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Commercial Airplanes 767 Service Bulletin Number: 767-27A0183 Original Issue: May 09, 2002 Revision 2: September 25, 2014 ATA System: 2751 5751 SUBJECT: FLIGHT CONTROLS - Flaps - Outboard Flap - Deflection Control Track - Inspection/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 © 2002 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Unpublished Work.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: May 09, 2002 767-27A0183Revision 2: September 25, 2014 1 of 23
3.0
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: May 09, 2002 767-27A0183Revision 2: September 25, 2014 2 of 23 BOEING SERVICE BULLETIN 767-27A0183
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Table of Contents
Revision Transmittal Sheet5
Summary7
1. PLANNING INFORMATION ........................................ 1 1 A. Effectivity ............................................... 1 1
1. Airplanes ............................................ 1 1
2. Spares Affected ........................................ 1 2 B. Concurrent Requirements ...................................... 1 2 C. Reason ................................................ 1 2 D. Description .............................................. 1 3 E. Compliance .............................................. 1 4 F. Approval ............................................... 1 4 G. Manpower .............................................. 1 4 H. Weight and Balance Changes .................................... 1 5 I. Electrical Load Data ......................................... 1 5 J. References .............................................. 1 5
1. Existing Data: ......................................... 1 5
2. Data Supplied with this Service Bulletin: ........................... 1 5
3. Installation Drawings Used in the Preparation of this Service Bulletin: ........... 1 5 K. Publications Affected ........................................ 1 6 L. Interchangeability and Intermixability of Parts ........................... 1 6 M. Software Accomplishment Summary ................................ 1 6
2. MATERIAL INFORMATION ........................................ 1 7 A. Material - Price and Availability ................................... 1 7 B. Industry Support Information .................................... 1 7 C. Parts Necessary for Each Airplane ................................. 1 7
1. Kits/Parts: ........................................... 1 7
2. Parts and Materials Supplied by the Operator: ........................ 1 7
3. Parts Modified and Reidentified: ............................... 1 7
4. Parts Removed and Not Replaced: .............................. 1 7 D. Parts Necessary to Change Spares ................................. 1 7 E. Special Tooling - Price and Availability ............................... 1 7 F. Special Tooling Necessary to do this Service Bulletin ....................... 1 7
3. ACCOMPLISHMENT INSTRUCTIONS .................................. 1 9 A. GENERAL INFORMATION ..................................... 1 9 B. WORK INSTRUCTIONS ....................................... 2 0 FIGURE 1: LOGIC DIAGRAM OF INSPECTION AND MAINTENANCE ALTERNATIVES ....... 2 1 FIGURE 2: OUTBOARD FLAP DETECTION CONTROL TRACK - AFT LOWER LUG INSPECTION . 22 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: May 09, 2002 767-27A0183Revision 2: September 25, 2014 3 of 23 BOEING SERVICE BULLETIN 767-27A0183
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: May 09, 2002 767-27A0183Revision 2: September 25, 2014 4 of 23 BOEING SERVICE BULLETIN 767-27A0183
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Commercial Airplanes 767 Service Bulletin Revision Transmittal SheetNumber: 767-27A0183Original Issue: May 09, 2002 Revision 2: September 25, 2014 ATA System: 2751 5751 SUBJECT: FLIGHT CONTROLS - Flaps - Outboard Flap - Deflection Control Track - Inspection/Replacement This revision includes all pages of the service bulletin.
COMPLIANCE INFORMATION RELATED TO THIS REVISION Federal Aviation Administration (FAA) Airworthiness Directive AD 2004-07-11 is related to this service bulletin.
No more work is necessary on the airplanes changed or inspected in accordance with the Revision 1 of this service bulletin.
REASON FOR REVISION This revision is sent to:
1. Revise the compliance time for airplanes VR087, VR106, VS710, VS711, VS712, VS731, VS732, VS882, VS883, VS891, and VS896 which were added to this service bulletin in Revision 1 to be the same as the original airplanes in the service bulletin. The initial compliance time for these airplanes was 1,200 flight cycles from Revision 1 date. One operator noted that the compliance time for the original airplanes in the service bulletin was before the accumulation of 12,000 total flight cycles, or within 1,200 flight cycles after the effective date of FAA AD 2004-07-11, whichever occurs later, and believes that it should be the same as the airplanes added in Revision 1. We agreed that the initial compliance time for the airplanes added in Revision 1 should be the same as the original airplanes in the service bulletin. This results in the effectivity being split into two groups to clarify the different compliance times for the airplanes in the Original Issue and the airplanes added in Revision 1.
