SB No.6 388
SB No.6 388
L. /
SERVICE BULLETIN
SUBJECT:
DHC-6 TWIN OTTER
FI ight Controls - Flap Control Rods Inspection and Sleeve
Installation - deHavilland Aircraft Engineering Order 66818, Modification
No. 6/1710 and 6/1714.
EFFECTIVITY:
1. DHC-6 Aircraft Serial No.1 thru 427 inclusive unless prior installation
of deHavilland Modification No. 6/1487 (Revision to Heat Treat) flap
control rods has been accomplished.
The change covered in the Service Bulletin for the above noted aircraft
(pre-Modification No. 6/1487) is introduced by E.O. 66818.
REASON:
Recent field reports have confirmed a low incidence of longitudinal
stress corrosion cracking in the tube material adjacent to the magneformed
ends in certain of the spanwise flap control rods in the above pre-Modification
No. 6/1487 aircraft. The Canadian Airworthiness Authority has called for a
more rigorous inspection of all rods and eventual replacement of the pre-
Modification No. 6/1487 rods. As an additional safety measure, external
sleeves are introduced at the rod ends to ensure there is no possibil ity of
rod end pullout under load substantially above maximum flight loads even
if cracking occurs and is undetected.
DESCRIPTION:
The two flap control rods in each wing and the two rods in the
fuselage area are removed from the aircraft, inspected for cracks and end
sleeves installed at each end of each serviceable rod. The rods are then
reinstal led on the aircraft and the flaps function tested.
The inspection requirements contained in Service Bulletin No. 6/381
and Canadian Department of Transport Airworthiness Directive CF-79-18 are
mOdified as detailed below under COMPLIANCE following installation of subject
sleeves. These later inspection requirements will be a subject of revision
to the Inspection Requirements Manual PSM 1-6-7.
COMPLIANCE:
..
1. For Ai rcraft Serial No.1 thru 427 operators must inspect and accompl ish
this installation as detailed in this Service Bulletin at the next in-
spection called for in paragraph 3 of AD-CF-79-18 or deHavilland Service
2. For Aircraft Serial No. 428 thru 656 or any earlier aircraft incorporating
post Modification No. 6/1487 control rods, operators must inspect rod ends
and accomplish Modification No. 6/1710 and 6/171~ as detailed in this Service
Bulletin, no later. than 800 flying hours or 1 year, whichever comes first~
as called for in paragraph 2 of AD CF-79-18 and noted in deHavilland Service
Bulletin No. 6/381 paragraph 3 of COMPLIANCE.
3. On all aircraft incorporating post MOdification No. 6/1710 and 6/1711, on flap
control rods, visually inspect rod" e1"!ds at intervals'-of -800 fly-jng hours or
1 year whichever comes first in areas shown in Figure 1.
HANHOURS:
Approximately twenty manhours will be required to incorporate this modification.
KIT COSTS:
Kit 19~1710-00i $174.00 per Aircraft
Kit 7MK1710-003 $159.00 per Aircraft
Kit 7~K17i4-001 $282.00 per Aircraft
Kit 7l1K1714-003 $267.00 per Aircraft
(Price is F.O.B. Toronto and in Canadian Funds. Subject to change without notice)
Kits are currently available at deHavi Jland Aircraft.
PUBLICATiONS AFFECTED:
Illustrated Parts Catalogue PSM 1-6-" and PSM 1-63-4
Inspection Requirements Manual PSM 1-6-7
REFERENCES:
Canadian Department of Transport Airworthiness Djrective CF-79-18 dated .,
October 1st, 1979 and CF-79-22 dated November 5, ~ 979. 8 8 ~_.
Federal Aviation Administration Airworthiness Directive 0-03-0 Amend- _.
ment 39-3682 January 31st, 1 9 8 0 . . j i
DeHaviiland Service Bulletin No. 6/381 Revision tel dated November 15th~ 197~. ".
