94-16-03 BOEING: Amendment 39-8993. Docket 93-NM-178-AD. Supersedes AD 92-03-03, Amendment 39-8157. \n\n\tApplicability: Model 767 series airplanes equipped with Pratt & Whitney JT9D-7R4 or General Electric CF6-80A series engines, certificated in any category. \n\n\tCompliance: Required as indicated, unless accomplished previously. \n\n\tTo ensure the integrity of the fail safe features of the thrust reverser system, accomplish the following: RESTATEMENT OF ACTIONS REQUIRED BY AD 92-03-03: \n\n\t(a)\tFor airplanes equipped with Pratt & Whitney JT9D-7R4 series engines: Within 60 days after January 27, 1992 (the effective date of AD 92-03-03, amendment 39-8157), and thereafter at intervals not to exceed 3,000 flight hours, perform the tests, inspections, and adjustments described in Boeing Service Bulletin 767-78-0054, dated December 13, 1991. \n\n\t\t(1)\tFollowing any maintenance action that could affect the thrust reverser system: Repeat the tests, inspections, and adjustments required by paragraph (a) of this AD on the affected engine, prior to further flight, in accordance with the service bulletin. \n\n\t\t(2)\tThereafter, following any maintenance action, continue to perform the repetitive tests, inspections, and adjustments required by paragraph (a) of this AD on the affected engine at intervals not to exceed 3,000 flight hours. \n\n\t(b)\tFor airplanes equipped with General Electric CF6-80A series engines: Within 60 days after January 27, 1992 (the effective date of AD 92-03-03, amendment 39-8157), and thereafter at intervals not to exceed 3,000 flight hours, perform the tests, inspections, and adjustments described in Boeing Service Bulletin 767-78-0053, dated December 13, 1991. \n\n\t\t(1)\tFollowing any maintenance action that could affect the thrust reverser system, repeat the tests, inspections, and adjustments required by paragraph (b) of this AD on the affected engine, prior to further flight, in accordance with the service bulletin. \n\n\t\t(2)\tThereafter, following any maintenance action, continue to perform the repetitive tests, inspections, and adjustments required by paragraph (b) of this AD on the affected engine at intervals not to exceed 3,000 flight hours. \n\n\t(c)\tIf any test, inspection, and/or adjustment required by paragraph (a) or (b) of this AD cannot be successfully performed, or if any test, inspection, and/or adjustment results in findings that are unacceptable in accordance with Boeing Service Bulletin 767-78-0054, dated December 13, 1991, or Boeing Service Bulletin 767-78-0053, dated December 13, 1991, as applicable, accomplish paragraphs (c)(1) and (c)(2) of this AD. \n\n\t\t(1)\tPrior to further flight, deactivate the associated thrust reverser in accordance with Section 78-31-1 of Boeing Document D630T002, "Boeing 767 Dispatch Deviation Guide," Revision 9, dated May 1, 1991. No more than one thrust reverser on any airplane may be deactivated under the provisions of this paragraph. \n\n\t\t(2)\tWithin 10 days after deactivation of any thrust reverser in accordance with this paragraph, the thrust reverser must be repaired in accordance with Boeing Service Bulletin 767-78-0054, dated December 13, 1991, or Boeing Service Bulletin 767-78-0053, dated December 13, 1991, as applicable; the tests and/or inspections required by paragraph (a) or (b) of this AD must be successfully accomplished; and the thrust reverser must then be reactivated.\n\n NEW ACTIONS REQUIRED BY THIS AD: \n\n\t(d)\tWithin 5 years after the effective date of this AD, install an additional thrust reverser system locking feature (synch-lock installation) in accordance with Boeing Service Bulletin 767-78-0060, Revision 2, dated August 19, 1993 (for Model 767 series airplanes equipped with General Electric CF6-80A series engines), or Boeing Service Bulletin 767-78-0061, Revision 1, dated August 5, 1993 (for Model 767 series airplanes equipped with Pratt & Whitney JT9D-7R4 series engines), as applicable. Installation of the additional thrust reverser system locking feature, as required by this paragraph, constitutes terminating action