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Commercial Airplanes 767 Service Bulletin ALERT Number: 767-27A0229 Original Issue: March 04, 2014 ATA System: 2751 SUBJECT: FLIGHT CONTROLS - Trailing Edge Flap System - TE Flap Rotary Actuator and Reaction Ring 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 © 2014 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Unpublished Work.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: March 04, 2014 767-27A0229 1 of 121
9.0
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: March 04, 2014 767-27A0229 2 of 121 BOEING SERVICE BULLETIN 767-27A0229
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BLANK PAGE
Table of Contents
Summary5
1. PLANNING INFORMATION9
A. Effectivity9
1. Airplanes9
2. Spares Affected ........................................ 1 5 B. Concurrent Requirements ...................................... 1 5 C. Reason ................................................ 1 5 D. Description .............................................. 1 6 E. Compliance .............................................. 1 7 F. Approval ............................................... 2 0 G. Manpower .............................................. 2 0 H. Weight and Balance Changes .................................... 2 2 I. Electrical Load Data ......................................... 2 2 J. References .............................................. 2 2
1. Existing Data: ......................................... 2 2
2. Data Supplied with this Service Bulletin: ........................... 2 2
3. Installation Drawings Used in the Preparation of this Service Bulletin: ........... 2 3 K. Publications Affected ........................................ 2 3 L. Interchangeability and Intermixability of Parts ........................... 2 3 M. Software Accomplishment Summary ................................ 2 4
2. MATERIAL INFORMATION ........................................ 2 5 A. Material - Price and Availability ................................... 2 5 B. Industry Support Information .................................... 2 5 C. Parts Necessary for Each Airplane ................................. 2 5
1. Kits/Parts ............................................ 2 5
2. Parts and Materials Supplied by the Operator ........................ 2 5
3. Parts Modified and Reidentified ................................ 2 8
4. Parts Removed and Not Replaced .............................. 2 8 D. Parts Necessary to Change Spares ................................. 2 9 E. Special Tooling - Price and Availability ............................... 2 9 F. Special Tooling Necessary to do this Service Bulletin ....................... 2 9
3. ACCOMPLISHMENT INSTRUCTIONS .................................. 3 1 A. GENERAL INFORMATION ..................................... 3 1 B. WORK INSTRUCTIONS ....................................... 3 3 FIGURE 1: OUTBOARD TRAILING EDGE FLAP SUPPORT POSITION #1, #2, #7 AND #8 - ROTARY ACTUATOR ASSEMBLY AND REACTION RING REMOVAL [Group 1-2] ......... 4 0 FIGURE 2: OUTBOARD TRAILING EDGE FLAP SUPPORT POSITION #1, #2, #7 AND #8 - ROTARY ACTUATOR ASSEMBLY AND REACTION RING INSTALLATION [Group 1-2] ...... 4 5 FIGURE 3: INBOARD TRAILING EDGE FLAP SUPPORT POSITION #3 AND #6 - ROTARY ACTUATOR ASSEMBLY AND REACTION RING REMOVAL [Group 1-2] ................ 4 9 FIGURE 4: INBOARD TRAILING EDGE FLAP SUPPORT POSITION #3 AND #6 - ROTARY ACTUATOR ASSEMBLY AND REACTION RING INSTALLATION [Group 1-2] .............. 5 3 FIGURE 5: INBOARD TRAILING EDGE FLAP SUPPORT POSITION #4 AND #5 - ROTARY ACTUATOR ASSEMBLY AND REACTION RING REMOVAL [Group 1-2] ................ 5 7 FIGURE 6: INBOARD TRAILING EDGE FLAP SUPPORT POSITION #4 AND #5 - ROTARY ACTUATOR ASSEMBLY AND REACTION RING INSTALLATION [Group 1-2] .............. 6 1 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
