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Commercial Airplanes 767 Service Bulletin Number: 767-53A0100 Original Issue: September 26, 2002 Revision 3: February 06, 2012 ATA System: 5350 SUBJECT: FUSELAGE - Section 45 - STA 955 Rear Spar Bulkhead Side Fittings - Fail-safe Strap
- Inspection 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BOEING PROPRIETARY, CONFIDENTIAL, AND/OR TRADE SECRET Copyright © 2002 The Boeing Company Unpublished Work - All Rights Reserved Boeing claims copyright in each page of this document only to the extent that the page contains copyrightable subject matter.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.
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Original Issue: September 26, 2002 767-53A0100Revision 3: February 06, 2012 1 of 309
4.0
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Original Issue: September 26, 2002 767-53A0100Revision 3: February 06, 2012 2 of 309 BOEING SERVICE BULLETIN 767-53A0100
BLANK PAGE
Table of Contents
Revision Transmittal Sheet5
Summary7
1. PLANNING INFORMATION ........................................ 1 1 A. Effectivity ............................................... 1 1
1. Airplanes ............................................ 1 1
2. Spares Affected ........................................ 1 8 B. Concurrent Requirements ...................................... 1 8 C. Reason ................................................ 1 8 D. Description .............................................. 2 0 E. Compliance .............................................. 2 1 F. Approval ............................................... 2 3 G. Manpower .............................................. 2 4 H. Weight and Balance Changes .................................... 2 5 I. Electrical Load Data ......................................... 2 5 J. References .............................................. 2 5
1. Existing Data: ......................................... 2 5
2. Data supplied with this Service Bulletin: ........................... 2 6
3. Installation Drawings Used in the Preparation of this Service Bulletin: ........... 2 6 K. Publications Affected ........................................ 2 7 L. Interchangeability and Intermixability of Parts ........................... 2 7
2. MATERIAL INFORMATION ........................................ 2 9 A. Material - Price and Availability ................................... 2 9 B. Industry Support Information .................................... 3 2 C. Parts Necessary For Each Airplane ................................. 3 2
1. Kits/Parts: ........................................... 3 2
2. Parts and Materials Supplied by the Operator: ........................ 5 1
3. Parts Modified and Reidentified: ............................... 5 2
4. Parts Removed and Not Replaced: .............................. 5 2 D. Parts Necessary to Change Spares ................................. 5 2 E. Special Tooling - Price and Availability ............................... 5 2 F. Special Tooling Necessary to do this Service Bulletin ....................... 5 2
3. ACCOMPLISHMENT INSTRUCTIONS .................................. 5 3 A. GENERAL INFORMATION ..................................... 5 3 B. WORK INSTRUCTIONS ....................................... 5 4 FIGURE 1: LOGIC DIAGRAM (DELETED) ................................ 6 1 FIGURE 2: STA 955 FAIL-SAFE STRAP INSPECTION ......................... 6 2 FIGURE 3: FASTENER/PART REMOVE/REPLACE - GROUP 1 AIRPLANES - LEFT SIDE [Group 1] . 64 FIGURE 4: FASTENER/PART REMOVE/REPLACE - GROUP 1 AIRPLANES - RIGHT SIDE [Group 1] . 73 FIGURE 5: FASTENER/PART REMOVE/REPLACE - GROUP 2, 3, 10 AIRPLANES - LEFT SIDE [Group 2-3, 10] ............................................. 8 2 FIGURE 6: FASTENER/PART REMOVE/REPLACE- GROUP 2, 3, 10 AIRPLANES - RIGHT SIDE [Group 2-3, 10] ............................................. 9 2 FIGURE 7: FASTENER/PART REMOVE/REPLACE- GROUP 4, 7 AIRPLANES - LEFT SIDE [Group 4, 7] ................................................. 1 0 2 FIGURE 8: FASTENER/PART REMOVE/REPLACE- GROUP 4, 7 AIRPLANES - RIGHT SIDE [Group 4, 7 ] ................................................ 1 1 2
