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Commercial Airplanes 747 Service Bulletin ALERT Number: 747-57A2343 Original Issue: September 12, 2013 Revision 1: June 23, 2014 ATA System: 5752 2751 SUBJECT: WINGS - Trailing Edge Flaps - Outboard Flap Inboard Actuator Attach Fittings (Gimbals No.s 2 and 7) - Inspection, Rework, and Replacement Export of this technology is controlled under the United States Export Administration Regulations (EAR) (15 CFR 300-774). 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 © 2013 Boeing.
Unpublished Work. All Rights Reserved.
Treatment of this document and its content is governed by contract with Boeing. Rights to use this document are licensed on a per aircraft basis and such rights may not be transferable. For more information, contact The Boeing Company.
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, KC-46, KDC-10, MD-10, MD-11, MD-80, MD-88, MD-90, P-8, Poseidon and Boeing liveries 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: September 12, 2013 747-57A2343Revision 1: June 23, 2014 1 of 68
5.0
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: September 12, 2013 747-57A2343Revision 1: June 23, 2014 2 of 68 BOEING SERVICE BULLETIN 747-57A2343
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BLANK PAGE
Table of Contents
Revision Transmittal Sheet5
Summary9
1. PLANNING INFORMATION ........................................ 1 3 A. Effectivity ............................................... 1 3
1. Airplanes ............................................ 1 3
2. Spares Affected ........................................ 2 2 B. Concurrent Requirements ...................................... 2 2 C. Reason ................................................ 2 2 D. Description .............................................. 2 3 E. Compliance .............................................. 2 4 F. Approval ............................................... 2 7 G. Manpower .............................................. 2 8 H. Weight and Balance Changes .................................... 2 9 I. Electrical Load Data ......................................... 3 0 J. References .............................................. 3 0
1. Existing Data: ......................................... 3 0
2. Data Supplied with this Service Bulletin: ........................... 3 0
3. Installation Drawings Used in the Preparation of this Service Bulletin: ........... 3 0 K. Publications Affected ........................................ 3 0 L. Interchangeability and Intermixability of Parts ........................... 3 1 M. Software Accomplishment Summary ................................ 3 1
2. MATERIAL INFORMATION ........................................ 3 3 A. Material - Price and Availability ................................... 3 3 B. Industry Support Information .................................... 3 3 C. Parts Necessary for Each Airplane ................................. 3 4
1. Kits/Parts ............................................ 3 4
2. Parts and Materials Supplied by the Operator ........................ 3 4
3. Parts Modified and Reidentified ................................ 3 4
4. Parts Removed and Not Replaced .............................. 3 4 D. Parts Necessary to Change Spares ................................. 3 4 E. Special Tooling - Price and Availability ............................... 3 5 F. Special Tooling Necessary to do this Service Bulletin ....................... 3 5
3. ACCOMPLISHMENT INSTRUCTIONS .................................. 3 7 A. GENERAL INFORMATION ..................................... 3 7 B. WORK INSTRUCTIONS ....................................... 3 9 FIGURE 1: LEFT WING - NO. 2 ACTUATOR ATTACH FITTING - PART NUMBER INSPECTION . . 45 FIGURE 2: LEFT WING - NO. 2 ACTUATOR ATTACH FITTING - DET INSPECTION ......... 4 7 FIGURE 3: LEFT WING - NO. 2 ACTUATOR ATTACH FITTING - MINIMUM WALL THICKNESS AND MACHINING DEFECT INSPECTION ............................. 5 0 FIGURE 4: RIGHT WING - NO. 7 ACTUATOR ATTACH FITTING - PART NUMBER INSPECTION . 55 FIGURE 5: RIGHT WING - NO. 7 ACTUATOR ATTACH FITTING - DET INSPECTION ........ 5 7 FIGURE 6: RIGHT WING - NO. 7 ACTUATOR ATTACH FITTING - MINIMUM WALL THICKNESS AND MACHINING DEFECT INSPECTION ............................. 6 0 APPENDIX A: LOGIC DIAGRAM ....................................... 6 5 APPENDIX B: INPUT SURVEY ........................................ 6 8 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: September 12, 2013 747-57A2343Revision 1: June 23, 2014 3 of 68 BOEING SERVICE BULLETIN 747-57A2343
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Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: September 12, 2013 747-57A2343Revision 1: June 23, 2014 4 of 68 BOEING SERVICE BULLETIN 747-57A2343
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Commercial Airplanes 747 Service Bulletin ALERT Revision Transmittal SheetNumber: 747-57A2343Original Issue: September 12, 2013 Revision 1: June 23, 2014 ATA System: 5752 2751 SUBJECT: WINGS - Trailing Edge Flaps - Outboard Flap Inboard Actuator Attach Fittings (Gimbals No.s 2 and 7) - Inspection, Rework, and Replacement This revision includes all pages of the service bulletin.
