AD/B747/277 Amdt 2 - Thrust Reverser Inspections and Tests

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AIRWORTHINESS DIRECTIVE


For the reasons set out in the background section, the CASA delegate whose signature appears below revokes Airworthiness Directive (AD) AD/B747/277 Amdt 1 and issues the following AD under subregulation 39.1 (1) of CASR 1998. The AD requires that the action set out in the requirement section (being action that the delegate considers necessary to correct the unsafe condition) be taken in relation to the aircraft or aeronautical product mentioned in the applicability section: (a) in the circumstances mentioned in the requirement section; and (b) in accordance with the instructions set out in the requirement section; and (c) at the time mentioned in the compliance section.


 

Boeing 747 Series Aeroplanes

 

AD/B747/277

Amdt 2


Thrust Reverser Inspections and Tests 1/2004

 

 

Applicability:  Boeing Model B747-400 series aeroplanes powered by Pratt & Whitney PW 4000 series engines, General Electric CF6-80C2 series engines or Rolls Royce RB211- 524G/H series engines.

 

Requirement: Note 1: See “Terminating Action” section of AD/B747/230 Amdt 1 and AD/B747/250 Amdt 1.

 

  1. Pratt & Whitney PW4000 series engines:

 

  1. Carry out an inspection to detect damage to the bullnose seal on the translating sleeve of the thrust reverser, and perform a test of the lock mechanism of the centre locking actuator, in accordance with the Accomplishment Instructions contained in:

 

  • Boeing Service Bulletin (SB) 747-78-2112, dated 11 November 1993, or
  • Boeing Alert SB 747-78A2112 Revision 1, dated 7 March 1994.
  1. Repeat the inspection and tests of Requirement 1(a).

 

c.         Carry out inspections and functional tests of the thrust reverser control and indication systems in accordance with the Accomplishment Instructions in Service Bulletins listed in Requirement 1(a).

 

d.        Repeat the inspection and tests of Requirement 1(c).

 

Compliance with AD/B747/250 Amdt 1 is terminating action for Requirement 1.

 

2.         General Electric CF6-80C2 series engines:

 

  1. Carry out an inspection to detect damage to the bullnose seal on the translating sleeve of the thrust reverser, and a continuity test of the position switch module of the Centre Drive Unit (CDU) and a cone brake test of the CDU, in accordance with the Accomplishment Instructions contained in:

 

  • Boeing Service Bulletin (SB) 747-78-2113, dated 11 November 1993, or

 

Boeing Alert SB 747-78A2113 Revision 1, dated 10 March 1994.

 

b.        Repeat the inspection and tests of Requirement 2(a).

 

c.         Carry out inspections and functional tests of the thrust reverser control and indication systems in accordance with the Accomplishment Instructions in Service Bulletins listed in Requirement 2(a).

 

d.        Repeat the inspections and functional tests of Requirement 2(c).

 

Compliance with AD/B747/298 functional test of CDU cone break is terminating action for cone break tests in this Requirement.

 

Alternative Means of Compliance (AMOC):

For aeroplanes on which the intent of Boeing SB 747-78- 2151 Revision 2, dated 13 January 2000, was accomplished during production, or retrofitted subsequently, and implementing the periodic checks of both the electro- mechanical brake/lock and Centre Drive Unit (CDU) cone brake as detailed in FAA Alternative Means of Compliance (AMOC) document, reference 99-140S- 295, dated 13 August 1999, is an alternative means of compliance to Requirement 2 of this Directive.

 

3.         Rolls-Royce RB211-524G/H series engines:

 

  1. Carry out inspections and functional tests of the thrust reverser control and indication systems in accordance with paragraphs III.D. to III.K. of the Accomplishment Instructions of Boeing Service Bulletin 747-78-2115, dated 28 October 1993; or paragraphs III.D. to III.L. of the Accomplishment Instructions of Boeing Alert Service Bulletin 747-78A2115 Revision 1, dated 4 March 1994.

 

b.        Repeat the inspections and functional tests of Requirement 3(a).

 

Compliance with AD/B747/230 Amdt 1 is terminating action for all of Requirement 3.

 

4.         If any of the inspections and/or functional tests required by this Airworthiness Directive cannot be successfully carried out, or if any discrepancy is found during those inspections and/or functional tests, correct the discrepancy found in accordance with:

 

  1. For Pratt & Whitney PW4000 series engines: Boeing Service Bulletin (SB) 747-78-2112, dated 11 November 1993, or Boeing Alert SB 747-78A2112 Revision 1, dated 7 March 1994.

