Tail Removal Flowchart
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Background
Section titled “Background”Use this topic to troubleshoot and diagnose a tail after removal from the aircraft. In many cases, removal is more practical than troubleshooting while the part is installed on the aircraft. Use this guide to disposition removed tails, usually in the Maintenance Holding location. This flow has three primary outcomes:
- Inspect, test, and return the part to service.
- Inspect, repair, test, and return the part to service.
- Inspect the part, remove salvageable spares, and scrap the part.
Troubleshooting Steps
Section titled “Troubleshooting Steps”graph TD
is-this-an-ev2-or-ev3-tail{"<small><b>Step 1</b></small><br/>Question: Is this an EV2 or EV3 tail?"}
remove-tail-from-aircraft["<small><b>Step 2</b></small><br/>Action: Remove the tail from the aircraft per..."]
is-part-number-003-or-006{"<small><b>Step 3</b></small><br/>Question: Is the tail part number -003, -006, -..."}
scrap-part-ineligible-pn["<small><b>Step 4</b></small><br/>Action: Scrap the part."]
do-visual-inspection["<small><b>Step 5</b></small><br/>Action: Do a visual inspection per 85.1.1 Ta..."]
is-there-structural-damage{"<small><b>Step 6</b></small><br/>Question: Is there damage to the structure?"}
is-damage-small-and-repairable{"<small><b>Step 7</b></small><br/>Question: Is the damage small and repairable? •..."}
is-damage-to-spar-or-leading-edge{"<small><b>Step 8</b></small><br/>Question: Is the damage to the spar or leading ..."}
remove-and-salvage-servo-linkage["<small><b>Step 9</b></small><br/>Action: Remove and salvage servo/linkage asse..."]
scrap-part-after-servo-salvage["<small><b>Step 10</b></small><br/>Action: Scrap the part."]
raise-tqri-for-structural-damage["<small><b>Step 11</b></small><br/>Action: Raise a TQRI. Escalate to P2 FSE On C..."]
raise-tqri-before-repair["<small><b>Step 12</b></small><br/>Action: Raise a TQRI. Escalate to P2 FSE On C..."]
execute-repair["<small><b>Step 13</b></small><br/>Action: Execute the repair."]
do-tail-eol-test["<small><b>Step 14</b></small><br/>Action: Perform the tail EOL test. 85.1.3.g ..."]
does-eol-pass{"<small><b>Step 15</b></small><br/>Question: Does the EOL pass?"}
place-tail-in-spares["<small><b>Step 16</b></small><br/>Action: Place tail in spares."]
failure-rpc-or-boot-issues{"<small><b>Step 17</b></small><br/>Question: Was the failure caused by RPC or boot..."}
inspect-servo-harness-and-m5-connector{"<small><b>Step 18</b></small><br/>Question: Inspect the servo harness per 20.2.2..."}
failure-range-incorrect{"<small><b>Step 19</b></small><br/>Question: Did either range test fail? • control..."}
failure-free-play-gt-5-deg{"<small><b>Step 20</b></small><br/>Question: Did the free play test fail 5 deg..."}
failure-friction{"<small><b>Step 21</b></small><br/>Question: Did the friction profile test fail? •..."}
scrap-part-after-friction-failure["<small><b>Step 22</b></small><br/>Action: Scrap the part."]
failure-sys-profile{"<small><b>Step 23</b></small><br/>Question: Did the system profile test fail? • c..."}
failure-analyze-data{"<small><b>Step 24</b></small><br/>Question: Did analyze_data fail? • control_surf..."}
raise-tqri["<small><b>Step 25</b></small><br/>Action: Raise a TQRI. Escalate to P2 FSE On C..."]
update-servo-in-eol-tester["<small><b>Step 26</b></small><br/>Action: Update the servo in the EOL tester. 1..."]
replace-servo-linkage-assy["<small><b>Step 27</b></small><br/>Action: Replace servo/linkage assembly. 85.1..."]
do-tail-eol-test-after-corrective-action["<small><b>Step 28</b></small><br/>Action: Perform the tail EOL test. 85.1.3.g ..."]
