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Commercial Airplanes 757 Service Bulletin ALERT Number: 757-27A0154 Original Issue: July 22, 2016 ATA System: 2761 SUBJECT: FLIGHT CONTROLS - Spoiler/Speedbrake Control System - Spoiler Power Control Unit 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 © 2016 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Unpublished Work.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: July 22, 2016 757-27A0154 1 of 21
7.0
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: July 22, 2016 757-27A0154 2 of 21 BOEING SERVICE BULLETIN 757-27A0154
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BLANK PAGE
Table of Contents
Summary5
1. PLANNING INFORMATION9
A. Effectivity9
1. Airplanes9
2. Spares Affected13
B. Concurrent Requirements13
C. Reason13
D. Description14
E. Compliance14
F. Approval14
G. Manpower15
H. Weight and Balance Changes15
I. Electrical Load Data15
J. References15
1. Existing Data:15
2. Data Supplied with this Service Bulletin:16
3. Installation Drawings Used in the Preparation of this Service Bulletin:16
K. Publications Affected16
L. Interchangeability and Intermixability of Parts16
M. Software Accomplishment Summary16
2. MATERIAL INFORMATION17
A. Material - Price and Availability17
B. Industry Support Information17
C. Parts Necessary for Each Airplane17
1. Kits/Parts17
2. Parts and Materials Supplied by the Operator17
3. Parts Modified and Reidentified17
4. Parts Removed and Not Replaced17
D. Parts Necessary to Change Spares17
E. Special Tooling - Price and Availability18
F. Special Tooling Necessary to do this Service Bulletin18
3. ACCOMPLISHMENT INSTRUCTIONS19
A. GENERAL INFORMATION19
B. WORK INSTRUCTIONS20
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: July 22, 2016 757-27A0154 3 of 21 BOEING SERVICE BULLETIN 757-27A0154
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Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: July 22, 2016 757-27A0154 4 of 21 BOEING SERVICE BULLETIN 757-27A0154
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Commercial Airplanes 757 Service Bulletin ALERT SummaryNumber: 757-27A0154Original Issue: July 22, 2016 ATA System: 2761 SUBJECT: FLIGHT CONTROLS - Spoiler/Speedbrake Control System - Spoiler Power Control Unit Replacement
THIS DOCUMENT 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 DOCUMENT TO THE NEW OPERATOR. IF APPLICABLE SPARES HAVE BEEN SOLD, SEND THIS DOCUMENT TO THE NEW OWNER.
CONCURRENT REQUIREMENTS None.
BACKGROUND Accomplishment of this service bulletin will prevent an uncommanded extension of affected spoiler Power Control Units (PCU's) during a hydraulic pressure loss event. If this service bulletin is not done, multiple spoiler PCU's could extend during a hydraulic pressure loss event which could result in an uncommanded roll of the airplane.
Boeing has received reports of single and multiple uncommanded spoiler panel extensions during flight. The condition known as "spoiler panel float" occurred when there was a hydraulic system pressure loss and the flaps were extended beyond 20 degrees. A subsequent investigation by Boeing and the supplier MOOG, which included an examination of returned defective spoiler PCU's from in-service airplanes, found that the spoiler PCU's Blocking and Thermal Relief Valve (BTRV) housings had reached a point of fatigue that made them likely to develop internal failures. One purpose of the spoiler PCU BTRV is to prevent the spoiler from extending during a loss of hydraulic pressure. As a result, MOOG developed a new spoiler PCU BTRV design, where the spoiler PCU BTRV housing material was changed from aluminium to stainless steel. The new stainless steel housing greatly improves the fatigue capacity of the spoiler PCU BTRV Housing.
This service bulletin gives instructions to replace affected spoiler PCU's with improved spoiler PCU's that have new improved BTRV housings. Installation of spoiler PCU's with the improved BTRV housings will prevent multiple uncommanded extensions of spoiler PCU's in the event of a single hydraulic system failure.
Boeing Fleet Team Digest (FTD) 757 FTD 27-14001 is related to this service bulletin.
Boeing Fleet Team Safety (FTS) 757 FTS 27-14022 is related to this service bulletin.
Boeing Service Letter (SL) 757-SL-27-65 and (SL) 757-SL-27-68 are related to this service bulletin.
Boeing Service Related Problem (SRP) 757-SRP-27-0276 is related to this service bulletin.
Boeing Service Bulletin 757-27A0105 and 757-27-0156 are related to this service bulletin.
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: July 22, 2016 757-27A0154 5 of 21
Federal Aviation Administration (FAA) Airworthiness Directive (AD) 92-17-10 is related to this service bulletin.
MOOG SB 3321500-27-14 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 Get access to the left and right wing and replace the Power Control Units (PCU's) at spoiler positions 2, 3, 4 and 9, 10, 11.
EFFECTIVITY All 757-200/-200CB/-200PF/-300 Airplane(s). Refer to Paragraph 1.A.1., Airplanes, for the list of affected airplane(s).
Refer to Paragraph 1.A.2., Spares Affected, for the list of affected components.
COMPLIANCE The Federal Aviation Administration (FAA) will possibly release an Airworthiness Directive related to this service bulletin. The Airworthiness Directive will make the compliance tasks and times given in this service bulletin mandatory.
Boeing recommends that the change given in this service bulletin be done within 51 months after the original issue date of this service bulletin.