 

b.        For General Electric CF6-80C2 series engines: Boeing Service Bulletin 747- 78-2113, dated 11 November 1993, or Boeing Alert Service Bulletin 747- 78A2113 Revision 1, dated 10 March 1994.

 

c.         For Rolls-Royce RB211-524G/H series engines: Boeing Service Bulletin 747-78-2115, dated 28 October 1993, or Boeing Alert Service Bulletin 747- 78A2115 Revision 1, dated 4 March 1994.

 

5.         If unable to comply with the requirements of Requirement 4:

 

  1. Operate the aeroplane in accordance with the conditions and limitations of the Minimum Equipment List (MEL), applicable to the registration mark of the aeroplane, provided the MEL only approves dispatch with:

 

(i)       no more than one thrust reverser on the aeroplane inoperative; and

 

(ii)     the thrust reverser is deactivated in accordance with approved maintenance data; AND

 

b.        If the aeroplane is operated in accordance with Requirement 5(a), repair the thrust reverser in accordance with the applicable Service Bulletins listed in Requirement 4; AND

 

c.         Repeat the inspections and tests after repair under Requirement 5(b) that were not carried out under Requirement 4; AND

 

d.        Carry out Requirement 4 if any inspection or test carried out under Requirement 5(c) was unsuccessful.

 

Note 2: FAA AD 94-15-05 and FAA Alternative Means of Compliance (AMOC) document reference 99-140s-295, dated 13 August 1999, issued by the FAA Transport Airplane Directorate, Aircraft Certification Section, Renton, Washington, refer.

 

Compliance: For Requirement 1(a): Prior to issue of Certificate of Airworthiness.

 

For Requirement 1(b): At intervals of 1,000 hours time-in-service after accomplishment of Requirement 1(a).

 

For Requirement 1(c): Prior to issue of Certificate of Airworthiness.

 

For Requirement 1(d): At intervals not to exceed 18 months after accomplishment of Requirement 1(c).

 

For Requirement 2(a): Remains unchanged as: Within 90 days after the effective date of amendment 1 of this Directive.

 

For Requirement 2(b): At intervals not to exceed 1,000 hours time-in-service after accomplishment of Requirement 2(a).

 

For Requirement 2(c): Remains unchanged as: Within 90 days after the effective date of amendment 1 of this Directive.

 

For Requirement 2(d): At intervals not exceeding 18 months after accomplishment of Requirement 2(c).

 

For Requirement 3(a): Remains unchanged as: Within 90 days after the effective date of amendment 1 of this Directive.

 

For Requirement 3(b): At intervals not exceeding 18 months after accomplishment of Requirement 3(a).

 

For Requirement 4: Prior to further flight. For Requirement 5(a): Prior to further flight.

For Requirement 5(b): Within 10 days after deactivation in accordance with the provisions of Requirement 5(a).

 

Requirement 5(c) and (d): Prior to further flight.

 

This Amendment becomes effective on 22 January 2004.

 

Background: This amendment changes the reference to terminating actions for the CDU cone brake functional test from AD/B747/231 Amdt 1 to AD/B747/298.

 

This Directive was prompted by a FAA/Boeing investigation to determine the controllability of model 747 series aeroplanes following in-flight thrust reverser deployment. The actions specified in this Directive are intended to ensure the integrity of the fail-safe features of the thrust reverser system by preventing possible failure modes in the thrust reverser control system that could result in inadvertent deployment of a thrust reverser during flight.

 

Amendment 1 of this Directive was issued to correct an error in the Alternate Means of Compliance paragraph of this Directive.

 

The original issue of this Airworthiness Directive became effective on 5 September 2002.


Jim Coyne

Delegate of the Civil Aviation Safety Authority 4 December 2003

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 


The above AD is notified in the Commonwealth of Australia Gazette on 24 December 2003.

Overview

The Civil Aviation Safety Authority (CASA) issued Airworthiness Directive AD/B747/277 Amendment 2 on 4 December 2003 under the authority granted by subregulation 39.1(1) of the Civil Aviation Safety Regulations 1998 (CASR). This directive addresses issues concerning the safety of Boeing 747-400 series aeroplanes powered by specific engine types, specifically the Pratt & Whitney PW4000, General Electric CF6-80C2, and Rolls-Royce RB211-524G/H series engines. The directive was prompted by an investigation into the controllability of model 747 series aeroplanes following in-flight thrust reverser deployment, with the aim of ensuring the integrity of the fail-safe features of the thrust reverser system and preventing possible failure modes that could result in inadvertent deployment during flight. This directive revokes AD/B747/277 Amendment 1 and sets out new requirements for inspections and tests to be conducted on the thrust reverser systems of the specified aircraft. The directive specifies the actions necessary to rectify unsafe conditions, including inspections and tests of the thrust reverser control and indication systems, and details the compliance timelines for these actions. It also outlines alternative means of compliance for certain conditions and provides instructions for operating the aircraft under specific circumstances if the required inspections and tests cannot be successfully carried out. The directive was amended to correct an error in the Alternate Means of Compliance paragraph and became effective on 22 January 2004. This Airworthiness Directive was published in the Commonwealth of Australia Gazette on 24 December 2003.