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FIGURE 9: FASTENER/PART REMOVE/REPLACE- GROUP 5 AIRPLANES - LEFT SIDE [Group 5] . 122 FIGURE 10: FASTENER/PART REMOVE/REPLACE - GROUP 5 AIRPLANES - RIGHT SIDE [Group 5] . 133 FIGURE 11: FASTENER/PART REMOVE/REPLACE- GROUP 6, 11 AIRPLANES - LEFT SIDE [Group 6, 11] ............................................... 1 4 4 FIGURE 12: FASTENER/PART REMOVE/REPLACE - GROUP 6, 11 AIRPLANES - RIGHT SIDE [Group 6, 11] ............................................... 1 5 5 FIGURE 13: TUBING - REMOVE/REPLACE - LEFT SIDE - GROUP 1-7, 10, 11 AIRPLANES [Group 1-7, 10-11] ............................................. 1 6 6 FIGURE 14: TUBING - REMOVE/REPLACE - RIGHT SIDE - GROUP 1-7, 10, 11 AIRPLANES [Group 1-7, 10-11] ............................................. 1 6 9 FIGURE 15: FAIL-SAFE STRAP REPAIR/MODIFICATION ....................... 1 7 2 FIGURE 16: FASTENER/PART REMOVE/REPLACE- GROUP 8 - LEFT SIDE [Group 8] ....... 1 7 7 FIGURE 17: FASTENER/PART REMOVE/REPLACE- GROUP 8 - RIGHT SIDE [Group 8] ...... 1 8 7 FIGURE 18: FASTENER/PART REMOVE/REPLACE- GROUP 9 - LEFT SIDE [Group 9] ....... 1 9 7 FIGURE 19: FASTENER/PART REMOVE/REPLACE - GROUP 9 - RIGHT SIDE [Group 9] ...... 2 0 8 FIGURE 20: TUBING - REMOVE/REPLACE - GROUP 8, 9 - LEFT SIDE [Group 8-9] ......... 2 1 9 FIGURE 21: TUBING - REMOVE/REPLACE - GROUP 8, 9 - RIGHT SIDE [Group 8-9] ........ 2 2 3 FIGURE 22: JACK AND SUPPORT WORK - GROUP 1, 2, 5, 10 AIRPLANES [Group 1, Configuration 1;
Group 2, 5, 10] ........................................ 2 2 6 FIGURE 23: JACK AND SUPPORT WORK - GROUP 3, 4, 6 AIRPLANES [Group 3; Group 4, Configuration 1; Group 6] .......................................... 2 2 9 FIGURE 24: JACK AND SUPPORT WORK - GROUP 8,9 AIRPLANES [Group 8-9] .......... 2 3 2 FIGURE 25: ACCESS AT WING/BODY INTERFACE - LEFT SIDE - GROUP 1-7, 10, 11 AIRPLANES [Group 1-7, 10-11] ........................................... 2 3 5 FIGURE 26: ACCESS AT WING/BODY INTERFACE - RIGHT SIDE - GROUP 1-7, 10, 11 AIRPLANES [Group 1-7, 10-11] ....................................... 2 3 9 FIGURE 27: ACCESS AT WING/BODY INTERFACE - LEFT SIDE - GROUP 8, 9 AIRPLANES [Group 8-9] ................................................. 2 4 3 FIGURE 28: ACCESS AT WING/BODY INTERFACE - RIGHT SIDE - GROUP 8, 9 AIRPLANES [Group 8-9] ................................................. 2 4 7 FIGURE 29: ACCESS AT WHEEL WELL/PRESSURE DECK - LEFT SIDE ............... 2 5 1 FIGURE 30: ACCESS AT WHEEL WELL/PRESSURE DECK - RIGHT SIDE .............. 2 5 7 FIGURE 31: AILERON CONTROL CABLE PULL/STOW - LEFT SIDE ................. 2 6 3 FIGURE 32: AILERON CONTROL CABLE PULL/STOW - RIGHT SIDE ................ 2 6 7 FIGURE 33: AILERON CONTROL CABLE RESTORE - LEFT SIDE ................... 2 7 2 FIGURE 34: AILERON CONTROL CABLE RESTORE - RIGHT SIDE .................. 2 7 6 FIGURE 35: PRESSURE DECK RESTORE - LEFT SIDE ........................ 2 8 1 FIGURE 36: PRESSURE DECK RESTORE - RIGHT SIDE ....................... 2 8 8 FIGURE 37: SKIN PANEL REPAIR - REMOVAL OF FRETTING AND/OR CORROSION ....... 2 9 5 FIGURE 38: SKIN PANEL REPAIR - MAKE/ASSEMBLE PARTS .................... 3 0 1 FIGURE 39: JACK AND SUPPORT WORK - GROUP 7, 11 AIRPLANES [Group 7, 11] ........ 3 0 7
BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: September 26, 2002 767-53A0100Revision 3: February 06, 2012 4 of 309 BOEING SERVICE BULLETIN 767-53A0100
Commercial Airplanes 767 Service Bulletin Revision Transmittal SheetNumber: 767-53A0100Original Issue: September 26, 2002 Revision 3: February 06, 2012 ATA System: 5350 SUBJECT: FUSELAGE - Section 45 - STA 955 Rear Spar Bulkhead Side Fittings - Fail-safe Strap
- Inspection This revision includes all pages of the service bulletin.
