Boeing ASB 767-53A0131: Revision 1, text

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Commercial Airplanes 767 Service Bulletin ALERT Number: 767-53A0131 Original Issue: March 30, 2006 Revision 1: March 12, 2009 ATA System: 5383 5385 SUBJECT: FUSELAGE - Section 48 - Main Frame and Skins - STA 1809.5 Bulkhead - Forward Outer Chord, Horizontal and Vertical Inner Chord, and External Skin - 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BOEING PROPRIETARY, CONFIDENTIAL, AND/OR TRADE SECRET Copyright © 2006 The Boeing Company Unpublished Work - All Rights Reserved Boeing claims copyright in each page of this document only to the extent that the page contains copyrightable subject matter.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, 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.

Original Issue: March 30, 2006 767-53A0131Revision 1: March 12, 2009 1 of 52

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Original Issue: March 30, 2006 767-53A0131Revision 1: March 12, 2009 2 of 52 BOEING SERVICE BULLETIN 767-53A0131

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Table of Contents

Revision Transmittal Sheet5

Summary7

1. PLANNING INFORMATION ........................................ 1 1 A. Effectivity ............................................... 1 1

1. Airplanes ............................................ 1 1

2. Spares Affected ........................................ 1 7 B. Concurrent Requirements ...................................... 1 7 C. Reason ................................................ 1 7 D. Description .............................................. 1 8 E. Compliance .............................................. 1 9 F . Approval ............................................... 2 1 G. Manpower .............................................. 2 2 H. Weight and Balance Changes .................................... 2 2 I. Electrical Load Data ......................................... 2 3 J. References .............................................. 2 3

1. Existing Data: .......................................... 2 3

2. Data supplied with this Service Bulletin: ........................... 2 3

3. Installation Drawings Used in the Preparation of this Service Bulletin: ........... 2 3 K. Publications Affected ......................................... 2 4 L. Interchangeability and Intermixability of Parts ........................... 2 4

2. MATERIAL INFORMATION ........................................ 2 5 A. Material - Price and Availability ................................... 2 5 B. Industry Support Information .................................... 2 5 C. Parts Necessary For Each Airplane ................................. 2 5

1. Kits/Parts: ............................................ 2 5

2. Parts and Materials Supplied by the Operator: ........................ 2 5

3. Parts Modified and Reidentified: ................................ 2 5

4. Parts Removed and Not Replaced: .............................. 2 5 D. Parts Necessary to Change Spares ................................. 2 5 E. Special Tooling - Price and Availability ............................... 2 5 F . Special Tooling Necessary to do this Service Bulletin ....................... 2 5

3. ACCOMPLISHMENT INSTRUCTIONS .................................. 2 7 A. GENERAL INFORMATION ..................................... 2 7 B. WORK INSTRUCTIONS ....................................... 2 7 FIGURE 1: DETAILED INSPECTION OF SKIN (EXTERNAL) - STA 1809.5 - LEFT SIDE ....... 3 1 FIGURE 2: DETAILED INSPECTION OF SKIN (EXTERNAL) - STA 1809.5 - RIGHT SIDE ....... 3 3 FIGURE 3: DET AILED AND SURFACE HFEC INSPECTIONS OF FORWARD OUTER CHORD (INTERNAL)

- LEFT SIDE .......................................... 3 5 FIGURE 4: DET AILED AND SURFACE HFEC INSPECTIONS OF FORWARD OUTER CHORD (INTERNAL)

- RIGHT SIDE ......................................... 3 8 FIGURE 5: DETAILED AND SURFACE HFEC INSPECTIONS OF HORIZONTAL INNER CHORD (INTERNAL) - LEFT SIDE ................................... 4 1 FIGURE 6: DETAILED AND SURFACE HFEC INSPECTIONS OF HORIZONTAL INNER CHORD (INTERNAL) - RIGHT SIDE .................................. 4 4 FIGURE 7: DETAILED AND SURFACE HFEC INSPECTIONS OF VERTICAL INNER CHORD (INTERNAL)

Original Issue: March 30, 2006 767-53A0131Revision 1: March 12, 2009 3 of 52 BOEING SERVICE BULLETIN 767-53A0131