does-eol-pass-after-corrective-action{"<small><b>Step 29</b></small><br/>Question: Does the EOL pass?"}
place-tail-in-spares-after-corrective-action["<small><b>Step 30</b></small><br/>Action: Place tail in spares."]
failure-rpc-or-boot-issues-after-corrective-action{"<small><b>Step 31</b></small><br/>Question: Was the failure caused by RPC or boot..."}
inspect-servo-harness-and-m5-connector-after-corrective-action{"<small><b>Step 32</b></small><br/>Question: Inspect the servo harness per 20.2.2..."}
failure-range-incorrect-after-corrective-action{"<small><b>Step 33</b></small><br/>Question: Did either range test fail? • control..."}
failure-free-play-gt-5-deg-after-corrective-action{"<small><b>Step 34</b></small><br/>Question: Did the free play test fail 5 deg..."}
failure-friction-after-corrective-action{"<small><b>Step 35</b></small><br/>Question: Did the friction profile test fail? •..."}
scrap-part-after-friction-failure-after-corrective-action["<small><b>Step 36</b></small><br/>Action: Scrap the part."]
failure-sys-profile-after-corrective-action{"<small><b>Step 37</b></small><br/>Question: Did the system profile test fail? • c..."}
failure-analyze-data-after-corrective-action{"<small><b>Step 38</b></small><br/>Question: Did analyze_data fail? • control_surf..."}
raise-tqri-after-corrective-action["<small><b>Step 39</b></small><br/>Action: Raise a TQRI. Escalate to P2 FSE On C..."]
update-servo-in-eol-tester-after-retest["<small><b>Step 40</b></small><br/>Action: Update the servo in the EOL tester. 1..."]
replace-servo-linkage-assy-after-retest["<small><b>Step 41</b></small><br/>Action: Replace servo/linkage assembly. 85.1..."]
do-tail-eol-test-after-retest-diagnostics["<small><b>Step 42</b></small><br/>Action: Perform the tail EOL test. 85.1.3.g ..."]
does-eol-pass-after-retest-diagnostics{"<small><b>Step 43</b></small><br/>Question: Does the EOL pass?"}
place-tail-in-spares-after-retest-diagnostics["<small><b>Step 44</b></small><br/>Action: Place tail in spares."]
failure-rpc-or-boot-issues-after-retest-diagnostics{"<small><b>Step 45</b></small><br/>Question: Was the failure caused by RPC or boot..."}
inspect-servo-harness-and-m5-connector-after-retest-diagnostics{"<small><b>Step 46</b></small><br/>Question: Inspect the servo harness per 20.2.2..."}
failure-range-incorrect-after-retest-diagnostics{"<small><b>Step 47</b></small><br/>Question: Did either range test fail? • control..."}
failure-free-play-gt-5-deg-after-retest-diagnostics{"<small><b>Step 48</b></small><br/>Question: Did the free play test fail 5 deg..."}
failure-friction-after-retest-diagnostics{"<small><b>Step 49</b></small><br/>Question: Did the friction profile test fail? •..."}
scrap-part-after-friction-failure-after-retest-diagnostics["<small><b>Step 50</b></small><br/>Action: Scrap the part."]
failure-sys-profile-after-retest-diagnostics{"<small><b>Step 51</b></small><br/>Question: Did the system profile test fail? • c..."}
failure-analyze-data-after-retest-diagnostics{"<small><b>Step 52</b></small><br/>Question: Did analyze_data fail? • control_surf..."}
raise-tqri-after-retest-diagnostics["<small><b>Step 53</b></small><br/>Action: Raise a TQRI. Escalate to P2 FSE On C..."]
update-servo-in-eol-tester-repeat["<small><b>Step 54</b></small><br/>Action: Update the servo in the EOL tester. 1..."]
replace-servo-linkage-assy-repeat["<small><b>Step 55</b></small><br/>Action: Replace servo/linkage assembly. 85.1..."]
repeat-eol-failure-troubleshooting["<small><b>Step 56</b></small><br/>Action: Perform the tail EOL test again. If i..."]
