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Commercial Airplanes 767 Service Bulletin ALERT Number: 767-57A0079 Original Issue: June 20, 2002 Revision 1: May 06, 2010 ATA System: 5750 SUBJECT: WINGS - Trailing Edge and Trailing Edge Devices - Inboard Main Flap - Hinge Fitting Lug 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BOEING PROPRIETARY, CONFIDENTIAL, AND/OR TRADE SECRET Copyright © 2002 The Boeing Company Unpublished Work - All Rights Reserved Boeing claims copyright in each page of this document only to the extent that the page contains copyrightable subject matter.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BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.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 1: May 06, 2010 1 of 39
4.0
BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: June 20, 2002 767-57A0079Revision 1: May 06, 2010 2 of 39 BOEING SERVICE BULLETIN 767-57A0079
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Table of Contents
Revision Transmittal Sheet5
Summary9
1. PLANNING INFORMATION ........................................ 1 3 A. Effectivity ............................................... 1 3
1. Airplanes ............................................ 1 3
2. Spares Affected ........................................ 1 3 B. Concurrent Requirements ...................................... 1 4 C. Reason ................................................ 1 4 D. Description .............................................. 1 5 E. Compliance .............................................. 1 5 F. Approval ............................................... 1 6 G. Manpower .............................................. 1 6 H. Weight and Balance Changes .................................... 1 7 I. Electrical Load Data ......................................... 1 7 J. References .............................................. 1 7
1. Existing Data: ......................................... 1 7
2. Data supplied with this Service Bulletin: ........................... 1 8
3. Installation Drawings Used in the Preparation of this Service Bulletin: ........... 1 8 K. Publications Affected ........................................ 1 8 L. Interchangeability and Intermixability of Parts ........................... 1 8
2. MATERIAL INFORMATION ........................................ 1 9 A. Material - Price and Availability ................................... 1 9 B. Industry Support Information .................................... 1 9 C. Parts Necessary For Each Airplane ................................. 1 9
1. Kits/Parts: ........................................... 1 9
2. Parts and Materials Supplied by the Operator: ........................ 2 0
3. Parts Modified and Reidentified: ............................... 2 1
4. Parts Removed and Not Replaced: .............................. 2 1 D. Parts Necessary to Change Spares ................................. 2 1 E. Special Tooling - Price and Availability ............................... 2 1 F. Special Tooling Necessary to do this Service Bulletin ....................... 2 1
3. ACCOMPLISHMENT INSTRUCTIONS .................................. 2 3 A. GENERAL INFORMATION ..................................... 2 3 B. WORK INSTRUCTIONS ....................................... 2 4 FIGURE 1: LOGIC DIAGRAM OF INSPECTION AND MAINTENANCE ALTERNATIVES ....... 2 7 FIGURE 2: HINGE FITTING - DETAILED INSPECTION ......................... 2 8 FIGURE 3: HINGE FITTING - DETAILED - EDDY CURRENT INSPECTION .............. 3 1 FIGURE 4: HINGE FITTING - REPLACEMENT .............................. 3 4
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BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: June 20, 2002 767-57A0079Revision 1: May 06, 2010 4 of 39 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 1: May 06, 2010 ATA System: 5750 SUBJECT: WINGS - Trailing Edge and Trailing Edge Devices - Inboard Main Flap - Hinge Fitting Lug 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 changed in accordance with the original issue of this service bulletin.
REASON FOR REVISION This revision is sent to:
1. To reduce the initial compliance time and repeat interval based on service reports. Subsequent to the original issue of this service bulletin, operators have reported finding 3 fractured hinge fitting assemblies. The fractured hinge fitting assemblies had accumulated less flight-cycles than the initial compliance threshold and in 1 case, the hinge fitting assembly fractured after the original inspection and prior to the next repeat inspection. Boeing Service Related Problem (SRP) 767-SRP-57-0233 was issued to address this issue.
2. Add instructions to transfer the stainless steel filler and the shims for the mid fairing roller from the old hinge fitting assembly to the new hinge fitting assembly.
3. Revise inspection area to show inspection from the center of the lug forward, not the end of the lug forward.
This moves the inspection forward to inspect additional area where cracking has been found, not the lug bore where cracking has not been found.