2. Clarify summary page illustration and work instructions to match changes in logic diagram made in Revision 1.
3. Clarify the compliance time for Group 1 Airplanes in the logic diagram to add: whichever occurs later.
Add Effective date of AD 2004-07-11 to Compliance section.
These sections were changed:
1. Summary
a. Illustration - Revised text to match Action paragraph.
2. Planning Information
a. Paragraph 1.C., Reason - Added reason for Revision 2.
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: May 09, 2002 767-27A0183Revision 2: September 25, 2014 5 of 23
b. Paragraph 1.D., Description - Added compliance information for Revision 2.
c. Paragraph 1.E., Compliance - Add effective date of AD 2004-07-11.
d. Paragraph 1.F., Approval - Added Revision 2 to AMOC Statement.
3. Material Information
a. No Changes.
4. Accomplishment Instructions
a. Paragraph 3.B., Work Instructions
(1) Step 3.B.2. - Added part number of track assembly requiring inspection to match logic diagram.
(2) Figure 1
(a) Added compliance time for Group 2 Airplanes.
(b) Corrected the compliance time for Group 1 airplane by adding, whichever occurs later.
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 May 09, 2002Original Issue:
April 04, 2014Revision 1:
September 25, 2014Revision 2:
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: May 09, 2002 767-27A0183Revision 2: September 25, 2014 6 of 23 BOEING SERVICE BULLETIN 767-27A0183
Commercial Airplanes 767 Service Bulletin SummaryNumber: 767-27A0183Original Issue: May 09, 2002 Revision 2: September 25, 2014 ATA System: 2751 5751 SUBJECT: FLIGHT CONTROLS - Flaps - Outboard Flap - Deflection Control Track - Inspection/Replacement
CONCURRENT REQUIREMENTS None.
BACKGROUND The related 767-200, -300, and -300F service bulletin is 767-27-0184 for line numbers 1 through 921.
Accomplishment of this service bulletin will detect cracking of the outboard flap deflection control track. A fractured deflection control track could result in the loss of an outboard flap in the event there is a loss of the primary flap support.
The outboard flap deflection control track is located at the outboard end of the outboard flap. The track reduces the deflection of the outboard flap and provides an alternate load path to retain the flap in the event there is a loss of the primary flap support. Two operators have reported cracked or fractured deflection control tracks on three airplanes with approximately 35,700 to 54,400 flight-hours and 6,550 to 14,100 flight-cycles. The cracks all initiated in the aft lower lug run-out region. In one case the crack initiated at inclusions that is typical of the slag products that are a result of the casting process. After a crack initiates it is propagated by fatigue until the track fractures. The three cases of cracking all occurred on 767-300 airplanes. However the tracks on the 767-400ER airplane are similar in design and cracking could occur on these airplanes at the same location.
Inspection of the track will detect cracking before the track fractures. Installation of the new outboard flap deflection control track assembly with thicker aft lug run-out will help prevent cracks and terminates the repeat inspections.
Boeing Service Related Problem (SRP) 767-SRP-57-0154 and 767-SRP-57-0156 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 AffectedNoSpares Affected Paragraph 1.E., Compliance and Paragraph
1.F., Approval YesAD Related Paragraph 1.H., Weight and Balance ChangesNoWeight and Balance Change Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: May 09, 2002 767-27A0183Revision 2: September 25, 2014 7 of 23
ReferenceAffectedPlanning Data Paragraph 1.I., Electrical Load DataNoElectrical Load Changed Paragraph 1.K., Publications AffectedNoPublications 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/PartsYesKits/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 B12901-31S) Extend the trailing edge flaps and deactivate. Do a High Frequency Eddy Current (HFEC) inspection of the aft lower lug of the outboard flap deflection control track for cracks. If no cracks are found, repeat the inspections at the interval shown in Figure 1. If cracks are found, replace the track assembly with a 113T8333-9 track assembly and terminate the repeat inspections. Retract the flaps.
EFFECTIVITY 767-200, -300, and 400ER Airplanes. Refer to Paragraph 1.A.1., Airplanes for the list of affected airplanes.
COMPLIANCE Federal Aviation Administration (FAA) Airworthiness Directive 2004-07-11 is related to this service bulletin.
See Figure 1 Logic Diagram of Inspection and Maintenance Alternatives.
INDUSTRY SUPPORT INFORMATION Boeing warranty remedies are not available for the inspection given in this service bulletin.