for the requirements of paragraphs (a) through (c) of this AD. \n\n\t(e)\tWithin 4,000 hours time-in-service after installing the synch-lock required by paragraph (d) of this AD (either in production or by retrofit), or within 4,000 hours time-in-service after the effective date of this AD, whichever occurs later; and thereafter at intervals not to exceed 4,000 hours time-in-service: Perform functional tests of the synch-lock in accordance with the "Thrust Reverser Synch-Lock Test" procedures specified below. If any discrepancy is found during any test, prior to further flight, correct it in accordance with procedures described in the Boeing 767 Maintenance Manual. The airplane may be operated in accordance with the provisions and limitations specified in the FAA-approved Master Minimum Equipment List (MMEL), provided that no more than one thrust reverser on an airplane is inoperative and thatno synch-lock on that airplane is in an unlocked position. \n\n\t\t\tTHRUST REVERSER SYNCH-LOCK TEST\n 1.\tGeneral \n\tA.\tThere are two thrust reverser synch-locks on each engine. The thrust reverser synch- locks are installed on the lower non-locking hydraulic actuator of each thrust reverser sleeve. \n\tB.\tThis task has two parts that must be accomplished: \n\t\t(1)\tThe first part does a test of the electrical circuit which controls the \n\t\t\toperation of each thrust reverser synch-lock. \n\t\t(2)\tThe second part does a test of the mechanical condition of each \t\t\t\tthrust reverser synch-lock. \n\tC.\tThe thrust reverser synch-lock is referred to as the "synch-lock" in this \t\t\tprocedure.\n 2.\tThrust Reverser Synch-Lock Integrity Test \n\tA.\tEquipment \n\t\t(1)\tMulti-meter, Simpson 260 or equivalent - commercially available. \n\tB.\tPrepare to do the integrity test for the synch-locks. \n\t\t(1)\tSupply electrical power. \n\t\t(2)\tFor the left engine, make sure these circuit breakers on the overhead \t\t\tcircuit breaker panel, P11, are closed: \n\t\t\t(a)\tL ENG T/R CONT \n\t\t\t(b)\tL ENG T/R IND \n\t\t\t(c)\tL ENG T/R SSL CONT \n\t\t(3)\tFor the right engine, make sure these circuit breakers on the overhead \t\t\tcircuit breaker panel, P11, are closed: \n\t\t\t(a)\tR ENG T/R CONT \n\t\t\t(b)\tR ENG T/R IND \n\t\t\t(c)\tR ENG T/R SSL CONT \n\t\t\t(d)\tAIRPLANES WITH HYDRAULIC MOTOR-DRIVEN \n\t\t\t\tGENERATORS (ETOPS): R ENG T/R CONT ALTN \n\t\t\t(e)\tAIRPLANES WITH HYDRAULIC MOTOR-DRIVEN \t\t\t\t\tGENERATORS (ETOPS): R ENG T/R IND ALTN \n\t\t(4)\tOpen the fan cowl panels. \n\tC.\tDo the electrical test for the synch-locks. \n\t\t(1)\tDo these steps to make sure there are no "hot" short circuits in the electrical system which can accidentally supply power to the synch-locks: \n\t\t\t(a)\tRemove the applicable L(R) electrical connectors, D20194(D20196), from the L(R) synch-locks, V170(V171). \nNOTE: You can find the synch-locks attached to the lower non-locking hydraulic actuators on the applicable thrust reverser sleeves. \n\t\t\t(b)\tUse a multi-meter on the plug end of the applicable electrical connector to make sure that these conditions are correct: \n\n\n\nFROM EQUIPMENT\nTO EQUIPMENT\nCONDITION \nD20194 PIN 1\nD20194 PIN 2\n-3 TO +1 VDC AND CONTINUITY \n(LESS THAN 5OHMS) \nD20196 PIN 1\nD20196 PIN 2\n-3 TO +1 VDC AND CONTINUITY \n(LESS THAN 5 OHMS) \n\n\t\t\t(c)\tIf you did not find these conditions to be correct, you must do \t\t\t\tthese steps: \n\t\t\t\t1)\tMake a careful visual inspection of all the electrical \t\t\t\t\twires and connectors between the synch-lock and its \t\t\t\t\tapplicable power circuit breaker. \n\t\t\t\t2)\tRepair all the unserviceable electrical wire and \t\t\t\t\t\tconnectors that you find. \n\t\t\t\t3)\tUse the multi-meter again to make sure there are no \t\t\t\t\t"hot" short circuits in the electrical system which can \t\t\t\t\taccidentally supply power to the synch-locks. \n\t\t\t(d)\tIf you find the correct conditions when you use the multi-meter, continue on and do the mechanical test of the synch-locks. NOTE: Make sure the circuit breakers shown above continue to be set to the closed position. Do not install the electrical connectors on the synch-locks at this time. \n\tD.