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Page 1Open in PDF

Original Issue: November 25, 2008 Revision 1: April 09, 2009 767-53A0193 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 1 of 268

ALERT ALERT Commercial Airplanes 767

ALERTALERT Service Bulletin Number: 767-53A0193 Original Issue: November 25, 2008 Revision 1: April 09, 2009 ATA System: 5311 SUBJECT: FUSELAGE - Skins - Inspections of the Fuselage Skin for Scribe Lines

BOEING PROPRIETARY, CONFIDENTIAL, AND/OR TRADE SECRET Copyright © 2008 The Boeing Company Unpublished Work - All Rights Reserved Boeing claims copyright in each page of this document only to the extent that the page contains copyrightable subject matter.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, 707, 717, 727, 737, 747, 757, 767, 777, BBJ, BOEING BUSINESS JET, DC-8, DC-9, DC-10, MD-10, MD-11, MD-80, MD-90, the Boeing logo and the Boeing livery are among the trademarks owned by Boeing or its subsidiaries. No intellectual property license (express or implied) is granted in connection with this document or otherwise.

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BLANK PAGE Original Issue: November 25, 2008 Revision 1: April 09, 2009 767-53A0193 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 2 of 268 BOEING SERVICE BULLETIN 767-53A0193

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Table of Contents Original Issue: November 25, 2008 Revision 1: April 09, 2009 767-53A0193 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 3 of 268 BOEING SERVICE BULLETIN 767-53A0193

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Table of Contents Revision Transmittal Sheet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

1. PLANNING INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 A. Effectivity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

1. Airplanes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

2. Spares Affected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 B. Concurrent Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 C. Reason . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 D. Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 E. Compliance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 F. Approval . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70 G. Manpower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70 H. Weight and Balance Changes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76 I. Electrical Load Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76 J. References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76

1. Existing Data: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76

2. Data supplied with this Service Bulletin: . . . . . . . . . . . . . . . . . . . . . . . . . 76

3. Installation Drawings Used in the Preparation of this Service Bulletin: . . . . . . . . . . 76 K. Publications Affected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77 L. Interchangeability and Intermix ability of Parts . . . . . . . . . . . . . . . . . . . . . . . . . 77

2. MATERIAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79 A. Material - Price and Availability. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79 B. Industry Support Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79 C. Parts Necessary For Each Airplane . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79

1. Kits/Parts: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79

2. Parts and Materials Supplied by the Operator : . . . . . . . . . . . . . . . . . . . . . . 79

3. Parts Modified and Reidentified: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79

4. Parts Removed and Not Replaced: . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79 D. Parts Necessary to Change Spar es . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79 E. Special Tooling - Price and Availability. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80 F. Special Tooling Necessary to do this Service Bulletin . . . . . . . . . . . . . . . . . . . . . 80

3. ACCOMPLISHMENT INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81 A. GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81 B. WORK INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83 FIGURE 1: FUSELAGE - SKIN LAP JOINT - ZONE 1 INSPECTION (GROUP 1) . . . . . . . . . . . 107 FIGURE 2: FUSELAGE - SKIN LAP JOINT - ZONE 1 INSPECTION (GROUP 2) . . . . . . . . . . . 109 FIGURE 3: FUSELAGE - SKIN LAP JOINT - ZONE 1 INSPECTION (GROUP 3) . . . . . . . . . . . 111 FIGURE 4: FUSELAGE - SKIN LAP JOINT - ZONE 1 INSPECTION (GROUP 4) . . . . . . . . . . . 113 FIGURE 5: FUSELAGE - SKIN LAP JOINT - ZONE 1 INSPECTION (GROUP 5) . . . . . . . . . . . 115 FIGURE 6: FUSELAGE - SKIN LAP JOINT - ZONE 1 INSPECTION (GROUP 6) . . . . . . . . . . . 117 FIGURE 7: FUSELAGE - SKIN LAP JOINT - ZONE 1 INSPECTION (GROUP 7) . . . . . . . . . . . 119 FIGURE 8: FUSELAGE - SKIN LAP JOINT - ZONE 1 INSPECTION (GROUP 8) . . . . . . . . . . . 121 FIGURE 9: FUSELAGE - SKIN LAP JOINT - ZONE 1 INSPECTION (GROUP 9) . . . . . . . . . . . 123 FIGURE 10: FUSELAGE - SKIN LAP JOINT - ZONE 1 INSPECTION (GROUP 10) . . . . . . . . . . 125 FIGURE 11: FUSELAGE - SKIN LAP JOINT - ZONE 1 INSPECTION (GROUP 11) . . . . . . . . . . 127