COMPLIANCE INFORMATION RELATED TO THIS REVISION Federal Aviation Administration (FAA) Airworthiness Directive AD 2013-23-03 is related to this service bulletin.
More work is required on airplanes with an actuator attach fitting 65B08564-7 installed which accomplished PART 3: OUTBOARD FLAP, INBOARD ACTUATOR ATTACH FITTING - MINIMUM THICKNESS INSPECTION in accordance with the Original Issue of this service bulletin. These airplanes should do PART 3: OUTBOARD
FLAP, INBOARD ACTUATOR ATTACH FITTING - MINIMUM THICKNESS AND MACHINING DEFECT INSPECTION to determine if the machining defect is present and accomplish any required follow-on actions within the compliance time in Paragraph 1.E., Compliance.
The Federal Aviation Administration (FAA) will possibly release an additional Airworthiness Directive related to Revision 1 of this service bulletin. The Airworthiness Directive will make the compliance tasks and times given in Revision 1 of this service bulletin mandatory.
REASON FOR REVISION This revision is sent to:
1. Add an inspection for a machining defect that can reduce the durability of the fitting. During inspection of the actuator fittings, many actuator attach fittings 65B08564-7 were found to have a machining defect, visible under the protective finishes, in the area where the tapered machining transitioned to the hemispherical machining at the top of the inner surface.
2. Limit the compliance time that fitting assemblies with a wall thickness 0.130 inch or greater and less than 0.140 inch and do not have a machining defect can remain in-service, to 48 months or 3,000 flight-cycles after the Original Issue date of this service bulletin, whichever occurs first.
These sections were changed:
1. Summary
a. Background - Add machining defect.
b. Action Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: September 12, 2013 747-57A2343Revision 1: June 23, 2014 5 of 68
(1) Add inspection for machining defect to Part 3.
(2) Part 5 - Overhaul - Add new part for fittings with minimum wall thickness greater than 0.140 inch to allow removal of the machining defect.
c. Compliance - Add Reference to AD 2013-23-03. Show that it is expected that additional rule-making is expected against Revision 1 of this service bulletin.
d. Manpower
(1) Revise title for Part 3 to account for inspection for the machining defect.
(2) Add new Part 5 - Overhaul.
e. Illustration
(1) Revise title for Part 3 to account for inspection for the machining defect.
(2) Add new Part 5 - Overhaul.
f. Material Information - Reference new Spares Input Survey in APPENDIX B.
2. Planning Information
a. Paragraph 1.C., Reason
(1) Add machining defect.
(2) Add Reason for revision
b. Paragraph 1.D., Description
(1) Add inspection for machining defect to Part 3.
(2) Part 5 - Overhaul - Add new part for fittings with minimum wall thickness greater than 0.140 inch to allow removal of the machining defect.
(3) Add compliance information related to the revision.
c. Paragraph 1.E., Compliance
(1) Add Reference to AD 2013-23-03. Show that it is expected that additional rule-making is expected against Revision 1 of this service bulletin.
(2) Add new row for airplanes which accomplished Part 3 - Inspection in accordance with the Original Issue.
(3) Add inspection for machining defect to Part 3.
(4) Include no machining defect in existing Conditions 5 and 6. Add new Conditions 8 and 9 which are the same as Conditions 5 and 6 with the machining defect. Show that for Condition 7 it does not matter if the machining defect is or is not present.
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: September 12, 2013 747-57A2343Revision 1: June 23, 2014 6 of 68 BOEING SERVICE BULLETIN 747-57A2343
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(5) Add Part 5 - Overhaul for fittings with minimum wall thickness greater than 0.140 inch to allow removal of the machining defect.