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FIGURE 8: DETAILED AND SURFACE HFEC INSPECTIONS OF VERTICAL INNER CHORD (INTERNAL)

Original Issue: March 30, 2006 767-53A0131Revision 1: March 12, 2009 4 of 52 BOEING SERVICE BULLETIN 767-53A0131

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Commercial Airplanes 767 Service Bulletin ALERT Revision Transmittal SheetNumber: 767-53A0131Original Issue: March 30, 2006 Revision 1: March 12, 2009 ATA System: 5383 5385 SUBJECT: FUSELAGE - Section 48 - Main Frame and Skins - STA 1809.5 Bulkhead - Forward Outer Chord, Horizontal and Vertical Inner Chord, and External Skin - Inspection This revision includes all pages of the service bulletin.

COMPLIANCE INFORMATION RELATED TO THIS REVISION Federal Aviation Administration (FAA) Airworthiness Directive FAA AD 2006-24-04 is related to this service bulletin.

More work is necessary on airplanes that have been inspected as given in the initial release of this service bulletin. At the time of the next inspection, do the inspections as given in this revision.

No airplane was added to the service bulletin effectivity.

REASON FOR REVISION This revision is sent to give a clarification for the horizontal inner chord inspection and add surface HFEC inspection for the vertical inner chord. The following sections of the service bulletin are affected:

— In SUBJECT, the words "and Vertical" was added to the title.

— In Paragraph 1.D., Description, added Affected Maintenance Zones table.

— In Paragraph 1.E., Compliance, added FAA AD 2006-24-04 reference.

— In Figures 5 and 6, Detailed and Surface HFEC Inspections of Horizontal Inner Chord (Internal) - Left Side and Right Side, respectively; a clarification was added to inspect only the exposed surfaces of the ends of the horizontal inner chord without the removal of existing splice straps, radius fillers, and support clips.

— Additional surface HFEC inspection was added for the vertical inner chord installed on the aft of Station (STA) 1809.5 bulkhead in the area of Buttock Line (BL) 28.5, Water Line (WL) 257. The surface HFEC inspection is to the flange and fillet radius of the vertical inner chord around the four (4) fasteners that pass through both vertical and horizontal inner chord. Subsequent to the release of the original Service Bulletin 767-53A0131, one operator reported that the STA 1809.5 bulkhead vertical inner chord was found cracked at RBL 28.5, WL 257. The crack was discovered while accomplishing STA 1809.5 bulkhead inspection.

Boeing Service Related Problem (SRP) 767-SRP-53-0320 is related to this vertical inner chord cracking.

— The following sections of the service bulletin are affected by the addition of the surface HFEC inspection of the vertical inner chord:

Original Issue: March 30, 2006 767-53A0131Revision 1: March 12, 2009 5 of 52

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— In Paragraph 1.E., Compliance, added compliance times for the vertical inner chord inspection.

— In Figures 5 and 6, a detailed inspection of the aft side of the bulkhead structure was moved to Figures 7 and 8.

— Figures 7 and 8 were added for the detailed and surface HFEC inspections of the vertical inner chord inspection.

Vertical lines are put on the left edge of each page show the location of important changes.

REVISION HISTORY March 30, 2006Original Issue:

March 12, 2009Revision 1:

Original Issue: March 30, 2006 767-53A0131Revision 1: March 12, 2009 6 of 52 BOEING SERVICE BULLETIN 767-53A0131

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Commercial Airplanes 767 Service Bulletin ALERT SummaryNumber: 767-53A0131Original Issue: March 30, 2006 Revision 1: March 12, 2009 ATA System: 5383 5385 SUBJECT: FUSELAGE - Section 48 - Main Frame and Skins - STA 1809.5 Bulkhead - Forward Outer Chord, Horizontal and Vertical Inner Chord, and External Skin - Inspection

THIS BULLETIN IS SENT TO THE OPERATORS OF RECORD OF THE AIRPLANES SHOWN IN PARAGRAPH

1.A., EFFECTIVITY . IF AN AIRPLANE HAS BEEN LEASED OR SOLD, SEND THIS SERVICE BULLETIN TO THE NEW OPERATOR. IF APPLICABLE SPARES HAVE BEEN SOLD, SEND THIS SERVICE BULLETIN TO THE NEW OWNER.