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Table of Contents Original Issue: November 25, 2008 Revision 1: April 09, 2009 767-53A0193 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 4 of 268 BOEING SERVICE BULLETIN 767-53A0193

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FIGURE 12: FUSELAGE - SKIN LAP JOINT - ZONE 1 INSPECTION (GROUP 12) . . . . . . . . . 129 FIGURE 13: FUSELAGE - SKIN LAP JOINT - ZONE 2 INSPECTION (GROUP 1) . . . . . . . . . . 131 FIGURE 14: FUSELAGE - SKIN LAP JOINT - ZONE 2 INSPECTION (GROUP 2) . . . . . . . . . . 133 FIGURE 15: FUSELAGE - SKIN LAP JOINT - ZONE 2 INSPECTION (GROUP 3) . . . . . . . . . . 135 FIGURE 16: FUSELAGE - SKIN LAP JOINT - ZONE 2 INSPECTION (GROUP 4) . . . . . . . . . . 137 FIGURE 17: FUSELAGE - SKIN LAP JOINT - ZONE 2 INSPECTION (GROUP 5) . . . . . . . . . . 139 FIGURE 18: FUSELAGE - SKIN LAP JOINT - ZONE 2 INSPECTION (GROUP 6) . . . . . . . . . . 141 FIGURE 19: FUSELAGE - SKIN LAP JOINT - ZONE 2 INSPECTION (GROUP 7) . . . . . . . . . . 143 FIGURE 20: FUSELAGE - SKIN LAP JOINT - ZONE 2 INSPECTION (GROUP 8) . . . . . . . . . . 145 FIGURE 21: FUSELAGE - SKIN LAP JOINT - ZONE 2 INSPECTION (GROUP 9) . . . . . . . . . . 147 FIGURE 22: FUSELAGE - SKIN LAP JOINT - ZONE 2 INSPECTION (GROUP 10) . . . . . . . . . 149 FIGURE 23: FUSELAGE - SKIN LAP JOINT - ZONE 2 INSPECTION (GROUP 11) . . . . . . . . . 151 FIGURE 24: FUSELAGE - SKIN LAP JOINT - ZONE 2 INSPECTION (GROUP 12) . . . . . . . . . 153 FIGURE 25: FUSELAGE - SKIN LAP JOINT - ZONE 3 INSPECTION (GROUP 1) . . . . . . . . . . 155 FIGURE 26: FUSELAGE - SKIN LAP JOINT - ZONE 3 INSPECTION (GROUP 2) . . . . . . . . . . 157 FIGURE 27: FUSELAGE - SKIN LAP JOINT - ZONE 3 INSPECTION (GROUP 3) . . . . . . . . . . 159 FIGURE 28: FUSELAGE - SKIN LAP JOINT - ZONE 3 INSPECTION (GROUP 4) . . . . . . . . . . 161 FIGURE 29: FUSELAGE - SKIN LAP JOINT - ZONE 3 INSPECTION (GROUP 5) . . . . . . . . . . 163 FIGURE 30: FUSELAGE - SKIN LAP JOINT - ZONE 3 INSPECTION (GROUP 6) . . . . . . . . . . 166 FIGURE 31: FUSELAGE - SKIN LAP JOINT - ZONE 3 INSPECTION (GROUP 7) . . . . . . . . . . 169 FIGURE 32: FUSELAGE - SKIN LAP JOINT - ZONE 3 INSPECTION (GROUP 8) . . . . . . . . . . 