\tDo the mechanical test for the synch-locks. \n\t\t(1)\tSupply hydraulic power. \n\n\t\t\tWARNING: MAKE SURE ALL PERSONS AND EQUIPMENT ARE \n\t\t\tCLEAR OF THE AREA BEHIND EACH THRUST REVERSER. IF \t\t\tYOU DO NOT OBEY THIS INSTRUCTION, INJURIES TO PERSONS \t\t\tOR DAMAGE TO EQUIPMENT CAN OCCUR IF THE \t\t\t\t\tSYNCH-LOCKS DO NOT OPERATE CORRECTLY AND THE \t\t\t\tTHRUST REVERSER EXTENDS. \n\n\t\t(2)\tMove the reverse thrust levers for the two engines to try to extend the thrust reversers with hydraulic power. \n\nNOTE: If the thrust reversers do not extend, the synch-locks are serviceable. If the thrust reversers extend, the applicable synch-locks did not operate correctly. \n\n\t\t(3)\tReplace the applicable synch-locks on the thrust reverser that extended when you moved the reverse thrust levers. \n\t\t(4)\tMake sure the reverse thrust levers are in the fully stowed position. \n\t\t(5)Install the applicable L(R) electrical connectors, D20194(D20196), on \t\t\tthe L(R) synch-locks, V170(V171). \n\n\t\t\tWARNING: MAKE SURE ALL PERSONS AND EQUIPMENT ARE \n\t\t\tCLEAR OF THE AREA BEHIND THE THRUST REVERSERS. IF \t\t\tYOU DO NOT OBEY THIS INSTRUCTION, INJURIES TO PERSONS \t\t\tOR DAMAGE TO EQUIPMENT CAN OCCUR WHEN THE THRUST \n\t\t\tREVERSERS ARE EXTENDED. \n\n\t\t(6)\tMove the reverser thrust levers for the two engines to extend the thrust reversers with hydraulic power. \n\nNOTE: If the thrust reversers extend, the synch-locks are serviceable. If the thrust reversers do not extend, the applicable synch-locks did not operate correctly. \n\n\t\t(7)\tReplace the applicable synch-locks on the thrust reverser that did not \t\t\textend when you moved the reverse thrust levers. \n\tE.\tPut the airplane back to its usual condition. \n\t\t(1)\tMove the reverse thrust levers to fully retract the thrust reversers on \t\t\tthe two engines with hydraulic power. \n\t\t(2)\tRemove the hydraulic power if it is not necessary. \n\t\t(3)\tRemove the electrical power if it is not necessary. \n\t\t(4)\tClose the fan cowl panels. \n\t(f)\tAn alternative method of compliance or adjustment of the compliance time that provides an acceptable level of safety may be used if approved by the Manager, Seattle Aircraft Certification Office (ACO), FAA, Transport Airplane Directorate. Operators shall submit their requests through an appropriate FAA Principal Maintenance Inspector, who may add comments and then send it to the Manager, Seattle ACO. \t\n\n\tNOTE: Information concerning the existence of approved alternative methods of compliance with this AD, if any, may be obtained from the Seattle ACO. \n\n\t(g)\tSpecial flight permits may be issued in accordance with sections 21.197 and 21.199 of the Federal Aviation Regulations (14 CFR 21.197 and 21.199) to operate the airplane to a location where the requirements of this AD can be accomplished. \n\t(h)\tThe installation shall be done in accordance with Boeing Service Bulletin767-78- 0060, Revision 2, dated August 19, 1993; and Boeing Service Bulletin 767-78-0061, Revision 1, dated August 5, 1993; as applicable. This incorporation by reference was approved by the Director of the Federal Register in accordance with 5 U.S.C. 552(a) and 1 CFR part 51. Certain other actions shall be done in accordance with Boeing Service Bulletin 767-78-0054, dated December 13, 1991; and Boeing Service Bulletin 767-78-0053, dated December 13, 1991; as applicable. The incorporation by reference of these documents was approved previously by the Director of the Federal Register in accordance with 5 U.S.C. 552(a) and 1 CFR part 51 as of January 27, 1992 (57 FR 3004, January 27, 1992). Copies may be obtained from Boeing Commercial Airplane Group, P.O. Box 3707, Seattle, Washington 98124-2207. Copies may be inspected at the FAA, Transport Airplane Directorate, 1601 Lind Avenue, SW., Renton, Washington; or at the Office of the Federal Register, 800 North Capitol Street, NW., suite 700, Washington, DC. \n\n\t(i)\tThis amendment becomes effective on September 12, 1994.