CONCURRENT REQUIREMENTS None.

BACKGROUND Accomplishment of the inspections in this service bulletin will make sure that cracks in the bulkhead structure at Station (STA) 1809.5 are found and repaired. If not repaired, cracks in the bulkhead structure at STA 1809.5 could become large and result in the inability of the STA 1809.5 bulkhead structure to carry horizontal stabilizer flight loads. This will have adverse effects on airplane controllability, and could cause loss of control of the airplane.

Two operators have reported finding fatigue cracks in the forward outer chord of the STA 1809.5 airframe bulkhead. A total of seven outer chord cracks were found on four different airplanes. The outer chord cracks were located between stringers 4 and 8 (left side and right side), and were found on airplanes that had between 13,942 and 29,588 total flight cycles. A crack, similar to those found in the forward outer chords on operators airplanes, was also found on the Boeing fatigue test airplane. Three operators also reported finding a crack in the horizontal inner chord that spans between stringer 12L and stringer 12R. A total of seven horizontal chord cracks were found on seven different airplanes. The horizontal chord cracks were at the lower flange near Buttock Line (BL) 28, and were found on airplanes that had between 8,448 and 35,991 total flight cycles.

In addition, one operator found small cracks in the external skin at STA 1809.5 between stringers 6 and 8 on the same airplane that also had approximately a one inch crack in the forward outer chord.

After the original release of this service bulletin, one operator found a fatigue crack in the vertical inner chord while doing the detailed inspection of the horizontal inner chord. A surface High Frequency Eddy Current (HFEC) inspection was done to confirm the crack. The crack was found on the right side of the structure at a fastener hole near BL 28.5, Water Line (WL) 257; common to both the horizontal and vertical inner chord. The vertical inner chord crack was found on an airplane with 28,234 total flight cycles.

Original Issue: March 30, 2006 767-53A0131Revision 1: March 12, 2009 7 of 52

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This service bulletin gives instructions to do inspections for cracks in the STA 1809.5 bulkhead forward outer chord, the horizontal inner chord, the vertical inner chord, and the external skin. If cracks are found in the forward outer chord, horizontal inner chord, or vertical inner chord, repairs per the applicable Structural Repair Manual (SRM) will be necessary. If cracks are found in the skin, Boeing will provide repair instructions.

Boeing Service Related Problem (SRP) 767-SRP-53-0263 is related to the original issue of this service bulletin.

Boeing SRP 767-SRP-53-0320 is related to this service bulletin.

ACTION Get access to the upper skin on the outside of the airplane at STA 1809.5. Do an external detailed inspection of the skin on each side of the airplane, between stringers 3 and 10.

Get access to the internal structure on the forward side of the STA 1809.5 bulkhead.

Do a detailed inspection for cracks in the structure between stringers 3L and 10L, and between stringers 3R and 10R, in the area of the forward outer chord.

Do a surface HFEC inspection of the forward outer chord for cracks between stringers 4L and 8L, and between stringers 4R and 8R.

Get access to the internal structure on the forward and aft sides of the STA 1809.5 bulkhead.

Do a detailed inspection for cracks in the structure at the intersection of the vertical inner chord and ends of the horizontal inner chord that spans between stringer 12L and stringer 12R on forward and aft sides of the STA 1809.5 bulkhead.

Do a surface HFEC inspection for cracks in the ends of the horizontal inner chord.

Do a surface HFEC inspection for cracks in the vertical inner chord common to the horizontal inner chord at approximately BL 28.5, WL 257.

If cracks are found in the forward outer chord, horizontal inner chord, and/or vertical inner chord, repair as specified in the applicable Structural Repair Manual (SRM). If cracks are found in the skin, or if cracks are found in any structure other than the forward outer chord, horizontal inner chord, or vertical inner chord, contact Boeing for repair instructions.

EFFECTIVITY All 767-200/-300/-300F/-400ER airplanes. Refer to Service Bulletin Paragraph 1.A.1. for effectivity.