COMPLIANCE INFORMATION RELATED TO THIS REVISION No more work is necessary on the airplane(s) changed in accordance with Revision 2 of this service bulletin.
Federal Aviation Administration (FAA) Airworthiness Directive 2004-19-06 R1 is related to this service bulletin.
REASON FOR REVISION This revision is sent to give less restrictive instruction for the access and restore work associated with the repair/modification given in this service bulletin. This revision is also sent to make the work instruction more clear.
These sections were changed:
1. Paragraph 1.C., Reason: Updated service history.
2. Paragraph 1.D., Description: Added maintenance zone data.
3. Paragraph 1.E., Compliance: Added statement regarding a possible new AD due to existing AD worksheet.
4. Paragraph 3.A., General Information: Added notes numbered 5, 9-13. Note 11 is added to give flexibility regarding access work.
5. Paragraph 3.B., Work Instructions: Added note to steps 9-12, 23, 24, 26 to give flexibility regarding the sequence of work.
6. Figure 15: Added a note to the step table to clarify the necessary work when the trim modification is accomplished on a crack-free strap.
7. Figures 22-24, 39: Changed instruction to recommend (vs. require) that all jacks be locked by mechanical means.
8. Figure 25-28: Changed the reference given for the installation and check of the bonding fastener. Also added alternative fastener data in fastener table.
9. Figure 28: Added a fastener code (B) that was inadvertantly omitted from sheet 1 graphic.
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Original Issue: September 26, 2002 767-53A0100Revision 3: February 06, 2012 5 of 309
10. Figure 29, 30: Revised sheet 3 graphic to give a more accurate depiction.
11. Figure 32, 34: Revised cable identification labels on sheet 2, 3 graphics.
12. Figure 35,36: Revised sheet 3 graphic to give a more accurate depiction.
13. Figure 37: Changed skin thickness allowable for group 5 airplanes from 0.360 to 0.324 in.
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 September 26, 2002Original Issue:
August 11, 2006Revision 1:
January 15, 2010Revision 2:
February 06, 2012Revision 3:
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Original Issue: September 26, 2002 767-53A0100Revision 3: February 06, 2012 6 of 309 BOEING SERVICE BULLETIN 767-53A0100
Commercial Airplanes 767 Service Bulletin SummaryNumber: 767-53A0100Original Issue: September 26, 2002 Revision 3: February 06, 2012 ATA System: 5350 SUBJECT: FUSELAGE - Section 45 - STA 955 Rear Spar Bulkhead Side Fittings - Fail-safe Strap
- Inspection
CONCURRENT REQUIREMENTS None.
BACKGROUND The inspections specified in this service bulletin are necessary to make sure that cracks and/or corrosion in a fail-safe strap will be found and repaired before the damage can have an effect on flight safety. The fail-safe strap is held/attached between the rear spar bulkhead side fitting and the body skin at body station 955 on both sides of the airplane. If the airplane is operated with a crack and/or corrosion in the fail-safe strap, a difficult repair that requires removal of the fail-safe strap could become necessary. Also, the damage in the strap could cause cracks in the body skin and other adjacent structure which then could be unable to sustain regulatory loads, possibly resulting in a loss of structural integrity.
It is anticipated that cracks and/or corrosion in the fail-safe strap will be found with the inspections given in this service bulletin before there is damage in the body skin and other adjacent structure, and before it is necessary to replace the strap. The repair specified in this service bulletin requires only a fraction of the work and down time required to replace the fail-safe strap.
Before the release of revision 1 of this service bulletin there were ten reports of cracks and/or corrosion in the fail-safe strap on nine airplanes as shown in the table below. All but one of the damaged fail-safe straps were replaced. One fail-safe strap was repaired with the trim-out repair given in this service bulletin.
CommentsDamageFlight HoursFlight Cycles Straps had extreme corrosion.Corrosion left and right side, cracks left and right side.
37,63413,472 Crack may have started from damage in strap surface.
Crack left side.55,60916,403 Crack started at area of small gouging and fretting on strap surface.
Crack left side.72,70618,061 Strap had extreme corrosionCorrosion on left side71,64315,694 Fastener hole elongationCorrosion and cracks right side62,36018,545 Strap had extreme corrosionCorrosion on left side63,54923,337
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Original Issue: September 26, 2002 767-53A0100Revision 3: February 06, 2012 7 of 309
CommentsDamageFlight HoursFlight Cycles Strap had extreme corrosionCorrosion on right side74,82323,987 Fretting, fastener hole elongationCrack right side66,46731,809 Strap repaired with trim-out repair given in this service bulletin.