ev3-do-an-eol-test{"<small><b>Step 57</b></small><br/>Question: Do an EOL test on the EV3 tail. What ..."}
ev3-replace-servo-gearbox-assembly["<small><b>Step 58</b></small><br/>Action: Remove and replace the servo gearbox ..."]
ev3-remove-gearbox-servo-assembly["<small><b>Step 59</b></small><br/>Action: Remove the gearbox servo assembly. Th..."]
ev3-is-there-still-binding{"<small><b>Step 60</b></small><br/>Question: Is there still binding after the gear..."}
ev3-control-surface-or-tail-body-rework["<small><b>Step 61</b></small><br/>Action: The binding is likely caused by the c..."]
ev3-replace-gearbox-assembly-after-binding-stops["<small><b>Step 62</b></small><br/>Action: If the binding stops once the gearbox..."]
ev3-rerun-eol-test["<small><b>Step 63</b></small><br/>Action: Re-run the EOL test. If it passes, re..."]
is-this-an-ev2-or-ev3-tail -->|EV2 tail| remove-tail-from-aircraft
is-this-an-ev2-or-ev3-tail -->|EV3 tail| ev3-do-an-eol-test
remove-tail-from-aircraft --> is-part-number-003-or-006
is-part-number-003-or-006 -->|Yes| scrap-part-ineligible-pn
is-part-number-003-or-006 -->|No| do-visual-inspection
do-visual-inspection --> is-there-structural-damage
is-there-structural-damage -->|Yes| is-damage-small-and-repairable
is-there-structural-damage -->|No| do-tail-eol-test
is-damage-small-and-repairable -->|Yes| raise-tqri-before-repair
is-damage-small-and-repairable -->|No| is-damage-to-spar-or-leading-edge
is-damage-to-spar-or-leading-edge -->|Yes| remove-and-salvage-servo-linkage
is-damage-to-spar-or-leading-edge -->|No| raise-tqri-for-structural-damage
remove-and-salvage-servo-linkage --> scrap-part-after-servo-salvage
raise-tqri-before-repair --> execute-repair
execute-repair --> do-tail-eol-test
do-tail-eol-test --> does-eol-pass
does-eol-pass -->|Yes| place-tail-in-spares
does-eol-pass -->|No| failure-rpc-or-boot-issues
failure-rpc-or-boot-issues -->|Yes| inspect-servo-harness-and-m5-connector
failure-rpc-or-boot-issues -->|No| failure-range-incorrect
inspect-servo-harness-and-m5-connector -->|Yes| replace-servo-linkage-assy
inspect-servo-harness-and-m5-connector -->|No| update-servo-in-eol-tester
failure-range-incorrect -->|Yes| replace-servo-linkage-assy
failure-range-incorrect -->|No| failure-free-play-gt-5-deg
failure-free-play-gt-5-deg -->|Yes| replace-servo-linkage-assy
failure-free-play-gt-5-deg -->|No| failure-friction
failure-friction -->|Yes| scrap-part-after-friction-failure
failure-friction -->|No| failure-sys-profile
failure-sys-profile -->|Yes| raise-tqri
failure-sys-profile -->|No| failure-analyze-data
failure-analyze-data -->|Yes| raise-tqri
failure-analyze-data -->|No| do-tail-eol-test-after-corrective-action
update-servo-in-eol-tester --> do-tail-eol-test-after-corrective-action
replace-servo-linkage-assy --> do-tail-eol-test-after-corrective-action
do-tail-eol-test-after-corrective-action --> does-eol-pass-after-corrective-action
does-eol-pass-after-corrective-action -->|Yes| place-tail-in-spares-after-corrective-action
does-eol-pass-after-corrective-action -->|No| failure-rpc-or-boot-issues-after-corrective-action
failure-rpc-or-boot-issues-after-corrective-action -->|Yes| inspect-servo-harness-and-m5-connector-after-corrective-action
failure-rpc-or-boot-issues-after-corrective-action -->|No| failure-range-incorrect-after-corrective-action
inspect-servo-harness-and-m5-connector-after-corrective-action -->|Yes| replace-servo-linkage-assy-after-retest
inspect-servo-harness-and-m5-connector-after-corrective-action -->|No| update-servo-in-eol-tester-after-retest
failure-range-incorrect-after-corrective-action -->|Yes| replace-servo-linkage-assy-after-retest