COMPLIANCE The Federal Aviation Administration (FAA) will possibly release another Airworthiness Directive related to this service bulletin. The Airworthiness Directive will make the compliance tasks and times given in this service bulletin mandatory.

Federal Aviation Administration (FAA) Airworthiness Directive FAA AD 2006-24-04 is related to this service bulletin.

Refer to Service Bulletin Paragraph 1.E. for information.

Original Issue: March 30, 2006 767-53A0131Revision 1: March 12, 2009 8 of 52 BOEING SERVICE BULLETIN 767-53A0131

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INDUSTRY SUPPORT INFORMATION Boeing warranty remedies are available for airplanes in warranty as of December 1, 2004. Please refer to Paragraph 2.B., Industry Support Information.

MANPOWER Elapsed HoursTotal Task HoursAirplanes

10.5015.00All

MATERIAL INFORMATION Operator Supplied Parts/Materials (if repairs are necessary).

Original Issue: March 30, 2006 767-53A0131Revision 1: March 12, 2009 9 of 52 BOEING SERVICE BULLETIN 767-53A0131

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BOEING SERVICE BULLETIN 767-53A0131

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SEE A DO A SURFACE HFEC

INSPECTION OF THE

FORWARD OUTER CHORD BETWEEN S-4 AND S-8.

DO AN EXTERNAL STA S-2L DETAILED INSPECTION 1809.50 OF THE SKIN STA S-3L SEVEN INCHES FORWARD 1809.50 AND AFT OF STA S-4L 1809.5, BETWEEN S-3 AND S-10.

_ S-6L

DO A DETAILED INSPECTION OF THE \ S-7L

FORWARD OUTER CHORD

AND SURROUNDING STRUCTURE BETWEEN , S-8L S-3 AND S-10.

UP S-10L → FWD

DO A DETAILED INSPECTION

OF THE HORIZONTAL INNER DO A SURFACE HFEC

CHORD, VERTICAL INNER INSPECTION OF THE

CHORD, AND SURROUNDING END OF THE

STRUCTURE FORWARD AND AFT

HORIZONTAL INNER OF STA 1809.50 BULKHEAD. CHORD.

LEFT SIDE SHOWN

RIGHT SIDE OPPOSITE

DO A SURFACE HFEC INSPECTION OF THE VERTICAL INNER CHORD.

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THIS BULLETIN IS SENT TO THE OPERATORS OF RECORD OF THE AIRPLANES SHOWN IN PARAGRAPH

1.A., EFFECTIVITY . IF AN AIRPLANE HAS BEEN LEASED OR SOLD, SEND THIS SERVICE BULLETIN TO THE NEW OPERATOR. IF APPLICABLE SPARES HAVE BEEN SOLD, SEND THIS SERVICE BULLETIN TO THE NEW OWNER.

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.

NOTE: This Service Bulletin is for the airplanes identified below. The Effectivity list shown below is complete for airplanes through line number 983. Airplanes after line number 983 are also affected by this service bulletin, and are in Group(s): 1

DESCRIPTIONCONFIGURATIONGROUP All 767-200/-300/-300F/-400ER airplanes.-1 Airplane Models:

Original Issue: March 30, 2006 767-53A0131Revision 1: March 12, 2009 11 of 52

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GroupVariable Number 1VA801 - VA810 1VB001 - VB002 1VB051 - VB055 1VB101 - VB125 1VB201 - VB202 1VB251 - VB253 1VB281 - VB284 1VB301 - VB302 1VB321 - VB332 1VB371 - VB373 1VB401 1VB441 - VB444 1VE001 - VE003 1VE021 - VE023 1VE041 - VE043 1VE061 - VE069 1VE083 - VE086 1VE101 - VE104 1VE116 - VE118 1VE121 - VE126 1VE141 - VE152 1VE171 - VE172 1VF001 - VF002 1VF041 - VF042 1VF051 1VF061 - VF062 1VF071 - VF072 1VF091 - VF093 1VF101 - VF102 1VF161 - VF162 1VF171 - VF172 1VF180 - VF184 1VF251 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.

Original Issue: March 30, 2006 767-53A0131Revision 1: March 12, 2009 12 of 52 BOEING SERVICE BULLETIN 767-53A0131

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