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Commercial Airplanes 767 Service Bulletin ALERT Number: 767-57A0079 Original Issue: June 20, 2002 Revision 2: March 23, 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BOEING PROPRIETARY, CONFIDENTIAL, AND/OR TRADE SECRET Copyright © 2002 The Boeing Company Unpublished Work - All Rights Reserved Boeing claims copyright in each page of this document only to the extent that the page contains copyrightable subject matter.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.
BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: June 20, 2002 767-57A0079Revision 2: March 23, 2012 1 of 38
3.0
BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: June 20, 2002 767-57A0079Revision 2: March 23, 2012 2 of 38 BOEING SERVICE BULLETIN 767-57A0079
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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 6
3. Installation Drawings Used in the Preparation of this Service Bulletin: ........... 1 6 K. Publications Affected ........................................ 1 6 L. Interchangeability and Intermixability of Parts ........................... 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 8
3. Parts Modified and Reidentified: ............................... 1 9
4. Parts Removed and Not Replaced: .............................. 1 9 D. Parts Necessary to Change Spares ................................. 1 9 E. Special Tooling - Price and Availability ............................... 1 9 F. Special Tooling Necessary to do this Service Bulletin ....................... 1 9
3. ACCOMPLISHMENT INSTRUCTIONS .................................. 2 1 A. GENERAL INFORMATION ..................................... 2 1 B. WORK INSTRUCTIONS ....................................... 2 2 FIGURE 1: LOGIC DIAGRAM OF INSPECTION AND MAINTENANCE ALTERNATIVES ....... 2 5 FIGURE 2: OUTBOARD HINGE FITTING - DETAILED INSPECTION ................. 2 6 FIGURE 3: OUTBOARD HINGE FITTING - DETAILED AND EDDY CURRENT INSPECTION .... 2 9 FIGURE 4: HINGE FITTING ASSEMBLY - REPLACEMENT ...................... 3 3
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Original Issue: June 20, 2002 767-57A0079Revision 2: March 23, 2012 3 of 38 BOEING SERVICE BULLETIN 767-57A0079
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BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: June 20, 2002 767-57A0079Revision 2: March 23, 2012 4 of 38 BOEING SERVICE BULLETIN 767-57A0079
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Commercial Airplanes 767 Service Bulletin ALERT Revision Transmittal SheetNumber: 767-57A0079Original Issue: June 20, 2002 Revision 2: March 23, 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 No more work is necessary on the airplanes changed in accordance with the original issue or Revision 1 of this service bulletin. However, operators must continue to do the repetitive inspections of the hinge fittings, at the times in accordance with Paragraph 1.E., Compliance until new hinge fitting assemblies 113T2271-419 (Left) and 113T2271-420 (Right) are installed.
REASON FOR REVISION This revision is sent to change the inspection requirements in Figure 2 and Figure 3 of this service bulletin. The inspection area on the trailing edge main flap hinge fitting is changed and limited to the outboard half only.
Subsequent to the release of Revision 1 of this service bulletin, one operator reported finding a fractured hinge fitting assembly. The fracture occurred on a hinge fitting assembly at approximately 780 flight-cycles after its last inspection on a 767-300 airplane. An examination of the fractured hinge fitting assembly showed that the crack 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. The latest service bulletin format standards have also been updated where applicable.
These sections are changed:
1. Service Bulletin Title updated.
2. Summary - Illustration - Illustration updated to show the expected crack location and direction.
3. Paragraph 1.F., Approval - AMOC statement updated.
4. Paragraph 1.G., Manpower - Table updated.
5. Paragraph 1.K.1., Publications - CMM reference added.
6. Paragraph 1.K.2., Damage Tolerance Based Structural Inspections - Damage Tolerance Inspections (DTI) statement added.
7. Paragraph 3.A., General Information - General notes updated.
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Original Issue: June 20, 2002 767-57A0079Revision 2: March 23, 2012 5 of 38
8. Paragraph 3.B., Work Instructions - Titles updated and Part 3, Steps 3 and 5 updated to correct the access panel numbers. Also the latest service bulletin format standards have also been updated where applicable.
9. Figure 1 - Illustration updated to revise the data in compliance Logic Diagram.
10. Figure 2 - Illustration updated to incorporate the new inspection requirements.
11. Figure 3 - Illustration updated to incorporate the new inspection requirements.
12. Figure 4 - Step table updated to remove the QTY for shims.
The data given in Alternative Method of Compliance Notice 767-57A0079-AMOC-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.
REVISION HISTORY June 20, 2002Original Issue:
May 06, 2010Revision 1:
March 23, 2012Revision 2:
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Original Issue: June 20, 2002 767-57A0079Revision 2: March 23, 2012 6 of 38 BOEING SERVICE BULLETIN 767-57A0079
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Commercial Airplanes 767 Service Bulletin ALERT SummaryNumber: 767-57A0079Original Issue: June 20, 2002 Revision 2: March 23, 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 could cause potential personal injury.
One operator of a 767-300 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 assembly. 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 assemblies. 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 fitting that have the additional material area of the optional tool runout. Service bulletin 767-57A0076 was released to inspect and replace the suspect hinge fittings if and as required on all 767-200, 767-300 and 767-300F airplanes line numbers 1 through 825. The inboard trailing edge main flap outboard hinge fittings on the 767-400ER are similar in design to the 767-200, 767-300 and 767-300F fittings. The 767-400ER fittings are wider and thicker; however, higher fatigue loads are associated with the 767-400ER in this area. Analysis indicates the 767-400ER fittings could be susceptible to early fatigue cracking and/or fractures as a result of these higher loads.