failure-range-incorrect-after-corrective-action -->|No| failure-free-play-gt-5-deg-after-corrective-action
failure-free-play-gt-5-deg-after-corrective-action -->|Yes| replace-servo-linkage-assy-after-retest
failure-free-play-gt-5-deg-after-corrective-action -->|No| failure-friction-after-corrective-action
failure-friction-after-corrective-action -->|Yes| scrap-part-after-friction-failure-after-corrective-action
failure-friction-after-corrective-action -->|No| failure-sys-profile-after-corrective-action
failure-sys-profile-after-corrective-action -->|Yes| raise-tqri-after-corrective-action
failure-sys-profile-after-corrective-action -->|No| failure-analyze-data-after-corrective-action
failure-analyze-data-after-corrective-action -->|Yes| raise-tqri-after-corrective-action
failure-analyze-data-after-corrective-action -->|No| do-tail-eol-test-after-retest-diagnostics
update-servo-in-eol-tester-after-retest --> do-tail-eol-test-after-retest-diagnostics
replace-servo-linkage-assy-after-retest --> do-tail-eol-test-after-retest-diagnostics
do-tail-eol-test-after-retest-diagnostics --> does-eol-pass-after-retest-diagnostics
does-eol-pass-after-retest-diagnostics -->|Yes| place-tail-in-spares-after-retest-diagnostics
does-eol-pass-after-retest-diagnostics -->|No| failure-rpc-or-boot-issues-after-retest-diagnostics
failure-rpc-or-boot-issues-after-retest-diagnostics -->|Yes| inspect-servo-harness-and-m5-connector-after-retest-diagnostics
failure-rpc-or-boot-issues-after-retest-diagnostics -->|No| failure-range-incorrect-after-retest-diagnostics
inspect-servo-harness-and-m5-connector-after-retest-diagnostics -->|Yes| replace-servo-linkage-assy-repeat
inspect-servo-harness-and-m5-connector-after-retest-diagnostics -->|No| update-servo-in-eol-tester-repeat
failure-range-incorrect-after-retest-diagnostics -->|Yes| replace-servo-linkage-assy-repeat
failure-range-incorrect-after-retest-diagnostics -->|No| failure-free-play-gt-5-deg-after-retest-diagnostics
failure-free-play-gt-5-deg-after-retest-diagnostics -->|Yes| replace-servo-linkage-assy-repeat
failure-free-play-gt-5-deg-after-retest-diagnostics -->|No| failure-friction-after-retest-diagnostics
failure-friction-after-retest-diagnostics -->|Yes| scrap-part-after-friction-failure-after-retest-diagnostics
failure-friction-after-retest-diagnostics -->|No| failure-sys-profile-after-retest-diagnostics
failure-sys-profile-after-retest-diagnostics -->|Yes| raise-tqri-after-retest-diagnostics
failure-sys-profile-after-retest-diagnostics -->|No| failure-analyze-data-after-retest-diagnostics
failure-analyze-data-after-retest-diagnostics -->|Yes| raise-tqri-after-retest-diagnostics
failure-analyze-data-after-retest-diagnostics -->|No| repeat-eol-failure-troubleshooting
update-servo-in-eol-tester-repeat --> repeat-eol-failure-troubleshooting
replace-servo-linkage-assy-repeat --> repeat-eol-failure-troubleshooting
ev3-do-an-eol-test -->|Free-play| ev3-replace-servo-gearbox-assembly
ev3-do-an-eol-test -->|Range or binding| ev3-remove-gearbox-servo-assembly
ev3-replace-servo-gearbox-assembly --> ev3-rerun-eol-test
ev3-remove-gearbox-servo-assembly --> ev3-is-there-still-binding
ev3-is-there-still-binding -->|Yes| ev3-control-surface-or-tail-body-rework
ev3-is-there-still-binding -->|No| ev3-replace-gearbox-assembly-after-binding-stops
ev3-replace-gearbox-assembly-after-binding-stops --> ev3-rerun-eol-test
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style ev3-rerun-eol-test fill:#dcfce7,stroke:#22c55e,color:#14532d Hover or focus a block to preview it. Select the block to keep the preview open.