(6) Revise the compliance time for Condition 6 due to durability concerns.
d. Paragraph 1.F., Approval - Add AMOC paragraph for AD 2013-23-03.
e. Paragraph 1.G., Manpower
(1) Revise title for Part 3.
(2) Add new table for Part 5 - Overhaul.
f. Paragraph 1.J., References - Add reference to AD 2013-23-03 and to SOPM for storage of fitting assemblies after overhaul or new.
3. Material Information
a. Paragraph 2.A., Material - Price and Availability - Add price and availability information for new 65B08564-9 Fitting Assembly and reference new Spares Input Survey in APPENDIX B.
b. Paragraph 2.C.2., Parts and Materials Supplied by the Operator
(1) Clarify the condition of the spare actuator assemblies sold by Boeing.
(2) Clarify what parts are not affected by this service bulletin.
c. Paragraph 2.B., Industry Support Information - Correct model number.
4. Accomplishment Instructions
a. Paragraph 3.B., Work Instructions
(1) General work Flow
(a) Add inspection for airplanes which accomplished Part 3 - Inspection in accordance with the Original Issue.
(b) Add inspection for machining defect to Part 3.
(c) Add Part 5 - Overhaul for fittings with minimum wall thickness greater than 0.140 inch to allow removal of the machining defect.
(2) Part 3 - DET Insection - Add inspection for machining defect.
(3) Part 4 Overhaul - Add additional Actuator attach fitting options.
(4) Part 5 - Overhaul - Add new part for fittings with minimum wall thickness greater than 0.140 inch to allow removal of the machining defect.
(5) FIGURE 2
(a) Revise illustration to help clarify cylindrical defect.
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: September 12, 2013 747-57A2343Revision 1: June 23, 2014 7 of 68 BOEING SERVICE BULLETIN 747-57A2343
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(b) Revise Flag Note 1 text to help clarify cylindrical defect.
(6) FIGURE 3
(a) General - Revise title to add inspection for machining defect.
(b) Illustration - Add new illustration showing a typical machining defect.
(c) Step 3 - Add new step to inspect for the machining defect. Note that finish restoration is not required if fitting is being overhauled.
(7) FIGURE 5
(a) Revise illustration to help clarify cylindrical defect.
(b) Revise Flag Note 1 text to help clarify cylindrical defect.
(8) FIGURE 6
(a) General - Revise title to add inspection for machining defect.
(b) Illustration - Add new illustration showing a typical machining defect.
(c) Step 3 - Add new step to inspect for the machining defect. Note that finish restoration is not required if fitting is being overhauled.
(9) APPENDIX A - Revise logic diagram to add inspection for machining defect. This adds new initial compliance time box for airplanes that accomplished Part 3 in accordance with the original issue of this service bulletin. Revise title of Part 3 to add inspection for the machining defect. Add Condition 8 and 9 which are the same as Condition 5 and 6 except with the machining defect. Revise compliance time for fitting replacement for Condition 6 (wall thickness
0.130 or greater and less than 0.140 inch and machining defect is not present).
(10) APPENDIX B - Add new appendix with Spares survey.
Vertical lines are put on the left edge of each page, except in Paragraph 1.A., Effectivity and format changes, to show the location of all content changes.
Pages with no vertical lines have no changes.
REVISION HISTORY September 12, 2013Original Issue:
June 23, 2014Revision 1:
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: September 12, 2013 747-57A2343Revision 1: June 23, 2014 8 of 68 BOEING SERVICE BULLETIN 747-57A2343
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Commercial Airplanes 747 Service Bulletin ALERT SummaryNumber: 747-57A2343Original Issue: September 12, 2013 Revision 1: June 23, 2014 ATA System: 5752 2751 SUBJECT: WINGS - Trailing Edge Flaps - Outboard Flap Inboard Actuator Attach Fittings (Gimbals No.s 2 and 7) - Inspection, Rework, and Replacement
THIS BULLETIN IS SENT TO THE OPERATORS OF RECORD OF THE AIRPLANES SHOWN IN PARAGRAPH
1.A., EFFECTIVITY. IF AN AIRPLANE HAS BEEN LEASED OR SOLD, SEND THIS SERVICE BULLETIN TO THE NEW OPERATOR. IF APPLICABLE SPARES HAVE BEEN SOLD, SEND THIS SERVICE BULLETIN TO THE NEW OWNER.