MANPOWER Elapsed HoursTotal Task Hours
5.5017.00
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: May 09, 2002 767-27A0183Revision 2: September 25, 2014 8 of 23 BOEING SERVICE BULLETIN 767-27A0183
BOEING SERVICE BULLETIN 767-27A0183 SEE Q WS 740 1000
TYPICAL CRACK
DO A HFEC INSPECTION OF THE AFT LOWER LUG RUN-OUT AREA FOR CRACKS.
IF NO CRACKS ARE FOUND, REPEAT THE INSPECTIONS. IF CRACKS ARE FOUND,
REPLACE THE TRACK ASSEMBLY WITH A 113T8333-9 TRACK ASSEMBLY AND
TERMINATE THE REPEAT INSPECTIONS
OUTBOARD FLAP DEFLECTION FWD < CONTROL TRACK ASSEMBLY (LEFT WING SHOWN, RIGHT WING OPPOSITE) V79743 Original Issue: May 09, 2002 Revision 2: September 25, 2014 PROPRIETARY - Copyright © Unpublished Export Controlled ECCN: 9E991 - BOEING Work - See page 1 for details. 767-27A0183 9 of 23
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: May 09, 2002 767-27A0183Revision 2: September 25, 2014 10 of 23 BOEING SERVICE BULLETIN 767-27A0183
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Commercial Airplanes 767 Service Bulletin Number: 767-27A0183 Original Issue: May 09, 2002 Revision 2: September 25, 2014 ATA System: 2751 5751 SUBJECT: FLIGHT CONTROLS - Flaps - Outboard Flap - Deflection Control Track - Inspection/Replacement
1. PLANNING INFORMATION A. Effectivity
1. Airplanes Refer to Service Bulletin Index Document D6-24T001 Part 3 for Airplane Variable Number, Line Number, and Serial Number data.
This service bulletin is for the airplanes shown below. Refer to PRR-B 12901-31S (PART D) for data about this change.
DESCRIPTIONCONFIGURATIONGROUP 767-400ER Airplanes line number 758 through 878.-1 767-200 and -300 airplanes 922 through 933-2 Airplane Models:
767-200, 767-300, 767-400ER GroupVariable Number 1VQ001 - VQ021 1VQ071 - VQ086 2VR087 2VR106 2VS710 - VS712 2VS731 - VS732 2VS882 - VS883 2VS891 2VS896 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: May 09, 2002 767-27A0183Revision 2: September 25, 2014 11 of 23
2. Spares Affected None.
B. Concurrent Requirements None.
C. Reason The related 767-200, -300, and -300F service bulletin is 767-27-0184 for line numbers 1 through 921.
Accomplishment of this service bulletin will detect cracking of the outboard flap deflection control track.
A fractured deflection control track could result in the loss of an outboard flap in the event there is a loss of the primary flap support.
The outboard flap deflection control track is located at the outboard end of the outboard flap. The track reduces the deflection of the outboard flap and provides an alternate load path to retain the flap in the event there is a loss of the primary flap support. Two operators have reported cracked or fractured deflection control tracks on three airplanes with approximately 35,700 to 54,400 flight-hours and 6,550 to 14,100 flight-cycles. The cracks all initiated in the aft lower lug run-out region. In one case the crack initiated at inclusions that is typical of the slag products that are a result of the casting process. After a crack initiates it is propagated by fatigue until the track fractures. The three cases of cracking all occurred on 767-300 airplanes. However the tracks on the 767-400ER airplane are similar in design and cracking could occur on these airplanes at the same location.
Inspection of the track will detect cracking before the track fractures. Installation of the new outboard flap deflection control track assembly with thicker aft lug run-out will help prevent cracks and terminates the repeat inspections.
Boeing Service Related Problem (SRP) 767-SRP-57-0154 and 767-SRP-57-0156 is related to this service bulletin.
Revision 1 is sent to:
1. This revision is sent to update the logic diagram in Figure 1 and add new outboard flap deflection control track assembly with thicker aft lug run-out as terminating action to the repeat inspections.
After Installing the new outboard flap deflection control track assembly with thicker aft lug run-out, it is not necessary to do the repeat inspections of the outboard flap deflection control track.
2. Add 767-200 and -300 Airplanes VR087, VR106, VS710, VS711, VS712, VS731, VS732, VS882, VS883, VS891, and VS896 to the service bulletin. These airplanes were delivered with the same flap installation as the 767-400ER airplanes and therefore should have been in this service bulletin.
3. The latest service bulletin format standards have also been updated where applicable.
4. Terminology has been changed in the Work Instructions to agree with the terminology defined in Paragraph 3.A., General Information - Notes.
Revision 2 is sent to:
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: May 09, 2002 767-27A0183Revision 2: September 25, 2014 12 of 23 BOEING SERVICE BULLETIN 767-27A0183