4. Add reference to the existing AD, add an AMOC to the existing AD, and reference the possible new AD which would make the compliance tasks and times in Revision 1 of this service bulletin mandatory.
5. Update the format of the service bulletin to meet current service bulletin standards.
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Original Issue: June 20, 2002 767-57A0079Revision 1: May 06, 2010 5 of 39
These sections were changed:
1. Summary:
a. Background - Add the new reports of fracture and reference to the new Boeing Service Related Problem (SRP) 767-SRP-57-0233.
b. Compliance - Add reference to the existing AD and the possible new AD which would make the compliance tasks and times in Revision 1 of this service bulletin mandatory.
2. 1., Planning:
a. C., Reason - Add new reports of fracture and reference to the new Boeing Service Related Problem (SRP) 767-SRP-57-0233.
b. D., Description - Add Compliance information related to the revision and Affected Maintenance Zone Table.
c. E., Compliance - Add reference to the existing the AD and the possible new AD which would make the compliance tasks and times in Revision 1 of this service bulletin mandatory.
d. F., Approval - Add AMOC statement for the existing AD.
e. J., References - Add reference to new SRP number. Add Reference to existing FAA AD.
3. 2., Material Information
a. A., Material - Price and Availability - Updated price data.
4. 3., Accomplishment Instructions:
a. A., General Notes:
(1) Note 6 - Revise note to remove the one grip length variance and refer to the SRM for installation standards. Operators have reported grip length variances greater than the 1 grip length.
b. B., Work Instructions:
c. Figure 1 - Revise the inital threshold and the repeat interval for the Part 2 - Detailed - Eddy Current Inspection due to reports of cracks.
d. Figure 3 - Illustration - Revise inspection area to show inspection from the center of the lug forward, not the end of the lug forward.
e. Figure 4:
(1) Illustration: Revise inspection area to show inspection from the center of the lug forward, not the end of the lug forward.
(2) Step Table: Add new steps 7 and 8 to transfer the stainless steel filler and the shims for the mid fairing roller from the old hinge fitting assembly to the new hinge fitting assembly.
(3) Fastener Table: Change "reference" to "refer to as an accepted procedure" to meet current service
BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: June 20, 2002 767-57A0079Revision 1: May 06, 2010 6 of 39 BOEING SERVICE BULLETIN 767-57A0079
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bulletin standards.
Paragraph 1.A., Effectivity, shows changes of airplane operators. Each operator should examine the Effectivity paragraph for changes.
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:
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Commercial Airplanes 767 Service Bulletin ALERT SummaryNumber: 767-57A0079Original Issue: June 20, 2002 Revision 1: May 06, 2010 ATA System: 5750 SUBJECT: WINGS - Trailing Edge and Trailing Edge Devices - Inboard Main Flap - Hinge Fitting Lug 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 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 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 inboard fitting was fractured through the lug hole. 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 767-400 are similar in design to the 767-200, 767-300 and 767-300F fittings. The 767-400 fittings are wider and thicker however higher fatigue loads are associated with the 767-400 in this area. Analysis indicates the 767-400 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, the initial threshold and repeat interval have been reduced.
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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 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 fitting assemblies for cracks and or fractures. If damaged fittings are found, complete terminating action. If damaged fittings are not found, repeat the inspections at the intervals in accordance with Figure 1 until terminating action is completed.
EFFECTIVITY 767-400 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.
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 Revision 1 of this service bulletin mandatory.
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 1: May 06, 2010 10 of 39 BOEING SERVICE BULLETIN 767-57A0079
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BOEING SERVICE BULLETIN 767-57A0079
ALERT ALERT SEE D
HINGE FITTING
ASSEMBLY FWD '
INBOARD FLAP - OUTBOARD LINKAGE
INSPECT HINGE FITTING
ASSEMBLY FOR CRACKS OR FRACTURES. IF DAMAGE IS
FOUND REPLACE HINGE
FITTING ASSEMBLY
LOCATIONS OF FRACTURES FWD S V85460 Original Issue: June 20, 2002 Revision 1: May 06, 2010 BOEING PROPRIETARY - 767-57A0079 Copyright © Unpublished Work - See page 1 for details. 11 of 39
BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: June 20, 2002 767-57A0079Revision 1: May 06, 2010 12 of 39 BOEING SERVICE BULLETIN 767-57A0079