1 question
Is this an EV2 or EV3 tail?
2 action
Remove the tail from the aircraft per 85.1.3.d Remove Tail Assembly.
3 question
Is the tail part number -003, -006, -009? (These tails are not qualified for fixed-wing flight)
4 action
Scrap the part.
5 action
Do a visual inspection per 85.1.1 Tail Allowable Damage Limitations.
6 question
Is there damage to the structure?
7 question
Is the damage small and repairable?
• Is the damage a crack that is less than 2.5 cm (1.0 in) or smaller? And/Or
• Is the damage surface damage or delamination damage to the trailing edge? And/Or
• Is the damage to paint or surface protection?
• Is the damage a crack that is less than 2.5 cm (1.0 in) or smaller? And/Or
• Is the damage surface damage or delamination damage to the trailing edge? And/Or
• Is the damage to paint or surface protection?
8 question
Is the damage to the spar or leading edge?
9 action
Remove and salvage servo/linkage assembly. 85.1.3.f Remove Tail Servo Motor
10 action
Scrap the part.
11 action
Raise a TQRI. Escalate to P2 FSE On Call (@p2-fse-on-call).
12 action
Raise a TQRI. Escalate to P2 FSE On Call (@p2-fse-on-call).
13 action
Execute the repair.
14 action
Perform the tail EOL test. 85.1.3.g Install Tail Servo Motor
15 question
Does the EOL pass?
16 action
Place tail in spares.
17 question
Was the failure caused by RPC or boot issues?
18 question
Inspect the servo harness per 20.2.2.c Inspect Wire Harness, and/or inspect the M5 connector per 51.1.2.a Inspect M5 Connector - Issues to Look For. Is the harness damaged?
19 question
Did either range test fail?
• control_surface_check.control_surface_tester.run_range_test
• control_surface_check.control_surface_tester.run_over_range_test
• control_surface_check.control_surface_tester.run_range_test
• control_surface_check.control_surface_tester.run_over_range_test
20 question
Did the free play test fail (> 5 deg)?
• control_surface_check.control_surface_tester.run_freeplay_test
• control_surface_check.control_surface_tester.run_freeplay_test
21 question
Did the friction profile test fail?
• control_surface_check.control_surface_tester.run_friction_profile
• control_surface_check.control_surface_tester.run_friction_profile
22 action
Scrap the part.
23 question
Did the system profile test fail?
• control_surface_check.control_surface_tester.run_sys_profile
• control_surface_check.control_surface_tester.run_sys_profile
24 question
Did analyze_data fail?
• control_surface_check.control_surface_tester.analyze_data
• control_surface_check.control_surface_tester.analyze_data
25 action
Raise a TQRI. Escalate to P2 FSE On Call (@p2-fse-on-call).
26 action
Update the servo in the EOL tester. 1. Run
sudo apt update. 2. Set firmware_update to yes before you start the test. If the test fails two times, replace the servo/linkage assembly and then perform the tail EOL test again. 27 action
Replace servo/linkage assembly. 85.1.3.f Remove Tail Servo Motor and 85.1.3.g Install Tail Servo Motor
28 action
Perform the tail EOL test. 85.1.3.g Install Tail Servo Motor
29 question
Does the EOL pass?
30 action
Place tail in spares.
31 question
Was the failure caused by RPC or boot issues?
32 question
Inspect the servo harness per 20.2.2.c Inspect Wire Harness, and/or inspect the M5 connector per 51.1.2.a Inspect M5 Connector - Issues to Look For. Is the harness damaged?
33 question
Did either range test fail?