CONCURRENT REQUIREMENTS None.
BACKGROUND The inspections and replacement in this service bulletin will help prevent fracture of the outboard flap, inboard actuator support fitting assembly (no. 2 or no. 7 gimbal). A fractured inboard actuator fitting combined with the loss of the outboard actuator load path could result in the uncontrolled retraction of the outboard flap and subsequent damage to flight control systems at the rear spar. Uncontrolled retraction of the flap or damage to flight control systems could lead to reduced controllability of the airplane.
One operator reported the fracture of a 65B08564-7 actuator attach fitting. The actuator attach fitting had approximately 5,500 flight-cycles and 20,600 flight-hours. The actuator attach fitting was installed by service bulletin 747-57A2316. The actuator attach fitting fractured in the internal conical machined area. Inspection of the actuator attach fitting revealed that a portion of the interior surface was machined with a cylindrical profile instead of a conical profile. This results in reduced wall thickness. The thickness of the fitting in the cylindrical area was approximately half the design wall thickness. The operator inspected the remaining airplanes in their fleet and found another actuator attach fitting with the cylindrical defect with a wall thickness below design requirements. An inspection of spare 65B08564-7 actuator attach fittings at Boeing revealed some actuator attach fittings with the cylindrical defect with reduced wall thicknesses. In addition, some actuator attach fittings which did not have the cylindrical defect had wall thicknesses which were below design requirements. Reduced wall thickness results in the inability of the actuator attach fitting to carry required loads. Some of the actuator assemblies inspected at Boeing also were found to have a machining defect at the point where the tapered machining transitioned to the hemispherical machining at the top of the inner surface. This defect was visible under the finishes. This defect could eventually lead to fatigue cracks and subsequent fracture.
This service bulletin provides instructions to inspect and replace 65B08564-7 no. 2 and no. 7 actuator attach fittings which could have insufficient wall thickness or the machining defect.
Boeing Service Related Problem (SRP) 747-SRP-57-0264 is related to this service bulletin.
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: September 12, 2013 747-57A2343Revision 1: June 23, 2014 9 of 68
Boeing Fleet Team Digest (FTD) 747 FTD 57-13003 is related to this service bulletin.
This table is provided to operators for planning purposes only. Refer to the applicable sections for more information.
ReferenceAffectedPlanning Data Paragraph 1.A.2., Spares AffectedYesSpares Affected Paragraph 1.E., Compliance and Paragraph
1.F., Approval YesAD Related Paragraph 1.H., Weight and Balance ChangesNoWeight and Balance Change Paragraph 1.I., Electrical Load DataNoElectrical Load Changed Paragraph 1.K., Publications AffectedYesPublications Affected Paragraph 1.K., Publications AffectedNoAirplane Flight Operations Affected (Flight Crew Operations Manual and/or FAA Approved Airplane Flight Manual) Paragraph 2.C.1., Kits/PartsNoKits/Parts Required Paragraph 2.C.2., Parts and Materials Supplied by the Operator YesOperator Supplied Parts/Material Paragraph 2.F., Special Tooling Necessary to do this Service Bulletin NoSpecial Tooling Required ACTION (PRR 85901-129RS) Part 1: Outboard Flap, Inboard Actuator Attach Fitting - Part Number Inspection Extend the trailing edge flaps to detent 30 and deactivate. Disconnect actuator ball screw nut from the actuator attach fitting. Do an inspection of the Actuator Attach Fitting to determine if a 65B08564-7 actuator attach fitting is installed. Attach actuator ball screw to the actuator attach fitting. Activate and retract the trailing edge flaps.
Part 2: Outboard Flap, Inboard Actuator Attach Fitting - DET Inspection Extend the trailing edge flaps to detent 30 and deactivate. Disconnect actuator ball screw nut from the actuator attach fitting. Do a Detailed (DET) inspection of the Actuator Attach Fitting to determine if it has the cylindrical defect. Attach actuator ball screw to the actuator attach fitting. Activate and retract the trailing edge flaps.