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FIGURE 7: OUTBOARD TRAILING EDGE FLAP SUPPORT POSITION #1, #2, #7 AND #8 - ROTARY ACTUATOR ASSEMBLY AND REACTION RING REMOVAL [Group 3] .......... 6 5 FIGURE 8: OUTBOARD TRAILING EDGE FLAP SUPPORT POSITION #1, #2, #7 AND #8 - ROTARY ACTUATOR ASSEMBLY AND REACTION RING INSTALLATION [Group 3] ....... 6 9 FIGURE 9: INBOARD TRAILING EDGE FLAP SUPPORT POSITION #3 AND #6 - ROTARY ACTUATOR ASSEMBLY AND REACTION RING REMOVAL [Group 3] ................. 7 3 FIGURE 10: INBOARD TRAILING EDGE FLAP SUPPORT POSITION #3 AND #6 - ROTARY ACTUATOR ASSEMBLY AND REACTION RING INSTALLATION [Group 3] ............... 7 7 FIGURE 11: INBOARD TRAILING EDGE FLAP SUPPORT POSITION #4 AND #5 - ROTARY ACTUATOR ASSEMBLY AND REACTION RING REMOVAL [Group 3] ................. 8 0 FIGURE 12: INBOARD TRAILING EDGE FLAP SUPPORT POSITION #4 AND #5 - ROTARY ACTUATOR ASSEMBLY AND REACTION RING INSTALLATION [Group 3] ............... 8 4 FIGURE 13: TRAILING EDGE ROTARY ACTUATOR ASSEMBLY FIXED RING GEAR DETAILED INSPECTION .......................................... 8 7 FIGURE 14: TRAILING EDGE REACTION RING DETAILED INSPECTION ............... 9 3 FIGURE 15: CORROSION AND PITTING REWORK FOR TITANIUM-CADMIUM PLATED (4340M) ROTARY ACTUATOR ASSEMBLY FIXED RING GEAR AND (4330M) REACTION RING SPLINES . 97 FIGURE 16: CORROSION AND PITTING REWORK FOR CADMIUM PLATED (15-5PH) REACTION RING SPLINES ........................................... 1 0 4 FIGURE 17: LIGHT SURFACE DAMAGE REWORK FOR TITANIUM-CADMIUM PLATED (4340M) ROTARY ACTUATOR ASSEMBLY FIXED RING GEAR AND (4330M) REACTION RING SPLINES . 110 FIGURE 18: LIGHT SURFACE DAMAGE REWORK FOR CADMIUM PLATED (15-5PH) REACTION RING SPLINES ........................................... 1 1 3 FIGURE 19: SPLINE BLENDOUT AND LIMIT GUIDE .......................... 1 1 7 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
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Commercial Airplanes 767 Service Bulletin ALERT SummaryNumber: 767-27A0229Original Issue: March 04, 2014 ATA System: 2751 SUBJECT: FLIGHT CONTROLS - Trailing Edge Flap System - TE Flap Rotary Actuator and Reaction Ring 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 Accomplishment of this service bulletin will provide operators with a repetitive inspection to check the outboard and inboard trailing edge flap rotary actuator joints, replace the rotary actuator or reaction ring if necessary and update the grease to a corrosion inhibiting compound. If this service bulletin is not done, flaps could separate from the airplane, which could lead to loss of airplane control during takeoff or landing.
Boeing recently received a report of an unexpected roll on a 767-300ER. The control input required to offset the condition was 0.5 to 1.5 units of aileron trim and was ultimately traced to an Outboard TE flap skew condition.
This was the first report of this condition in the fleet. Investigation by the operator revealed that the #7 TE flap rotary actuator had slipped relative to its mating reaction ring that is attached to the flap support rib. Removal of the reaction ring and actuator revealed that the mating splines were severely corroded. The noted airplane was delivered in June 1997 and had accumulated approximately 79,000 hours and 14,000 cycles in service.
The potential for the subject condition exists on all 767-200/-300/-300F airplanes prior to L/N 922. The early design of this interface utilized MIL-PRF-23827 grease to lubricate the mating splines of the actuator and reaction ring. The 767-400ER installation utilized BMS 3-27 corrosion inhibiting compound(CIC). Boeing later revised the actuator / reaction ring interface to be assembled using BMS 3-38, also a CIC material, for all other 767 models, from L/N 922 and on. The MIL-PRF-23827 grease must not be used on the mating splines of the actuator and reaction ring. After further evaluation of the joint design for the 767-400ER, and for all other model 767's, from L/N 922 and on, it was determined that periodic teardown inspections and reapplication of the BMS 3-38 was required to prevent significant corrosion of this joint over the life of the airplane. Boeing recommends checking 767-200/-300/-300F airplanes from L/N 922 and on and 767-400ER airplanes from L/N 758 and on, for the subject condition as recommended by the Compliance Table.