172 FIGURE 33: FUSELAGE - SKIN LAP JOINT - ZONE 3 INSPECTION (GROUP 9) . . . . . . . . . . 175 FIGURE 34: FUSELAGE - SKIN LAP JOINT - ZONE 3 INSPECTION (GROUP 10) . . . . . . . . . 178 FIGURE 35: FUSELAGE - SKIN LAP JOINT - ZONE 3 INSPECTION (GROUP 11) . . . . . . . . . 181 FIGURE 36: FUSELAGE - SKIN LAP JOINT - ZONE 3 INSPECTION (GROUP 12) . . . . . . . . . 183 FIGURE 37: FUSELAGE - EXTERNAL APPROVED REPAIRS - ZONE 1 INSPECTION (GROUP 1) 185 FIGURE 38: FUSELAGE - EXTERNAL APPROVED REPAIRS - ZONE 1 INSPECTION (GROUP 2) 187 FIGURE 39: FUSELAGE - EXTERNAL APPROVED REPAIRS - ZONE 1 INSPECTION (GROUP 3) 189 FIGURE 40: FUSELAGE - EXTERNAL APPROVED REPAIRS - ZONE 1 INSPECTION (GROUP 4) 191 FIGURE 41: FUSELAGE - EXTERNAL APPROVED REPAIRS - ZONE 1 INSPECTION (GROUP 5) 193 FIGURE 42: FUSELAGE - EXTERNAL APPROVED REPAIRS - ZONE 1 INSPECTION (GROUP 6) 195 FIGURE 43: FUSELAGE - EXTERNAL APPROVED REPAIRS - ZONE 1 INSPECTION (GROUP 7) 197 FIGURE 44: FUSELAGE - EXTERNAL APPROVED REPAIRS - ZONE 1 INSPECTION (GROUP 8) 199 FIGURE 45: FUSELAGE - EXTERNAL APPROVED REPAIRS - ZONE 1 INSPECTION (GROUP 9) 201 FIGURE 46: FUSELAGE - EXTERNAL APPROVED REPAIRS - ZONE 1 INSPECTION (GROUP 10) 203 FIGURE 47: FUSELAGE - EXTERNAL APPROVED REPAIRS - ZONE 1 INSPECTION (GROUP 11) 205 FIGURE 48: FUSELAGE - EXTERNAL APPROVED REPAIRS - ZONE 1 INSPECTION (GROUP 12) 207 FIGURE 49: FUSELAGE - EXTERNAL FEATURES - ZONE 2 INSPECTION (GROUP 1) . . . . . . 209 FIGURE 50: FUSELAGE - EXTERNAL FEATURES - ZONE 2 INSPECTION (GROUP 2) . . . . . . 211 FIGURE 51: FUSELAGE - EXTERNAL FEATURES - ZONE 2 INSPECTION (GROUP 3) . . . . . . 213 FIGURE 52: FUSELAGE - EXTERNAL FEATURES - ZONE 2 INSPECTION (GROUP 4) . . . . . . 215 FIGURE 53: FUSELAGE - EXTERNAL FEATURES - ZONE 2 INSPECTION (GROUP 5) . . . . . . 217 FIGURE 54: FUSELAGE - EXTERNAL FEATURES - ZONE 2 INSPECTION (GROUP 6) . . . . . . 219 FIGURE 55: FUSELAGE - EXTERNAL FEATURES - ZONE 2 INSPECTION (GROUP 7) . . . . . . 221 FIGURE 56: FUSELAGE - EXTERNAL FEATURES - ZONE 2 INSPECTION (GROUP 8) . . . . . . 223 FIGURE 57: FUSELAGE - EXTERNAL FEATURES - ZONE 2 INSPECTION (GROUP 9) . . . . . . 225

