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Commercial Airplanes 767 Service Bulletin ALERT Number: 767-57A0076 Original Issue: October 26, 2000 Revision 3: April 04, 2012 ATA System: 5750 SUBJECT: WINGS - Trailing Edge and Trailing Edge Devices - Inboard Main Flap - Hinge Fitting Assembly Inspection and Replacement Export of this technology is controlled under the United States Export Administration Regulations (EAR) (15 CFR 730-774). 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BOEING PROPRIETARY, CONFIDENTIAL, AND/OR TRADE SECRET Copyright © 2000 The Boeing Company Unpublished Work - All Rights Reserved Boeing claims copyright in each page of this document only to the extent that the page contains copyrightable subject matter. Boeing also claims copyright in this document as a compilation and/or collective work.
This document includes proprietary information owned by The Boeing Company and/or one or more third parties.
Treatment of the document and the information it contains is governed by contract with Boeing. For more information, contact The Boeing Company, P.O. Box 3707, Seattle, Washington 98124.
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, KDC-10, MD-10, MD-11, MD-80, MD-88, MD-90, P-8A, Poseidon and the Boeing livery 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.
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Original Issue: October 26, 2000 767-57A0076Revision 3: April 04, 2012 1 of 46
2.0
BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: October 26, 2000 767-57A0076Revision 3: April 04, 2012 2 of 46 BOEING SERVICE BULLETIN 767-57A0076
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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 ........................................ 1 8 B. Concurrent Requirements ...................................... 1 8 C. Reason ................................................ 1 8 D. Description .............................................. 1 9 E. Compliance .............................................. 2 0 F. Approval ............................................... 2 0 G. Manpower .............................................. 2 1 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 2 K. Publications Affected ........................................ 2 3 L. Interchangeability and Intermixability of Parts ........................... 2 3
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 6
4. Parts Removed and Not Replaced: .............................. 2 7 D. Parts Necessary to Change Spares ................................. 2 7 E. Special Tooling - Price and Availability ............................... 2 8 F. Special Tooling Necessary to do this Service Bulletin ....................... 2 8
3. ACCOMPLISHMENT INSTRUCTIONS .................................. 2 9 A. GENERAL INFORMATION ..................................... 2 9 B. WORK INSTRUCTIONS ....................................... 3 0 FIGURE 1: LOGIC DIAGRAM OF INSPECTION AND MAINTENANCE ALTERNATIVES ....... 3 3 FIGURE 2: OUTBOARD HINGE FITTING - DETAILED INSPECTION ................. 3 4 FIGURE 3: OUTBOARD HINGE FITTING - DETAILED AND EDDY CURRENT INSPECTION .... 3 8 FIGURE 4: HINGE FITTING ASSEMBLY - REPLACEMENT ...................... 4 3
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Original Issue: October 26, 2000 767-57A0076Revision 3: April 04, 2012 3 of 46 BOEING SERVICE BULLETIN 767-57A0076
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BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: October 26, 2000 767-57A0076Revision 3: April 04, 2012 4 of 46 BOEING SERVICE BULLETIN 767-57A0076
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Commercial Airplanes 767 Service Bulletin ALERT Revision Transmittal SheetNumber: 767-57A0076Original Issue: October 26, 2000 Revision 3: April 04, 2012 ATA System: 5750 SUBJECT: WINGS - Trailing Edge and Trailing Edge Devices - Inboard Main Flap - Hinge Fitting Assembly Inspection and Replacement This revision includes all pages of the service bulletin.
COMPLIANCE INFORMATION RELATED TO THIS REVISION Federal Aviation Administration (FAA) Airworthiness Directive AD 2003-13-01 is related to this service bulletin.
No more work is necessary on airplanes which previously accomplished Part 3 - Terminating Action of this service bulletin.
No more work is necessary on airplanes that have been previously inspected in accordance with the original issue, Revision 1, or Revision 2 that have hinge fittings with the tool runout.