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: March 04, 2014 767-27A0229 5 of 121
Boeing worked with the operator to gather more information after the initial report and performed a safety analysis of the event and potential cascading implications beyond that which was reported. It was found that if the corrosion were to affect the mating splines on either surface (actuator or ring) to the point where they could no longer effectively engage, the actuator would be prone to possible slippage. Due to the similarity of the design, the potential condition could develop at multiple flap supports. Should degradation reach the point where both actuators on a single flap were unable to react the torsion created by air loads, a flap blowback could occur.
The condition of uncommanded roll with flaps extended, due to flap blowback or loss, could potentially degrade handling performance and preclude continued safe flight and landing.
Boeing Service Related Problem (SRP) 767-SRP-27-0238 is related to this service bulletin.
Boeing Fleet Team Digest Article 767 FTD FTD-27-13001 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 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 PART 1: AIRPLANE WORK - TRAILING EDGE FLAP - SUPPORT POSITIONS 1, 2, 3, 4, 5, 6, 7 AND 8 -
ROTARY ACTUATOR ASSEMBLY FIXED RING GEAR AND REACTION RING SPLINE INSPECTION – Prepare the access in accordance with PART 3.
– Remove the rotary actuator assembly and the reaction ring if necessary in accordance with PART 4.
– Do a Detailed Inspection of the rotary actuator assembly fixed ring gear splines and reaction ring splines.
– If there is no corrosion on the rotary actuator assembly fixed ring gear splines or reaction ring splines, then no rework is required and the parts are ready to be reinstalled onto the airplane in accordance with PART
5.
– If there is corrosion on the rotary actuator assembly fixed ring gear splines, replace the rotary actuator assembly with a new rotary actuator assembly, or with a rotary actuator assembly that has been repaired in accordance with PART 2. Install rotary actuator assembly in accordance with PART 5.
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
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– If there is corrosion on the reaction ring splines, replace the reaction ring with a new reaction ring, or a reaction ring that has been repaired in accordance with PART 2. Install the reaction ring in accordance with PART 5.
PART 2: COMPONENT WORK - TRAILING EDGE FLAP - SUPPORT POSITIONS 1, 2, 3, 4, 5, 6, 7 AND 8 -
ROTARY ACTUATOR ASSEMBLY FIXED RING GEAR AND REACTION RING SPLINE REPAIR – Do a Detailed Inspection of the rotary actuator assembly fixed ring gear splines and reaction ring splines in accordance with PART 1.
– Repair the rotary actuator assembly fixed ring gear splines and reaction ring splines in accordance with PART 2.
EFFECTIVITY 767-200, -300, -300F, -400ER Airplanes. Refer to Paragraph 1.A., Effectivity for the list of affected airplanes.
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. Refer to Paragraph 1.E., Compliance.
INDUSTRY SUPPORT INFORMATION Boeing warranty remedies are not available for the inspections and repair procedures given in this service bulletin.
MANPOWER Refer to Paragraph 1.G., Manpower.
MATERIAL INFORMATION None.
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
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BOEING SERVICE BULLETIN 767-27A0229
ALERT ALERT ROTARY
ACTUATOR
ASSEMBLY NO. 6 ROTARY ROTARY
ACTUATOR ACTUATOR ROTARY ACTUATOR NO. 7 ASSEMBLY ASSEMBLY NO. 8
ASSEMBLY NO. 5 ROTARY
ACTUATOR
ASSEMBLY ROTARY NO. 3 ACTUATOR
ASSEMBLY NO. 4
OUTBOARD
ROTARY FLAP
ACTUATOR
ASSEMBLY NO. 2
INBOARD
ROTARY FLAP
ACTUATOR
ASSEMBLY NO. 1
AT ROTARY ACTUATOR ASSEMBLY LOCATIONS, DO A GENERAL HE
VISUAL INSPECTION (GVI) FOR CORROSION ON THE MATING
SPLINE SURFACES OF THE ROTARY ACTUATOR ASSEMBLY FIXED RING GEAR AND THE RE ACTION RING. IF THERE IS CORROSION
ON THE ROTARY ACT OR ASSEMBLY FIXED RING GEAR
SPLINES, REPLACE THE ROTARY ACTUATOR ASSEMBLY WITH A
NEW ROTARY ACTUATOR ASSEMBLY, OR WITH A ROTARY
ACTUATOR ASSEMBLY FIXED RING GEAR THAT HAS BEEN REPAIRED. IF THERE IS CORROSION ON THE REACTION RING
SPLINES, REPLACE THE REACTION RING WITH A NEW REACTION RING, OR WITH A REACTION RING THAT HAS BEEN REPAIRED.
