94-12-10 BOEING: Amendment 39-8938. Docket 93-NM-142-AD. Supersedes AD 92-24-03, Amendment 39-8408. \n\n\tApplicability: Model 767 series airplanes equipped with Pratt & Whitney PW4000 series engines; certificated in any category. \n\n\tCompliance: Required as indicated, unless accomplished previously. \n\n\tNOTE 1: Paragraphs (a) and (b) of this AD restate the requirements of AD 92-24-03, amendment 39-8408, paragraphs (a) and (b). As allowed by the phrase, "unless accomplished previously," if the requirements of AD 92-24-03 have been accomplished previously, paragraphs (a) and (b) of this AD do not require that they be repeated. \n\n\tNOTE 2: Paragraph (c)(1) of this AD restates the requirement for an initial and repetitive inspections, tests, adjustments, and functional checks contained in paragraph (c)(1) of AD 92-24-03. Therefore, for operators who have previously accomplished at least the initial inspection in accordance with AD 92-24-03, paragraph (c)(1) of this AD requires that the next scheduled inspection be performed within 3,000 flight hours after the last inspection performed in accordance with paragraph (c)(1) of AD 92-24-03. \n\n\tNOTE 3: Paragraph (c)(2) of this AD restates the requirement for an initial and repetitive checks of the grounding wire contained in paragraph (c)(2) of AD 92-24-03. Therefore, for operators who have previously accomplished at least the initial inspection in accordance with AD 92-24-03, paragraph (c)(2) of this AD requires that the next scheduled inspection be performed within 1,500 flight hours after the last inspection performed in accordance with paragraph (c)(2) of AD 92-24-03. \n\n\tTo ensure the integrity of the fail safe features of the thrust reverser system, accomplish the following: \n\n\t(a)\tWithin 7 days after August 23, 1991 (the effective date of AD 91-18-51, amendment 39-8069), accomplish the following: \n\n\t\t(1)\tDeactivate both left and right thrust reversers in accordance with Section 78-31-1 of BoeingDocument D630T002, "Boeing 767 Dispatch Deviation Guide," Revision 9, dated May 1, 1991. \n\n\t\t(2)\tAdd the following to the Limitations Section of the FAA-approved Airplane Flight Manual (AFM). This may be accomplished by placing a copy of this AD in the AFM. "Reduce by five percent the available accelerate-stop distance resulting from the Airplane Flight Manual takeoff performance analysis when the runway is wet or contaminated." \n\n\t(b)\tWithin 60 days after November 8, 1991 (the effective date of AD 91-22-09, amendment 39-8069), modify the thrust reverser system in accordance with Boeing Service Bulletin 767-78-0051, dated October 9, 1991. Once this modification is accomplished, the thrust reverser system shall be re-activated and the AFM limitation required by paragraph (a)(2) of this AD may be removed. \n\n\t(c)\tAccomplish the actions specified in paragraphs (c)(1) and (c)(2) of this AD at the times specified in those paragraphs. \n\n\t\t(1)\tPrior to the accumulation of 3,000 flight hours since manufacture, or within 30 days after November 24, 1992 (the effective date of AD 92-24-03, amendment 39-8408), whichever occurs later, perform all inspections, tests, adjustments, and functional checks of the thrust reverser control and indication system and engine wiring specified in Boeing Service Bulletin 767-78-0046, Revision 1, dated September 17, 1992, in accordance with the procedures described in that service bulletin. \n\n\t\t\t(i)\tRepeat those actions thereafter at intervals not to exceed 3,000 flight hours. \n\n\t\t\t(ii)\tWhenever maintenance action is taken that could disturb any portion of the thrust reverser control system, the functional test or tests relative to the system shall be performed in accordance with the Boeing 767 Maintenance Manual. After this test(s) is accomplished, the repetitive inspections, tests, adjustments and functional tests required by paragraph (c)(1)(i) of this AD shall continue. \n\n\t\t(2)\tPrior to the accumulation of 1,500 flight hours since manufacture, or within 30 days after November 24, 1992 (the effective date of AD 92-24-03, amendment 39-8408), whichever occurs later, perform a check of the grounding wire for the thrust reverser directional control valve (DCV) in accordance with Section III, paragraph B., of Boeing Service Bulletin 767- 78-0046, Revision 1, dated September 17, 1992. Thereafter, repeat this check at the times specified in paragraph (c)(2)(i) and (c)(2)(ii) of this AD. \n\n\t\t\t(i)\tAt intervals not to exceed 1,500 flight hours; and \n\t\t\t(ii)\tWhenever maintenance action is taken that could disturb the \t\t\t\tDCV grounding circuit. \n\n\t(d)\tIf any of the inspections, tests, adjustments, and/or functional checks required by paragraph (c) of this AD cannot be performed successfully as specified in the service bulletin, prior 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. The thrust reverser shall remain deactivated until all inspections, tests, adjustments, and functional tests required by paragraph (c) of this AD are completed successfully.\n \n\t(e)\tWithin 3 years after the effective date of this AD, install an additional thrust reverser system locking feature (sync-lock) in accordance with Boeing Service Bulletin 767-78-0062, Revision 2, dated June 3, 1993, or Revision 3, dated February 24, 1994. Installation of this additional locking feature constitutes terminating action for the requirements of paragraph (c) of this AD. \n\n\t(f)\tWithin 4,000 hours time-in-service after accomplishing the modification required by paragraph (e) of this AD, 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 the integrity test of the thrust reverser synchronous shaft locks specified below to detect latent failures of the components and to ensure the integrity of the thrust reverser system. Prior to further flight, repair any discrepancy found in accordance with procedures described in the Boeing 767 Maintenance Manual. \n\n\t\tTHRUST REVERSER SYNC-LOCK - ADJUSTMENT/TEST \n1.\tGeneral \n\n\tA.\tThere are two sync-locks for each engine thrust reverser. The sync-lock is installed on the lower non-locking hydraulic actuator of each thrust reverser sleeve. \n\tB.\tThe Thrust Reverser Sync-Lock Integrity Test has two tasks: \n\t\t(1)\tThe first task tests the electrical circuit which controls the operation of the sync-lock on each thrust reverser sleeve. \n\t\t(2)\tThe second task tests the mechanical function of the sync-lock on each thrust reverser sleeve. \n\tC.\tThe thrust reverser sync-lock is referred to as the sync-lock in this procedure. \n\n2.\tThrust Reverser Sync-Lock Integrity Test \n\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 sync-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)\tFOR ETOPS AIRPLANES, CLOSE THESE ADDITIONAL \n\t\t\t\tCIRCUIT BREAKERS: \n\t\t\t\t1)\tR ENG T/R CONT ALTN \n\t\t\t\t2)\tR ENG T/R IND ALTN \n\t\t(4)\tOpen the fan cowl panels. \n\t\n\tC.\tDo the Electrical Integrity Test for the sync-locks. \n\t\t(1)\tDo these steps to make sure there are no "hot" short circuits in the electrical system that may accidentally supply power to the sync-locks: \n\t\t\t(a)\tRemove the electrical connector, D20194, from the sync-locks, V170, on the left sleeve of the thrust reverser. \n\t\t\t(b)\tRemove the electrical connector, D20196, from the sync-lock, V171, on the right sleeve of the thrust reverser. \n\t\t\t(c)\tUse a multi-meter on the plug end of the applicable electrical connector to make sure that these conditions are correct: \n\nFROM EQUIPMENT\t\tTO EQUIPMENT\t\tCONDITION \nD20194, PIN 1\t\t\tD20194, PIN 2\t\t\t-3 TO +1 V DC AND \n\t\t\t\t\t\t\t\tCONTINUITY (LESS \n\t\t\t\t\t\t\t\tTHAN 5 OHMS) \n\nD20196, PIN 1\t\t\tD20196, PIN 2\t\t\t-3 TO +1 V DC AND \n\t\t\t\t\t\t\t\tCONTINUITY (LESS \n\t\t\t\t\t\t\t\tTHAN 5 OHMS) \n\n\t\t\t(d)\tIf you did not find these conditions to be correct, you must do \n\t\t\t\tthese steps: \n\n\t\t\t\t1)\tMake a careful visual inspection of all the electrical \t\t\t\t\twires and connectors between the sync-lock and its power circuit breaker. \n\t\t\t\t2)\tRepair all the unserviceable electrical wire and connectors 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 that can accidentally supply power to the sync-locks. \n\n\t\t\t(e)\tIf you find the correct conditions, do the Mechanical Integrity \t\t\t\tTest for the sync-locks. \n\tD.