October 23rd, 1979 SIB No. 6/388
Rev i 5 ion 1 A I , November 15th) ]979 Page 2 of 1Z
Revision JCI. October 29th, 1982
ACCOMPLISHMENT INSTRUCTIONS:
1. From Aircraft Serial No.1 thru 656, remove flap control rods from
each wing, as follows:
(a) Ensure aircraft is positioned with each wing tip rib a mInI-
mum distance of 13 feet from hanger wall or any other ob-
struction.
(b) Remove each wing tip and access panels No. 33A, 35, 36 and 37
on lower surfaces of each wing behind main spar as shown in
Figure 1-2 of PSM 1-6-2 or in Figure 1 Chapter 12-00-00 of
PSM 1-63-2.
(g) Connect one end of a 30 foot length of heavy cord to the in-
board end of rod assembly C6CW1029-1 or -3.
(h) Working through access panel No. 37, carefully pass the rod
assembJ ies spanwise through the rib lightening holes untit the
rods are free from the wing. Ensure cord remains in wing.
NOTE
On some aircraft there may be equip-
ment partially blocking I ightening hole
in tip rib which will require temporary
removal to permit extraction of rod as-
sembI ies.
2. From Aircraft Serial No.1 thru 656, remove cabin roof upholstery
panels to gain access to area between Stations 219.00 and 230.00.
Disconnect fuselage flap rod flexible boot from flanged tubular
structure at side of fuselage and fold back boot as required.
4. Remove paint and/or primer from ends of each rod using Turco 5469 or
Cee-Bee R256A or equivalent paint itripper, to a distance of approxi-
mately 6.0 inches from magneformed area.
WARNING
Be careful not to remove the anodic
finish on rods. Rods with the anodized
finish removed must be rejected.
6. On rods which are free of cracks following inspection replace finish using
zinc chromate primer and paint as required.
NOTE
Operators in U.S.A. will receive a kit
which does not contain the primer. The
primer should be procured locally.
NOTE
Operators in U.S.A. wi 11 receive a kit which
does not include the sealant. For procure-
ment of sealant refer to KIT OF MATERIALS below.
9. On the OppOS i te end of each rod as semb 1y C6CW1024-1 (C6Z 1183-1 or -2) or
C6CW1051-1 or -3, install a sleeve CSP358-2 in the same manner as described
in paragraph 7 above. Rubber stamp or write EO 66818 alongside current part
number on rod C6CW1024-1 (C6Z1183-1 or -2) or C6CW1051-1 and C6Z2048-3 along-
side current part number on rod C6CW1051-3. Refer to Table 1.
10. Install a sleeve C6CF1460-27 to each end of each rod assembly C6CF1085-1,
-3 or -5 in the same manner as described in paragraph 7 above. Refer to
drawing C6Z2053 for rework of rod C6CF1085-1 and -3 and C6Z2050 for rework
•
to rod C6CF1085-5 and note that on one end of rod assembly, filing is per-
missible to facilitate sleeve installation and slots in sleeve must be
October 23rd, 1979 SiB No. 6/388 ."
Revision IAI, November 15th, 1979 6-27-6
Page 4 of 12
ACCOMPLISHMENT INSTRUCTIONS:
14. Operate flaps and ensure that a 0.060 inch mInImum clearance exists
between newly installed sleeves on rods C6CF1085-1, -3 or -5 and
C6CWI029-1 or -3 and the full length and circumference of the flanged
t~be C6CF1217-3 or -4 to which the flexible boot is normally secured.
T~is minimum clearance must be obtainable. If clearance exists, re-
connect flexible boot and cei ling panels removed in paragraph 2 above.
If the 0.060 inch clearance is not available, one of the following
alternative procedures must be carried out:
15. Refer to Figure 2 and from the flap rod roller assembly in the wing,
outboard of the fuselage cut-out, remove bolt AN3-23A, spacer C6CWM1034-27,
upper roller C3CF97-5, washer AN960010 and nut MS21042-3. Retain all
items except the nut.