• control_surface_check.control_surface_tester.run_range_test
• control_surface_check.control_surface_tester.run_over_range_test
• control_surface_check.control_surface_tester.run_range_test
• control_surface_check.control_surface_tester.run_over_range_test
34 question
Did the free play test fail (> 5 deg)?
• control_surface_check.control_surface_tester.run_freeplay_test
• control_surface_check.control_surface_tester.run_freeplay_test
35 question
Did the friction profile test fail?
• control_surface_check.control_surface_tester.run_friction_profile
• control_surface_check.control_surface_tester.run_friction_profile
36 action
Scrap the part.
37 question
Did the system profile test fail?
• control_surface_check.control_surface_tester.run_sys_profile
• control_surface_check.control_surface_tester.run_sys_profile
38 question
Did analyze_data fail?
• control_surface_check.control_surface_tester.analyze_data
• control_surface_check.control_surface_tester.analyze_data
39 action
Raise a TQRI. Escalate to P2 FSE On Call (@p2-fse-on-call).
40 action
Update the servo in the EOL tester. 1. Run
sudo apt update. 2. Set firmware_update to yes before you start the test. If the test fails two times, replace the servo/linkage assembly and then perform the tail EOL test again. 41 action
Replace servo/linkage assembly. 85.1.3.f Remove Tail Servo Motor and 85.1.3.g Install Tail Servo Motor
42 action
Perform the tail EOL test. 85.1.3.g Install Tail Servo Motor
43 question
Does the EOL pass?
44 action
Place tail in spares.
45 question
Was the failure caused by RPC or boot issues?
46 question
Inspect the servo harness per 20.2.2.c Inspect Wire Harness, and/or inspect the M5 connector per 51.1.2.a Inspect M5 Connector - Issues to Look For. Is the harness damaged?
47 question
Did either range test fail?
• control_surface_check.control_surface_tester.run_range_test
• control_surface_check.control_surface_tester.run_over_range_test
• control_surface_check.control_surface_tester.run_range_test
• control_surface_check.control_surface_tester.run_over_range_test
48 question
Did the free play test fail (> 5 deg)?
• control_surface_check.control_surface_tester.run_freeplay_test
• control_surface_check.control_surface_tester.run_freeplay_test
49 question
Did the friction profile test fail?
• control_surface_check.control_surface_tester.run_friction_profile
• control_surface_check.control_surface_tester.run_friction_profile
50 action
Scrap the part.
51 question
Did the system profile test fail?
• control_surface_check.control_surface_tester.run_sys_profile
• control_surface_check.control_surface_tester.run_sys_profile
52 question
Did analyze_data fail?
• control_surface_check.control_surface_tester.analyze_data
• control_surface_check.control_surface_tester.analyze_data
53 action
Raise a TQRI. Escalate to P2 FSE On Call (@p2-fse-on-call).
54 action
Update the servo in the EOL tester. 1. Run
sudo apt update. 2. Set firmware_update to yes before you start the test. If the test fails two times, replace the servo/linkage assembly and then perform the tail EOL test again. 55 action
Replace servo/linkage assembly. 85.1.3.f Remove Tail Servo Motor and 85.1.3.g Install Tail Servo Motor
56 action
Perform the tail EOL test again. If it fails again, repeat the EOL failure checks in this order using the latest failure: RPC or boot issues, range test, free play, friction profile, system profile, and analyze_data. Apply the same corrective action or disposition for the failed test, then perform the tail EOL test again.
57 question
Do an EOL test on the EV3 tail. What failed?
58 action
Remove and replace the servo gearbox assembly per UMM Draft EV3 57 Replace Tail Assembly Gearbox Servo Assembly.
59 action
Remove the gearbox servo assembly. Then attempt to actuate the control surface.
60 question
Is there still binding after the gearbox servo assembly is removed?
61 action
The binding is likely caused by the control surface or tail body tolerance. Repair through rework, then re-run the EOL test before returning the tail to spares.
62 action
If the binding stops once the gearbox is removed, replace the gearbox assembly.
63 action
Re-run the EOL test. If it passes, return the tail to spares as a serviceable part.
Resolution note
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