No more work is necessary on airplanes that have been previously inspected in accordance with the original issue, Revision 1, or Revision 2 that have hinge fittings without the tool runout but continued inspections are required at reduced intervals as follows:
1. Airplanes that were last inspected in accordance with Part 1 - Detailed Inspection: Repeat Part 1 - Detailed Inspection or Do Part 2 - Detailed and Eddy Current Inspection within 300 flight-cycles of the last Part 1 - Detailed Inspection.
2. Airplanes that were last inspected in accordance with Part 2 - Detailed and Eddy Current Inspection: Repeat Part 2 - Detailed and Eddy Current Inspection or Do Part 1 - Detailed Inspection within 750 flight-cycles, from the last Part 2 - Detailed and Eddy Current Inspection or before 300 flight-cycles after the Revision 3 date of this service bulletin, whichever is later, but not to exceed 1,500 flight cycles.
Do continued inspections and actions in accordance with Paragraph 1.E., Compliance.
REASON FOR REVISION This revision is sent to reduce the compliance time for the repeat inspection interval of the inboard trailing edge main flap outboard hinge fittings and change the area and limit to the outboard half only. Subsequent to the release of Revision 2 of this service bulletin, one operator reported finding a fractured hinge fitting assembly.
The fracture occurred on a hinge fitting assembly, that did not have the runout option, at approximately 780 flight-cycles after its last inspection, which was a significant number of flight-cycles before the next scheduled repeat Part 2 inspection. As a result, the repeat inspection interval for Part 2 Inspection is reduced from 1500 flight-cycles to 750 flight-cycles. An examination of the fractured hinge fitting assembly showed that the crack
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Original Issue: October 26, 2000 767-57A0076Revision 3: April 04, 2012 5 of 46
started at the edge of the current inspection area. The service bulletin illustrations have been updated to clearly show the expected crack location and direction. A new Boeing Service Related Problem (SRP) 767-SRP-57-0251 was initiated as a result of this in service report. This service bulletin also corrects the existing warranty date to show remedies are available for airplanes in warranty as of March 8, 2000 instead of August 3, 2000. The latest service bulletin format standards have also been updated where applicable.
Terminology has been changed in the Work Instructions to agree with the terminology defined in Paragraph
3.A., General Information - Notes.
These sections are changed:
1. Service Bulletin Title updated.
2. Summary - Background - Reference to Boeing Service Related Problem (SRP) 767-SRP-57-0251 added.
3. Summary - Industry Support Information - Warranty date updated.
4. Summary - Illustration - Illustration updated to show the expected crack location and direction.
5. Paragraph 1.C., Reason - Reference to Boeing Service Related Problem (SRP) 767-SRP-57-0251 added.
6. Paragraph 1.D., Description - Affected Maintenance Zone Table added.
7. Paragraph 1.G., Manpower - Table updated.
8. Paragraph 1.J.1., Existing Data - Reference to Boeing Service Related Problem (SRP) 767-SRP-57-0251 added.
9. Paragraph 1.K.1, Publications - Table updated.
10. Paragraph 1.K.2., Damage Tolerance Based Structural Inspections - Damage Tolerance Inspections (DTI) statement added.
11. Paragraph 2.B., Industry Support Information - Warranty date updated.
12. Paragraph 3.A., General Information - General notes updated.
13. Paragraph 3.B., Work Instructions - Titles updated and the latest service bulletin format standards have also been updated where applicable.
14. Figure 1 - Compliance information in the logic table updated.
15. Figure 2 - Illustrations and step table updated to incorporate the new inspection requirements.
16. Figure 3 - Illustrations and step table updated to incorporate the new inspection requirements.
The data given in Information Notice 767-57A0076 IN 01 is included in this revision.
Vertical lines are put on the left edge of each page, except in Paragraph 1.A., Effectivity, to show the location of important changes.
Pages with no vertical lines have no important changes.
