAS Lock Holding Torque Checks per AMM 78-34-07/501 (or an equivalent approved procedure) are accomplished (refer to Section 3.E.). MRAS requests operators to record accomplishment of the initial TRAS Lock Holding Torque Checks following in stallation of the new flexible drive cables on the Installation Record & Operator Torque Checks Feedback Form (refer to Figures 2 & 3) and to return the Installation Record & Operator Torque Checks Feedback Form to MRAS (refer to the fax number and the e-mail address at the bottom of the Installation Record).

NOTE: Two forms are required for the four fan reversers on a 747.

FAA Airworthiness Directives require accomp lishment of TRAS Lock Holding Torque Checks at an interval of 1,000 Flight Hours (FH). MRAS requests operators to record the results (pass or fail) of these periodic torque checks on the same Installation Record & Operator Torque Checks Feedback Form completed for each fan reverser half following installation of the new flexible drive cables and to return the Installation Record & Operator Torque Checks Feedback Form to MRAS after each torque check.

After MRAS has collected the initial and three subsequent periodic torque checks results for fan

reverser halves with the new flexible drive cables installed, Boeing will petition FAA for an extension of the torque check interval bas ed on anticipated positive results.

# CF6-80C2B SERVICE BULLETIN

EXHAUST - Fan Reverser – Thrust Reverser Actu ation System (TRAS) Lock Flexible Drive Cables Part Numbers 491B1200036-001 (Left-Hand) and 491B1200036-002 (Right-Hand) - Introduction

17 August 2010 CF6-80C2B S/B 78-1168 Revision 2, 19 April 2011 Page 13

MRAS PROPRIETARY INFORMATION – Subject to the restrictions on the first page. MR70950-00-A

Replacement of TRAS Lock Flexible Drive Cable Figure 1, Sheet 1 of 2

# CF6-80C2B SERVICE BULLETIN

EXHAUST - Fan Reverser – Thrust Reverser Actu ation System (TRAS) Lock Flexible Drive Cables Part Numbers 491B1200036-001 (Left-Hand) and 491B1200036-002 (Right-Hand) - Introduction

17 August 2010 CF6-80C2B S/B 78-1168 Revision 2, 19 April 2011 Page 14

MRAS PROPRIETARY INFORMATION – Subject to the restrictions on the first page. MR70951-00-A

Replacement of TRAS Lock Flexible Drive Cable Figure 1, Sheet 2 of 2

# CF6-80C2B SERVICE BULLETIN

EXHAUST - Fan Reverser – Thrust Reverser Actu ation System (TRAS) Lock Flexible Drive Cables Part Numbers 491B1200036-001 (Left-Hand) and 491B1200036-002 (Right-Hand) - Introduction

17 August 2010 CF6-80C2B S/B 78-1168 Revision 2, 19 April 2011 Page 15

MRAS PROPRIETARY INFORMATION – Subject to the restrictions on the first page. Legend for Figure 1

Item

No. Part Name Part Number Quantity

Per

TR Half

1 Thrust Reverser Actuation System (TRAS ) Lock 1806M46P05 1

2 Flexible Drive Cable 1806M47P01 (Removed – RH only)

or 1806M47P02 (Removed – LH or RH)

or 1806M47P05 (Removed – LH or RH)

491B1200036-001 (LH – Installed)

or 491B1200036-002 (RH – Installed) 1

3 Machine Bolt MS9489-07 2

4 Flat Washer AN960C10L 2

5 Upper End Actuator Top Drive Pad --- 1

6 Machine Bolt MS9490-11 3

7 Flat Washer AN960C416 3

8 TRAS Lock Bracket 1806M48P01 or P03 (RH) 1806M48P02 or P04 (LH) 1

# CF6-80C2B SERVICE BULLETIN

EXHAUST - Fan Reverser – Thrust Reverser Actu ation System (TRAS) Lock Flexible Drive Cables Part Numbers 491B1200036-001 (Left-Hand) and 491B1200036-002 (Right-Hand) - Introduction

17 August 2010 CF6-80C2B S/B 78-1168 Revision 2, 19 Ap r il 20 11 P age 16

MRAS PROPRIETARY INFORMATION – Subject to the restrictions on the first page. INSTALLATION RECORD & OPERATOR TORQUE CHECKS FEEDBACK FORM (OPTIONAL)

This installation record and operator torque checks feedback form is optional. The TRAS lock holding torque check data will be used to justify an extensi on of the current 1,000 flight-hour TRAS lock holding torque check interval for fan reversers wi th Flexible Drive Cables PNs 491B1200036-001 &

491B1200036-002 installed.