Subsequent to the original issue of this service bulletin, 3 reports of hinge fitting assembly fracture have been received. The fractures all occurred at approximately 9,100 flight-cycles and in 1 case fracture at approximately 1,400 flight-cycles after the last detailed - eddy current inspection. Based on the reports of the fractured hinge fitting assemblies prior to the initial threshold and the repeat interval, revision 1 reduced the initial threshold and repeat interval. Revision 2 changed the inspection area to show clearly the expected crack location and direction.
BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: June 20, 2002 767-57A0079Revision 2: March 23, 2012 7 of 38
Replacement of the hinge fitting assembly with a more robust designed fitting will ensure the structural integrity of the aft flap, prevent damage to the surrounding structure and stop the potential for personal injury.
Boeing Service Related Problem (SRP) 767-SRP-57-0119 is related to this service bulletin.
Boeing Service Related Problem (SRP) 767-SRP-57-0233 is related to this service bulletin.
ACTION Inspect the inboard trailing edge main flap outboard hinge fittings on the left and right wing for cracks or fractures.
If any cracks or fractures are found, complete terminating action. If cracks or fractures are not found, repeat the inspections at the intervals in accordance with FIGURE 1 until terminating action is completed.
EFFECTIVITY 767-400ER Airplanes. Refer to Paragraph 1.A., Effectivity, for the list of affected airplanes.
COMPLIANCE Federal Aviation Administration (FAA) Airworthiness Directive AD 2003-13-01 is related to this service bulletin.
Refer to FIGURE 1 Logic Diagram for Inspection and Maintenance Alternatives.
INDUSTRY SUPPORT INFORMATION Boeing warranty remedies are not available for the configuration changes, inspection and/or repair procedures given in this service bulletin.
MANPOWER Refer to Paragraph 1.G., Manpower.
MATERIAL INFORMATION Boeing Supplied Kits/Parts.
Refer to Paragraph 2.A., Material - Price and Availability.
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Original Issue: June 20, 2002 767-57A0079Revision 2: March 23, 2012 8 of 38 BOEING SERVICE BULLETIN 767-57A0079
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BOEING SERVICE BULLETIN 767-57A0079
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
CRACKS AND FRACTURES FWD& RIGHT WING SIMILAR LEFT WING SHOWN V85460 Original Issue: June 20, 2002 Revision 2: March 23, 2012 767-57A0079
BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 9 of 38
BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: June 20, 2002 767-57A0079Revision 2: March 23, 2012 10 of 38 BOEING SERVICE BULLETIN 767-57A0079
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BLANK PAGE
Commercial Airplanes 767 Service Bulletin ALERT Number: 767-57A0079 Original Issue: June 20, 2002 Revision 2: March 23, 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.
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. An equivalent change is on subsequent production airplanes. Refer to PRR12901-9S for data about this change.
DESCRIPTIONCONFIGURATIONGROUP 767-400ER airplanes line numbers 758 through 877.-1 Airplane Models:
767-400ER GroupVariable Number 1VQ001 - VQ021 1VQ071 - VQ085
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Original Issue: June 20, 2002 767-57A0079Revision 2: March 23, 2012 11 of 38
2. Spares Affected Examine your 767-400ER inboard trailing edge main flap spares supply for the 113T2271-401 and 113T2271-402 outboard hinge fitting assemblies. If any parts are found, refer to Paragraph 2.C., Parts Necessary for Each Airplane and Paragraph 2.D., Parts Necessary to Change Spares for the recommended use.
B. Concurrent Requirements None.
C. Reason 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 fittings could result in the inboard aft flap becoming unrestrained potentially striking the aircraft upon departure, resulting in significant damage to the surrounding structure and could cause potential personal injury.
One operator of a 767-300 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 assembly. The outboard fitting was fractured just above the lug hole. The fractured 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 assemblies. 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 fitting that have the additional material area of the optional tool runout. Service bulletin 767-57A0076 was released to inspect and replace the suspect hinge fittings if and as required on all 767-200, 767-300 and 767-300F airplanes line numbers 1 through 825. The inboard trailing edge main flap outboard hinge fittings on the 767-400ER are similar in design to the 767-200, 767-300 and 767-300F fittings.
The 767-400ER fittings are wider and thicker; however, higher fatigue loads are associated with the 767-400ER in this area. Analysis indicates the 767-400ER fittings could be susceptible to early fatigue cracking and/or fractures as a result of these higher loads.
Subsequent to the original issue of this service bulletin, 3 reports of hinge assembly fracture have been received. The fractures all occurred at approximately 9,100 flight-cycles and in 1 case fracture at approximately 1,400 flight-cycles after the last detailed - eddy current inspection. Based on the reports of the fractured hinge fitting assemblies prior to the initial threshold and the repeat interval, revision 1 reduced the initial threshold and repeat interval. Revision 2 changed the inspection area to show clearly the expected crack location and direction.
Replacement of the outboard hinge fitting with a more robust designed fitting will ensure the structural integrity of the aft flap, prevent damage to the surrounding structure and stop the potential for personal injury.
Boeing Service Related Problem (SRP) 767-SRP-57-0119 is related to this service bulletin.
Boeing Service Related Problem (SRP) 767-SRP-57-0233 is related to this service bulletin.
BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: June 20, 2002 767-57A0079Revision 2: March 23, 2012 12 of 38 BOEING SERVICE BULLETIN 767-57A0079