\tDo the Mechanical Integrity Test for the sync-locks. \n\t\t(1)\tSupply hydraulic power.\n\n WARNING: MAKE SURE ALL PERSONS AND EQUIPMENT ARE CLEAR OF THE AREA BEHIND EACH THRUST REVERSER. IF YOU DO NOT OBEY THIS INSTRUCTION, INJURIES TO PERSONS OR DAMAGE TO EQUIPMENT CAN OCCUR IF THE SYNC-LOCKS DO NOT OPERATE CORRECTLY AND THE THRUST REVERSER EXTENDS. \n\t\t(2)\tMove the L(R) reverser thrust lever aft to try to extend the thrust \t\t\t\treverser. \n\nNOTE: If the thrust reverser sleeves do not extend, the sync-locks are serviceable. If the thrust reverser sleeve extends, the applicable sync-lock did not operate correctly. \n\n\t\t(3)\tReplace the sync-lock(s) for the thrust reverser sleeve(s) that \t\t\t\textended. \n\t\t(4)\tMake sure the reverse thrust levers are in the fully stowed position. \n\t\t(5)\tInstall the electrical connectors, D20194, on the sync-locks, V170, on the left sleeve of the thrust reverser. \n\t\t(6)\tInstall the electrical connector, D20196, onthe sync-lock, V171, on the right sleeve of the thrust reverser.\n\n WARNING: MAKE SURE ALL PERSONS AND EQUIPMENT ARE CLEAR OF THE AREA BEHIND THE THRUST REVERSERS. IF YOU DO NOT OBEY THIS INSTRUCTION, INJURIES TO PERSONS OR DAMAGE TO EQUIPMENT CAN OCCUR WHEN THE THRUST REVERSERS ARE EXTENDED. \n\n\t\t(7)\tMove the L(R) reverser thrust lever aft to extend the thrust reverser. \n\nNOTE: If the thrust reverser sleeves extend, the sync-locks are serviceable. If the thrust reverser sleeve did not extend, the applicable sync-lock did not operate correctly. \n\n\t\t(8)\tReplace the sync-lock(s) on the thrust reverser sleeve(s) that did not extend when you moved the reverse thrust levers. \n\tE.\tRepeat the Thrust Reverser Sync-Lock Integrity Test for the opposite engine. \n\tF.\tPut the airplane back to its usual condition. \n\t\t(1)\tMove the reverser thrust levers to fully retract the thrust reversers on the 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\n\tG.\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. \n\n\tNOTE 4: Information concerning the existence of approved alternative methods of compliance with this AD, if any, may be obtained from the Seattle ACO.\n \n\tH.\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\n\tI.\tThe installation shall be done in accordance with Boeing Service Bulletin 767-78- 0062, Revision 2, dated June 3, 1993; or Boeing Service Bulletin 767-78-0062, Revision 3, dated February 24, 1994. The incorporation by reference of these documents was approved by the Director of the Federal Register in accordance with 5 U.S.C. 552(a) and 1 CFR part 51. The inspections, tests, adjustments, and functional checks shall be done in accordance with Boeing Service Bulletin 767-78-0046, Revision 1, dated September 17, 1992. The incorporation by reference of this document 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 November 24, 1992 (57 FR 53258, November 9, 1992). The modification and deactivation shall be done in accordance with Boeing Service Bulletin 767-78-0051, dated October 9, 1991; and Boeing Document D630T002, "Boeing 767 Dispatch Deviation Guide," Revision 9, dated May 1, 1991. 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 November 8, 1991 (56 FR 55066, October 24, 1991). 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\tJ.\tThis amendment becomes effective on July 20, 1994.