COMPONENT WORK:
REPAIR MATING SPLINE SURFACES OF THE ROTARY ACTUATOR ASSEMBLY FIXED RING GEAR AND REACTION RING.
TRAILING EDGE FLAP ROTARY ACTUATOR LOCATIONS 2267964 Original Issue: March 04, 2014 PROPRIETARY - Copyright © Unpublished Export Controlled ECCN: 9E991 - BOEING 767-27A0229 Work - See page 1 for details. 8 of 121
Commercial Airplanes 767 Service Bulletin ALERT Number: 767-27A0229 Original Issue: March 04, 2014 ATA System: 2751 SUBJECT: FLIGHT CONTROLS - Trailing Edge Flap System - TE Flap Rotary Actuator and Reaction Ring 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.
1. PLANNING INFORMATION A. Effectivity
1. Airplanes This service bulletin is for the airplane(s) shown below.
Refer to Service Bulletin Index D624T001 Part 3 for Airplane Variable Number, Line Number, and Serial Number data.
NOTE: The Variable Number table below includes all affected airplanes up to Line Number 1083.
Affected airplanes after Line Number 1083 will be added to the service bulletin's MyBoeingFleet.com (MBF) "get effectivity" result when they are added to the MBF Fleet Profile Page.
DESCRIPTIONCONFIGURATIONGROUP 767-200, -300, -300F Airplanes from Line Number 1 through 921.-1 767-200, -300, -300F Airplanes from Line Number 922 and on.-2 767-400ER Airplanes from Line Number 758 and on.-3 Airplane Models:
767-200, 767-300, 767-300F, 767-400ER GroupVariable Number 1VA001 - VA020 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
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GroupVariable Number 1VA301 - VA315 1VA501 - VA530 1VA701 - VA719 1VA801 - VA810 1VB001 - VB002 1VB051 - VB055 1VB101 - VB125 1VB201 - VB202 1VB251 - VB253 1VB281 - VB284 1VB301 - VB302 1VB321 - VB332 1VB371 - VB373 1VB401 1VB441 - VB444 1VE001 - VE003 1VE021 - VE023 1VE041 - VE043 1VE061 - VE069 1VE083 - VE086 1VE101 - VE104 1VE116 - VE118 1VE121 - VE126 1VE141 - VE152 1VE171 - VE172 1VF001 - VF002 1VF041 - VF042 1VF051 1VF061 - VF062 1VF071 - VF072 1VF091 - VF093 1VF101 - VF102 1VF161 - VF162 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
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GroupVariable Number 1VF171 - VF172 1VF180 - VF184 1VF251 1VK001 - VK016 1VK021 - VK022 1VK031 - VK056 1VK081 - VK113 1VK131 - VK133 1VK141 - VK148 1VK161 - VK164 1VK171 1VK181 1VK186 1VL001 - VL006 1VL011 1VL701 - VL703 1VL751 - VL755 1VL806 - VL807 1VL871 - VL873 1VL891 - VL900 1VL911 - VL914 1VL931 - VL932 1VL941 1VN001 - VN041 1VN051 - VN064 1VN081 - VN099 1VN111 - VN127 1VN130 - VN137 1VN151 - VN158 1VN163 - VN168 1VN171 - VN174 1VN191 - VN198 1VN211 - VN212 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
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GroupVariable Number 1VN221 - VN225 1VN231 - VN234 1VN241 - VN243 1VN251 - VN276 1VN291 - VN293 1VN301 - VN314 1VN371 - VN372 1VN376 1VN381 - VN388 1VN421 - VN427 1VN436 1VN471 - VN472 1VN491 - VN513 1VN531 - VN532 1VN536 - VN537 1VN541 - VN542 1VN546 - VN547 1VN551 1VN556 - VN557 1VN561 - VN562 1VN631 - VN638 1VN651 - VN658 1VN671 - VN672 1VN676 1VN681 - VN691 1VN731 - VN732 1VN751 - VN753 1VN791 - VN792 1VN811 - VN813 1VN921 - VN922 1VN931 - VN936 1VN951 - VN953 1VN966 - VN972 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
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