Crack right side51,12936,635 Crack growth in the fail-safe strap is not due to classical tensile fatigue. Boeing has found that the fatigue is due to residual tension in the fail-safe strap. This tension is from locally high compressive stress yielding the part.
The fatigue occurs when the yielded section of the fail-safe strap repeatedly goes through cyclic loading. The 767 fatigue test aircraft was tested for 100,000 flight cycles and cracks were found in the fail-safe strap on both the right and left sides of the test airplane.
At the release of revision 2 of this service bulletin, cracks have been found in 51 fail-safe straps on 41 airplanes.
Of these cases, 42 fail-safe straps were repaired in accordance with this service bulletin and nine fail-safe straps were not repairable and were replaced. Fail-safe straps were repaired on 33 airplanes with flight-cycles ranging from 9,250 to 38,490 and flight-hours ranging from 39,886 to 89,236. Fail-safe straps were replaced on nine airplanes with flight-cycles ranging from 12,565 to 31,809 and flight-hours ranging from 48,704 to 93,212. Also, four fail-safe straps have been replaced due to corrosion damage only (no cracks) on four airplanes with flight-cycles ranging from 12,540 to 23,987 and flight-hours ranging from 37,634 to 74,823.
At the release of revision 2 of this service bulletin, there has also been one report of a crack found in the "T" fitting which connects the fail-safe strap and the pressure deck. The cracked "T" fitting was found at 13,449 flight-cycles / 74,008 flight-hours and the crack was located at the lower of the three fastener holes common to the fail-safe strap. As a result of this finding, instruction to do an open hole HFEC inspection of the "T" fitting has been added to this service bulletin.
As of the release of revision 3 of this service bulletin, cracks have been found in 108 fail-safe straps on 79 airplanes. Of these cases, 94 fail-safe straps were repaired in accordance with this service bulletin and 14 fail-safe straps were not repairable and were replaced. Fail-safe straps have been repaired on airplanes with flight-cycles ranging from 8,214 to 41,120, and fail-safe straps have been replaced on 14 airplanes with flight-cycles ranging from 12,565 to 40,421. Also, seven fail-safe straps have been replaced due to corrosion damage only (no cracks) on seven airplanes with flight-cycles ranging from 12,540 to 25, 867. Also, two fail-safe straps have been repaired (in place) to remove corrosion from the tab area.
See Boeing Fleet Team Digest Article Number 767-FTD-53-02004 for pictures and more information of cracks that have been found in-service on the fail-safe strap.
Boeing Service Related Problem (SRP) 767-SRP-53-0180 is related to this service bulletin.
Boeing Structural Item Interim Advisory (SIIA) 767-21 is related to this service bulletin.
The Federal Aviation Administration (FAA) has issued an Airworthiness Directive (AD) which requires incorporation of this service bulletin for group 1-7, 10, 11 airplanes.
ACTION (PRR B12901-63S) A detailed and HFEC inspection for corrosion and crack damage are to be done over the visible surface of the fail-safe strap on each side of the airplane. Also, an ultrasonic inspection is to be done to find if there is a crack in the area of the fail-safe strap under (covered by) the "T" fitting which is connected to the fail-safe strap and to the outboard edge of the sloping pressure deck.
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Original Issue: September 26, 2002 767-53A0100Revision 3: February 06, 2012 8 of 309 BOEING SERVICE BULLETIN 767-53A0100
If no corrosion or cracks are found with the inspections, repeat inspections are to be made at regular intervals.
If cracks and/or corrosion are found, a repair must be made before more flights. If crack damage has not extended outside the tab part of the strap where the "T" fitting is attached, the fail-safe strap repair given in this service bulletin is to be made. If crack damage extends outside the specified area, it will be necessary to replace the strap. Boeing plans to release service bulletin 767-53-0116 at a later date with instructions to install a replacement strap.
NOTE: The change made to the airplane with the fail-safe strap repair given in this service bulletin can be made at any time to end the need for more inspections per this service bulletin at the side of the airplane that has the repair.
EFFECTIVITY 767-200/-300/-300F/-400ER airplanes. Refer to paragraph 1.A.1 for effectivity.
COMPLIANCE Federal Aviation Administration (FAA) Airworthiness Directive 2004-19-06 R1 is related to this service bulletin.
The Federal Aviation Administration (FAA) will possibly release a new Airworthiness Directive related to this service bulletin. The Airworthiness Directive will make the compliance tasks and times given in this service bulletin mandatory for all the airplanes affected by this service bulletin.