Part 3: Outboard Flap, Inboard Actuator Attach Fitting - Minimum Thickness and Machining Defect Inspection Extend the trailing edge flaps to detent 30 and deactivate. Remove the Actuator Attach Fitting. Do an Ultrasonic (UT) inspection or mechanically determine the minimum wall thickness of the Actuator Attach Fitting. Do a DET to determine if the machining defect is present on the inner wall. Install the Actuator Attach Fitting. Activate and retract the trailing edge flaps.
Part 4: Outboard Flap, Inboard Actuator Attach Fitting - Replacement Extend the trailing edge flaps to detent 30 and deactivate. Remove the Actuator Attach Fitting. Install actuator attach fitting assemblies not affected by this service bulletin. Activate and retract the trailing edge flaps.
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: September 12, 2013 747-57A2343Revision 1: June 23, 2014 10 of 68 BOEING SERVICE BULLETIN 747-57A2343
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Part 5: Outboard Flap, Inboard Actuator Attach Fitting - Overhaul Extend the trailing edge flaps to detent 30 and deactivate. Remove the Actuator Attach Fitting. Overhaul the Actuator attach fitting and remove the machining defect. Install the Actuator Attach Fitting. Activate and retract the trailing edge flaps.
EFFECTIVITY 747-100, -100B, -100B SUD, -200B, -200C, -200F, -300, -400, -400D, -400F,and 747SR Airplanes. Refer to Paragraph 1.A.1., Airplanes, for the list of affected airplanes.
COMPLIANCE Federal Aviation Administration (FAA) Airworthiness Directive AD 2013-23-03 is related to this service bulletin.
The effective date of AD 2013-23-03 is November 29, 2013.
The Federal Aviation Administration (FAA) will possibly release an Airworthiness Directive related to Revision 1 of this service bulletin. The Airworthiness Directive will make the compliance tasks and times given in Revision 1 of this service bulletin mandatory.
Refer to Paragraph 1.E., Compliance.
INDUSTRY SUPPORT INFORMATION Boeing warranty remedies are available for airplanes in warranty as of June 5, 2013. Please refer to Paragraph
2.B., Industry Support Information. The warranty remedies will expire eight years from the original issue date of this service bulletin.
MANPOWER Elapsed HoursTotal Task Hours
4.007.00Part 1: Outboard Flap, Inboard Actuator Attach Fitting - Part Number Inspection
4.007.00Part 2: Outboard Flap, Inboard Actuator Attach Fitting - DET Inspection
5.008.00Part 3: Outboard Flap, Inboard Actuator Attach Fitting - Minimum Thickness and Machining Defect Inspection
6.006.00Part 4: Outboard Flap, Inboard Actuator Attach Fitting - Replacement
3.006.00Part 5: Outboard Flap, Inboard Actuator Attach Fitting - Overhaul
MATERIAL INFORMATION Boeing Supplied Kits/Parts.
Refer to Paragraph 2.A., Material - Price and Availability.
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: September 12, 2013 747-57A2343Revision 1: June 23, 2014 11 of 68 BOEING SERVICE BULLETIN 747-57A2343
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BOEING SERVICE BULLETIN 747-57A2343
ALERT ALERT Operators are encouraged to complete the survey provided in the Appendix of this service bulletin to help Boeing predict the quantity and timing of the Boeing Supplied Kits/Parts.
PART 1:
DO AN INSPECTION TO DETERMINE IF A 65B08564-7 IS INSTALLED PART 2:
DO A DET TO DETERMINE IF ACTUATOR
ATTACH FITTING HAS THE CYLINDRICAL DEFECT PART 3:
RIGHT WING OPPOSITE LEFT WING SHOWN, DETERMINE THE MINIMUM WALL DO A UT INSPECTION OR MECHANICALLY
THICKNESS OF THE ACTUATOR ATTACH
FITTING AND A DET TO DETERMINE IF
MACHINING DEFECT IS PRESENT PART 4:
REPLACE ACTUATOR ATTACH FITTING
WITH FITTING NOT AFFECTED BY THIS
SERVICE BULLETIN PART 5:
OVERHAUL FITTING AND REMOVE
MACHINING DEFECT
ACTUATOR
ATTACH FITTING
•PART NUMBER
LOCATION A-A 2267858 Original Issue: September 12, 2013 Revision 1: June 23, 2014 PROPRIETARY - Copyright © Unpublished Export Controlled ECCN: 9E991 - BOEING 747-57A2343 Work - See page 1 for details. 12 of 68