16. Remove the stud C6CWM1033-27, lower rollers C3CF98-3, washers AN960010
and AN96oo416 and nuts MS21042-3 and MS21042-4. Retain all items ex-
cept the nuts.
17. Rework upper roller C3CF97-5 by removing end projections and 0.40 inch
from center of roller as shown in Figure 3. Roller is now identified
C6Z2060-27.
19. Obtain locally two nuts MS17825-3, one nut MS17825-4, washers
AN960D416 and AN9600416L and three cotte~ pins MS24665-159.
23. With the 0.060 inch clearance assured and the roller assembly secure,
mark or indent locations on bolt and stud through castellations of nuts
to allow for drill ing of cotter pin holes.
24. Remove assemblies and drill cotter pin holes in bolt and smaller dia-
meter end of stud using a No. 50 (0.070 in. dia.) drill and a hole in
the larger diameter end of stud using a No. 48 (0.076 in. dia.) drill.
25. Grease spacer C6CWMI034-27 and stud C6CWM1033-27 with grease MIL-G23827
or equivalent and reassemble roller assemblies, securing nuts with cotter
pins MS24665-159. Recheck gaps are maintained at upper rollers and
cant ro 1 rod.
26. Function test flaps, confirm clearance through whole flap movement then
replace all access panels and reinstall wing tips.
Kit C6Z2049-11 - Sleeve Installation to Flap Control Rods (U.S.A. Operators only)
(b) Detai led Kit Conten:
Qty per Ki t Replaces
Pa r t No. -9 -11 Description Part No. Remarks
C6Z2049 Drawing - Rework
JI CSP358-1
CSP358-2
6
2
6
2
Sleeve
Sleeve
OHMS S3.01/B2 Sealant 1/2 pint
TT-P-1757 1 P rime r 12 0 z ca n
C6MK1714
-1 -3
C6MK1714 Drawing Ki t
c6Z2050 Drawing - Rework
C6CF1460-27 4 4 Sleeve
OHMS S3.01/B2 Sealant 1/2 pint
For U.S. Operators receiving retrofit kits that do not include the OHMS S3.01/82 sealant
the following alternatives are listed:
•
I
I •
. "
(
, --- - -'.
----+--~lt__-.-- -
SLEEVE
·z .....
OI..D
<-.....J
(l)1..D
3
0-
(l)
""I
C6CF1085 ROD ASSEMBLY
\TI
M'
:r
..... ::z
o (j'\
I
0
•
o-t')-.....J
NO'"
le
........
u..>
~.
I
--~
(j'\ 0:>
N 0::
C6Z2060-27
TO ACHIEVE ADEQUATE
CLEARANCE (0.06 MIN)
AN960D416L AN960D416
MS17825-4 NUT 1- REQ WASHE"RS
AN960D416 WASHER 1- REQ
MS24665-159 COTTER 1 - REQ
DRILL BOLT 0.076 DIA
FOR COTTER. DO Nor
OVER-TIGHTEN NUT. ROLLERS-
MUST BE. FREE TO· ROTATE.
AN3-23A BOLT (REF)
C-'6CWM1034-27
SPACER (REF)
0.030 GAP
(MINIMUM)
, 0.005 GAP
- 0.015
C6CWM1033-~7D
STUD (RET)
tiS t 7825-3
NUT 2 - REQ
AH:J60Dl0
WASHER 2 - REQ
MS24665-159
COTTER - 2 - REQ
AN960D416L DRILL BOLTS 0.070
AN960D416 DIA FOR COTTER INSl
WASHERS AS REQ'D
TO ACHIEVE GAP
DETAIL C6Z2060-29
/+-
REWORK C3-CF-97-5 ROLLER AS SHOWN
DETAIL C6Z20~0~27
FIGURE 3