INDUSTRY SUPPORT INFORMATION Boeing warranty remedies are not available for the repair procedure given in this service bulletin.
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: July 22, 2016 757-27A0154 6 of 21 BOEING SERVICE BULLETIN 757-27A0154
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MANPOWER Refer to Paragraph 1.G., Manpower.
MATERIAL INFORMATION Operator Supplied Parts/Materials.
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: July 22, 2016 757-27A0154 7 of 21 BOEING SERVICE BULLETIN 757-27A0154
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BOEING SERVICE BULLETIN 757-27A0154
ALERT ALERT A POSITION 1 SPOILE POSITION 11 LA SPOILER A POSITIO POSITIONS A SPOILER POSITION 4
SPOILER POSITION 2
SPOILER POSITION 3
SPOILER
ELECTRICAL
CONNECTOR
REPLACE THE POWER
CONTROL UNITS (PCU'S)
AT SPOILER POSITIONS SPOILER POWER CONTROL UNIT 2,3,4 AND 9,10,11. (TYPICAL) ACTUATOR 2479066 Original Issue: July 22, 2016 Export Controlled ECCN: 9E991 - BOEING 757-27A0154 PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 8 of 21
Commercial Airplanes 757 Service Bulletin ALERT Number: 757-27A0154 Original Issue: July 22, 2016 ATA System: 2761 SUBJECT: FLIGHT CONTROLS - Spoiler/Speedbrake Control System - Spoiler Power Control Unit Replacement
THIS DOCUMENT 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 DOCUMENT TO THE NEW OPERATOR. IF APPLICABLE SPARES HAVE BEEN SOLD, SEND THIS DOCUMENT TO THE NEW OWNER.
1. PLANNING INFORMATION A. Effectivity
1. Airplanes Refer to Service Bulletin Index D624N001 Part 3 for Airplane Variable Number, Line Number, and Serial Number data.
This service bulletin is applicable to 757-200/-200CB/-200PF/-300 Airplanes, line numbers 1 thru 1050 in 1 Group. The Variable Numbers and Group Information for the applicable airplanes is given below.
DESCRIPTIONCONFIGURATIONGROUP All 757-200/-200CB/-200PF/-300 airplanes with spoiler Power Control Units (PCU's) MOOG P/N 3321500-( ) installed.
-1 Airplane Models:
757-200, 757-200CB, 757-200PF, 757-300 GroupVariable Number 1NA001 - NA028 1NA191 - NA199 1NA201 - NA239 1NA301 - NA305 1NA341 - NA352 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: July 22, 2016 757-27A0154 9 of 21
GroupVariable Number 1NA391 - NA399 1NA401 - NA408 1NA441 - NA447 1NA501 - NA586 1NB001 - NB004 1NB021 - NB023 1NB036 - NB041 1NB051 - NB053 1NB061 - NB073 1NB079 1NB131 - NB148 1NB161 - NB162 1NB166 - NB168 1NB201 - NB204 1NB221 - NB228 1NB230 1NB236 1NB239 1NB261 - NB267 1NB291 - NB299 1NB301 - NB302 1NB311 - NB312 1NB321 - NB331 1NB421 - NB438 1NB446 1NB451 - NB454 1NB501 - NB523 1NB561 1NB571 1NB581 - NB583 1NC001 - NC033 1NC041 - NC042 1NC051 - NC052 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: July 22, 2016 757-27A0154 10 of 21 BOEING SERVICE BULLETIN 757-27A0154
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GroupVariable Number 1NC056 - NC062 1NC066 - NC084 1NC091 - NC094 1NC151 1NC161 1NC901 - NC951 1NC971 - NC974 1ND001 - ND007 1ND011 - ND059 1ND111 - ND113 1ND161 - ND199 1ND201 - ND203 1ND221 - ND225 1ND241 - ND248 1ND301 - ND322 1ND401 1ND891 1ND895 1NE001 - NE008 1NE011 - NE088 1NE091 - NE094 1NE141 - NE150 1NE161 - NE177 1NE201 - NE204 1NE301 - NE302 1NE311 - NE325 1NJ001 - NJ004 1NJ031 - NJ032 1NJ551 - NJ555 1NL001 - NL002 1NL006 - NL017 1NL101 - NL109 1NL141 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: July 22, 2016 757-27A0154 11 of 21 BOEING SERVICE BULLETIN 757-27A0154
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GroupVariable Number 1NL601 - NL616 1NN001 - NN002 1NN051 - NN052 1NP901 - NP904 1NS601 - NS616 1NT001 - NT009 1NT201 - NT202 1NT231 - NT234 1NT237 - NT240 1NT242 1NT245 - NT248 1NT281 - NT289 1NT341 - NT347 1NT351 - NT360 1NT371 - NT373 1NT375 - NT379 1NT381 - NT386 1NT401 - NT409 1NT411 - NT412 1NT426 - NT427 1NT431 - NT432 1NT436 - NT438 1NT441 - NT442 1NT446 1NT701 - NT769 1NT791 - NT796 1NT861 - NT862 1NT881 - NT885 1NT901 - NT916 1NT971 - NT985 1NU031 - NU038 1NU701 - NU705 1NU721 - NU728 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: July 22, 2016 757-27A0154 12 of 21 BOEING SERVICE BULLETIN 757-27A0154