Scope and Application

This Airworthiness Directive (AD) applies specifically to Boeing 747-400 series aeroplanes powered by Pratt & Whitney PW 4000 series engines, General Electric CF6-80C2 series engines or Rolls Royce RB211- 524G/H series engines. The AD outlines the necessary inspections and tests that must be carried out to ensure the integrity of the thrust reverser control system, particularly focusing on the bullnose seal and lock mechanisms of the thrust reversers. The directive is applicable across the Commonwealth of Australia, as it is issued by the Civil Aviation Safety Authority (CASA) under subregulation 39.1 (1) of the Civil Aviation Safety Regulations 1998 (CASR 1998). The AD requires specific actions to be taken before the issue of a Certificate of Airworthiness, at intervals of 1,000 hours time-in-service, and before further flight, depending on the engine type and the specific requirement. Compliance with this AD is mandatory, and any failure to comply can lead to operational restrictions as outlined in the Minimum Equipment List (MEL) of the aeroplane. The AD also provides for alternative means of compliance under certain conditions, such as when specific production or retrofit measures have been taken. This amendment revokes the previous AD and incorporates corrections and updates to ensure the safety and airworthiness of the specified aircraft models.

Key Provisions

The Airworthiness Directive (AD) AD/B747/277 Amdt 1 has been revoked and replaced by a new AD issued under subregulation 39.1(1) of the Civil Aviation Safety Regulations 1998 (CASR 1998). This new AD applies to Boeing Model B747-400 series aeroplanes powered by Pratt & Whitney PW 4000 series engines, General Electric CF6-80C2 series engines, or Rolls Royce RB211-524G/H series engines (section 1). The primary requirement of this AD is that specific inspections and tests of the thrust reverser systems must be carried out on these aircraft to ensure the integrity of the fail-safe features and prevent possible failure modes that could result in inadvertent thrust reverser deployment during flight (section 1). The AD imposes specific obligations on the operators and maintainers of the affected aircraft. For Pratt & Whitney PW4000 series engines, the requirement is to inspect and test the bullnose seal on the translating sleeve of the thrust reverser and the lock mechanism of the centre locking actuator, following the instructions in Boeing Service Bulletin (SB) 747-78-2112 or Boeing Alert SB 747-78A2112 Revision 1 (section 1(a)). For General Electric CF6-80C2 series engines, inspections and tests must be conducted on the bullnose seal, position switch module continuity, and cone brake of the Centre Drive Unit (CDU), as per Boeing SB 747-78-2113 or Boeing Alert SB 747-78A2113 Revision 1 (section 2(a)). For Rolls-Royce RB211-524G/H series engines, inspections and functional tests must be carried out on the thrust reverser control and indication systems according to the instructions in Boeing SB 747-78-2115 or Boeing Alert SB 747-78A2115 Revision 1 (section 3(a)). All inspections and tests must be repeated at specified intervals (sections 1(b), 2(b), and 3(b)). If any discrepancies are found during these inspections and tests, they must be corrected in accordance with the applicable Boeing Service Bulletins (section 4). If compliance with the AD cannot be achieved, the aircraft must be operated in accordance with the Minimum Equipment List (MEL) conditions, and any necessary repairs must be carried out within 10 days (section 5). Failure to comply with the requirements of this Airworthiness Directive could result in serious safety risks, including the potential for inadvertent thrust reverser deployment during flight, which could endanger the aircraft and its occupants. While the legislation itself does not explicitly state specific penalties for non-compliance, non-compliance with ADs generally could result in enforcement actions by the Civil Aviation Safety Authority (CASA), including fines, suspension or revocation of airworthiness certificates, or other regulatory actions. Additionally, operators may face liability for any accidents or incidents resulting from non-compliance with airworthiness requirements.

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Sourced from the Federal Register of Legislation at 26 August 2026. For the latest information on Australian Government law please go to https://www.legislation.gov.au.