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REVISION HISTORY October 26, 2000Original Issue:
March 29, 2001Revision 1:
November 22, 2006Revision 2:
April 04, 2012Revision 3:
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Commercial Airplanes 767 Service Bulletin ALERT SummaryNumber: 767-57A0076Original Issue: October 26, 2000 Revision 3: April 04, 2012 ATA System: 5750 SUBJECT: WINGS - Trailing Edge and Trailing Edge Devices - Inboard Main Flap - Hinge Fitting Assembly Inspection 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 detect cracks, prevent fractures and ensure the structural integrity of the inboard trailing edge main flap outboard hinge fittings. Fracture of the hinge fitting assemblies could result in the inboard aft flap becoming unrestrained potentially striking the aircraft upon departure, resulting in significant damage to the surrounding structure and cause potential personal injury.
One operator reported lug fractures on both the inboard and outboard hinge fittings of the outboard hinge assembly mounted to the main flap. The hinge assembly provides one of two primary attachment points of the inboard trailing edge aft flap. The outboard hinge fitting was fractured just above the lug hole. The fractured hinge fittings were found during a routine maintenance inspection. The airplane had accumulated 9,598 flight-hours and 5,393 flight-cycles.
During root cause analysis of the fractured hinge fitting it was discovered that an optional tool runout was not present on the damaged fitting assembly. The tool runout option allows the part to be machined thicker within the area reported to be fractured. Boeing has received no reports of cracks or fractures on fittings that have the optional tool runout.
Replacement of the hinge fittings without the tool runout option will ensure the structural integrity of the aft flap, prevent damage to the surrounding structure and the potential for personal injury.
Subsequent to the release of Revision 2 of this service bulletin, one operator reported finding a fractured hinge fitting assembly. The fracture occurred on a hinge fitting assembly, that did not have the runout option, at approximately 780 flight-cycles after its last inspection, which was a significant number of flight-cycles before the next scheduled repeat Part 2 inspection. The service bulletin illustrations have been updated to clearly show the expected crack location and direction. A new Boeing Service Related Problem (SRP) 767-SRP-57-0251 was initiated as a result of this in service report.
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Original Issue: October 26, 2000 767-57A0076Revision 3: April 04, 2012 9 of 46
Boeing Service Related Problem (SRP) 767-SRP-57-0119 and 767-SRP-57-0251 are related to this service bulletin.
ACTION Inspect the inboard trailing edge main flap outboard hinge fittings of the left and right wing for cracks, fractures and tool runout option. If any cracks or fractures are found, complete terminating action. If fittings have the tool runout option and no cracks or fractures are found, no further action is required. If fittings do not have the tool runout option and no cracks or fractures are found, repeat inspections until terminating action is completed.
EFFECTIVITY 767-200/300/300F Airplanes. Refer to Paragraph 1.A.1., Airplanes, for the list of affected airplanes.
COMPLIANCE Refer to FIGURE 1 Logic Diagram for Inspection and Maintenance Alternatives.
Federal Aviation Administration (FAA) Airworthiness Directive AD 2003-13-01 is related to this service bulletin.
INDUSTRY SUPPORT INFORMATION Boeing warranty remedies are available for airplanes in warranty as of March 8, 2000. Please refer to Paragraph
2.B., Industry Support Information.
MANPOWER Refer to Paragraph 1.G., Manpower.
MATERIAL INFORMATION Operator Supplied Parts/Materials.
Refer to Paragraph 2.A., Material - Price and Availability.
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Original Issue: October 26, 2000 767-57A0076Revision 3: April 04, 2012 10 of 46 BOEING SERVICE BULLETIN 767-57A0076
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BOEING SERVICE BULLETIN 767-57A0076
ALERT ALERT SEE A
HINGE FITTING
ASSEMBLY FWD
INBOARD FLAP - OUTBOARD LINKAGE
INSPECT OUTBOARD HINGE
FITTING FOR CRACKS OR FRACTURES. IF CRACKS OR
FRACTURES ARE FOUND REPLACE
HINGE FITTING ASSEMBLY
LOCATION OF FATIGUE FWD< CRACKS AND FRACTURES RIGHT WING SIMILAR LEFT WING SHOWN V37977 Original Issue: October 26, 2000 Revision 3: April 04, 2012 767-57A0076
BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 11 of 46
BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: October 26, 2000 767-57A0076Revision 3: April 04, 2012 12 of 46 BOEING SERVICE BULLETIN 767-57A0076