Aircraft Model 767 Operator: _______________________________ Date: ____________________

Aircraft Tail No. _____________________________

FLEXIBLE DRIVE CABLES PART NUMBER 491B1200036-001 WERE INSTALLED ON THE

FOLLOWING LEFT-HAND FAN REVERSER HALVES:

Wing Position 1 Left-Hand Fan Reverser Half Serial No. __________________________________

TRAS LOCK HOLDING TORQUE CHECK DATE (MM/DD/YYYY) RESULTS INITIAL (STEP 3.E.) PASS / FAIL (circle) + 1,000 FLIGHT HOURS PASS / FAIL (circle) + 2,000 FLIGHT HOURS PASS / FAIL (circle) + 3,000 FLIGHT HOURS PASS / FAIL (circle)

Wing Position 2 Left-Hand Fan Reverser Half Serial No. __________________________________

TRAS LOCK HOLDING TORQUE CHECK DATE (MM/DD/YYYY) RESULTS INITIAL (STEP 3.E.) PASS / FAIL (circle) + 1,000 FLIGHT HOURS PASS / FAIL (circle) + 2,000 FLIGHT HOURS PASS / FAIL (circle) + 3,000 FLIGHT HOURS PASS / FAIL (circle)

FLEXIBLE DRIVE CABLES PART NUMBER 491B1200036-002 WERE INSTALLED ON THE

FOLLOWING RIGHT-HAND FAN REVERSER HALVES:

Wing Position 1 Right-Hand Fan Reverser Half Serial No. _________________________________

TRAS LOCK HOLDING TORQUE CHECK DATE (MM/DD/YYYY) RESULTS INITIAL (STEP 3.E.) PASS / FAIL (circle) + 1,000 FLIGHT HOURS PASS / FAIL (circle) + 2,000 FLIGHT HOURS PASS / FAIL (circle) + 3,000 FLIGHT HOURS PASS / FAIL (circle)

Wing Position 2 Right-Hand Fan Reverser Half Serial No. _________________________________

TRAS LOCK HOLDING TORQUE CHECK DATE (MM/DD/YYYY) RESULTS INITIAL (STEP 3.E.) PASS / FAIL (circle) + 1,000 FLIGHT HOURS PASS / FAIL (circle) + 2,000 FLIGHT HOURS PASS / FAIL (circle) + 3,000 FLIGHT HOURS PASS / FAIL (circle)

Return to: Middle River Aircraft Systems ATTN: Product Support Engineering E-mail: technical_support@mras-usa.com

Fax: 410.682.0100

Installation Record & Operator Torque Checks Feedback Form (767) Figure 2

# CF6-80C2B SERVICE BULLETIN

EXHAUST - Fan Reverser – Thrust Reverser Actu ation System (TRAS) Lock Flexible Drive Cables Part Numbers 491B1200036-001 (Left-Hand) and 491B1200036-002 (Right-Hand) - Introduction

17 August 2010 CF6-80C2B S/B 78-1168 Revision 2, 19 April 2011 P age 17

MRAS PROPRIETARY INFORMATION – Subject to the restrictions on the first page. INSTALLATION RECORD & OPERATOR TORQUE CHECKS FEEDBACK FORM (OPTIONAL)

This installation record and operator torque checks feedback form is optional. The TRAS lock holding torque check data will be used to justify an extensi on of the current 1,000 flight-hour TRAS lock holding torque check interval for fan reversers wi th Flexible Drive Cables PNs 491B1200036-001 &

491B1200036-002 installed.

Aircraft Model 747 Operator: _______________________________ Date: ____________________

Aircraft Tail No. _____________________________

FLEXIBLE DRIVE CABLES PART NUMBER 491B1200036-001 WERE INSTALLED ON THE

FOLLOWING LEFT-HAND FAN REVERSER HALVES:

Wing Position 1 or 3 (circle) Left-Hand Fan Reverser Half Serial No. ________________________

TRAS LOCK HOLDING TORQUE CHECK DATE (MM/DD/YYYY) RESULTS INITIAL (STEP 3.E.) PASS / FAIL (circle) + 1,000 FLIGHT HOURS PASS / FAIL (circle) + 2,000 FLIGHT HOURS PASS / FAIL (circle) + 3,000 FLIGHT HOURS PASS / FAIL (circle)

Wing Position 2 or 4 (circle) Left-Hand Fan Reverser Half Serial No. ________________________

TRAS LOCK HOLDING TORQUE CHECK DATE (MM/DD/YYYY) RESULTS INITIAL (STEP 3.E.) PASS / FAIL (circle) + 1,000 FLIGHT HOURS PASS / FAIL (circle) + 2,000 FLIGHT HOURS PASS / FAIL (circle) + 3,000 FLIGHT HOURS PASS / FAIL (circle)

FLEXIBLE DRIVE CABLES PART NUMBER 491B1200036-002 WERE INSTALLED ON THE

FOLLOWING RIGHT-HAND FAN REVERSER HALVES:

Wing Position 1 or 3 (circle) Right-Hand Fan Reverser Half Serial No. _______________________

TRAS LOCK HOLDING TORQUE CHECK DATE (MM/DD/YYYY) RESULTS INITIAL (STEP 3.E.) PASS / FAIL (circle) + 1,000 FLIGHT HOURS PASS / FAIL (circle) + 2,000 FLIGHT HOURS PASS / FAIL (circle) + 3,000 FLIGHT HOURS PASS / FAIL (circle)

Wing Position 2 or 4 (circle) Right-Hand Fan Reverser Half Serial No. _______________________

TRAS LOCK HOLDING TORQUE CHECK DATE (MM/DD/YYYY) RESULTS INITIAL (STEP 3.E.) PASS / FAIL (circle) + 1,000 FLIGHT HOURS PASS / FAIL (circle) + 2,000 FLIGHT HOURS PASS / FAIL (circle) + 3,000 FLIGHT HOURS PASS / FAIL (circle)

Return to: Middle River Aircraft Systems ATTN: Product Support Engineering E-mail: technical_support@mras-usa.com

Fax: 410.682.0100

Installation Record & Operator Torque Checks Feedback Form (747) Figure 3