Refer to Paragraph 1.E., Compliance.
INDUSTRY SUPPORT INFORMATION Boeing warranty remedies are not available for the inspection given in this service bulletin.
MANPOWER Elapsed HoursTotal Task HoursAirplanes
2.04.0Group 1-10 Elapsed HoursTotal Task HoursAirplanes 85295Group 1-7, 10 86297Group 8, 9
MATERIAL INFORMATION Boeing Supplied Kits/Parts.
Refer to Paragraph 2.A., Material - Price and Availability.
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Original Issue: September 26, 2002 767-53A0100Revision 3: February 06, 2012 9 of 309 BOEING SERVICE BULLETIN 767-53A0100
BOEING SERVICE BULLETIN 767-53A0100 STA 955
FAILSAFE STRAP
T-FITTING REAR SPAR
BULKHEAD
FITTING SEE
DO ULTRASONIC INSPECTION OF
THE AREA OF THE FAILSAFE
STRAP UNDER THE T-FITTING
INSPECTION AREA
T- FITTING , FWD
TYPICAL CRACK
IN FAILSAFE
LEFT SIDE SHOWN, STRAP
RIGHT SIDE OPPOSITE
DO A DETAILED INSPECTION AND A SURFACE HFEC INSPECTION OF TYPICAL V88417
ACCESSABLE AREAS OF FAILSAFE STRAP CORROSION Original Issue: September 26, 2002 Revision 3: February 06, 2012 BOEING PROPRIETARY - 767-53A0100 Copyright © Unpublished Work - See page 1 for details. 10 of 309
Commercial Airplanes 767 Service Bulletin Number: 767-53A0100 Original Issue: September 26, 2002 Revision 3: February 06, 2012 ATA System: 5350 SUBJECT: FUSELAGE - Section 45 - STA 955 Rear Spar Bulkhead Side Fittings - Fail-safe Strap
- Inspection
1. PLANNING INFORMATION A. Effectivity
1. Airplanes Refer to Service Bulletin Index Document D624T001 Part 3 for Airplane Variable Number, Line Number, and Serial Number data.
This service bulletin is for the airplanes shown below. An equivalent change is on subsequent production airplanes. Refer to PRR B12901-63S for data about this change.
DESCRIPTIONCONFIGURATIONGROUP 767-200 with longeron splice installation 145T0083-7/-8, -9/-10, -11/-12 -1 Not modified to Boeing Approved Special Freighter configuration1 767-200 with longeron splice installation 145T0083-11/-12 and Special Freighter modification which is given in Boeing service bulletin 767-53-0125 and is applicable to VA511 only 2 767-200 with longeron splice installation 145T0083-19/-20-2 767-300 with longeron splice installation 145T0083-13/-14-3
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Original Issue: September 26, 2002 767-53A0100Revision 3: February 06, 2012 11 of 309
DESCRIPTIONCONFIGURATIONGROUP 767-300 with longeron splice installation 145T0083-21/-22, -25/-26, -33/-34 -4 Not modified to Boeing Converted Freighter (BCF) configuration1 Longeron splice installation 145T0083-21/-22 and BCF modification which is given in Boeing service bulletin 767-53-0140 and is applicable to VN191 only 2 Longeron splice installation 145T0083-21/-22 and BCF modification which is given in Boeing service bulletin 767-53-0148 and is applicable to VN192 only 3 Longeron splice installation 145T0083-21/-22 and BCF modification which is given in Boeing service bulletin 767-53-0150 and is applicable to VN 193 only 4 Longeron splice installation 145T0083-21/-22 and BCF modification which is given in Boeing service bulletin 767-53-0154 and is applicable to VN194 only 5 Longeron splice installation 145T0083-21/-22 and BCF modification which is given in Boeing service bulletin 767-53-0157 and is applicable to VN195 - VN197 only 6 767-200 with longeron splice installation 145T0083-41/-42-5 767-300 with longeron splice installation 145T0083-45/-46, -47/-48-6 767-300F with longeron splice installation 145T0083-25/-26, -27/-28, -37/-38 -7 767-400ER with longeron splice installation 145T0083-31/-32-8 767-400ER with longeron splice installation 145T0083-43/-44-9 767-200 with longeron splice installation 145T0083-13/-14-10 767-300F with longeron splice installation 145T0083-49/-50-11 Airplane Models:
767-200, 767-300, 767-300F, 767-400ER GroupVariable Number 1VA001 - VA020 1VA301 - VA315
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Original Issue: September 26, 2002 767-53A0100Revision 3: February 06, 2012 12 of 309 BOEING SERVICE BULLETIN 767-53A0100