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FIGURE 58: FUSELAGE - EXTERNAL FEATURES - ZONE 2 INSPECTION (GROUP 10) . . . . . . 227 FIGURE 59: FUSELAGE - EXTERNAL FEATURES - ZONE 2 INSPECTION (GROUP 11) . . . . . . 229 FIGURE 60: FUSELAGE - EXTERNAL FEATURES - ZONE 2 INSPECTION (GROUP 12) . . . . . . 231 FIGURE 61: FUSELAGE - DECALS - ZONE 3 INSPECTION (GROUP 1) . . . . . . . . . . . . . . . 233 FIGURE 62: FUSELAGE - DECALS - ZONE 3 INSPECTION (GROUP 2) . . . . . . . . . . . . . . . 235 FIGURE 63: FUSELAGE - DECALS - ZONE 3 INSPECTION (GROUP 3) . . . . . . . . . . . . . . . 237 FIGURE 64: FUSELAGE - DECALS - ZONE 3 INSPECTION (GROUP 4) . . . . . . . . . . . . . . . 239 FIGURE 65: FUSELAGE - DECALS - ZONE 3 INSPECTION (GROUP 5) . . . . . . . . . . . . . . . 241 FIGURE 66: FUSELAGE - DECALS - ZONE 3 INSPECTION (GROUP 6) . . . . . . . . . . . . . . . 243 FIGURE 67: FUSELAGE - DECALS - ZONE 3 INSPECTION (GROUP 7) . . . . . . . . . . . . . . . 245 FIGURE 68: FUSELAGE - DECALS - ZONE 3 INSPECTION (GROUP 8) . . . . . . . . . . . . . . . 247 FIGURE 69: FUSELAGE - DECALS - ZONE 3 INSPECTION (GROUP 9) . . . . . . . . . . . . . . . 249 FIGURE 70: FUSELAGE - DECALS - ZONE 3 INSPECTION (GROUP 10) . . . . . . . . . . . . . . 251 FIGURE 71: FUSELAGE - DECALS - ZONE 3 INSPECTION (GROUP 11) . . . . . . . . . . . . . . 253 FIGURE 72: FUSELAGE - DECALS - ZONE 3 INSPECTION (GROUP 12) . . . . . . . . . . . . . . 255 APPENDIX A: SEALANT REMOVAL PROCEDURE FOR EXTERIOR PRESSURIZED FUSELAGE SKIN 257 APPENDIX B: REPORTING SYSTEM - LIMITE D RETURN TO SERVICE PROCEDURE FOR AIRPLANES WITH SCRIBE LINES . . . . . . . . . . . . . . . . . . . . . . . . . . . 263 APPENDIX C: AIRPLANE FUSELAGE SCRIBE LINE MARK SUMMARY TABLES . . . . . . . . . . 265 APPENDIX D: SCRIBE LINE SAMPLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 267

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Original Issue: November 25, 2008 Revision 1: April 09, 2009 767-53A0193 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 7 of 268

ALERT ALERT Commercial Airplanes 767

ALERTALERT Service Bulletin Number: 767-53A0193 Revision Transmittal Sheet Original Issue: November 25, 2008 Revision 1: April 09, 2009 ATA System: 5311 SUBJECT: FUSELAGE - Skins - Inspections of the Fuselage Skin for Scribe Lines This Revision includes all pages of the service bulletin.

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

More work is necessary for airplanes that have accomplished skin lap joint inspections as shown in the original issue of this service bulletin. Operators that have incorporated the original issue of this service bulletin for the skin lap joint inspections must review the REASON FOR REVISION information below, and do additional skin lap joint inspections, as necessary, to comply with Revision 1 of this service bulletin.

If scribe lines were found as a result of the skin lap joint inspections, but not repaired, and the Limited Return to Service (LRTS) program was elected, operators must review the LRTS Compliance tables for changes in inspection locations and repeat inspection intervals.

More work may be required if external approved repair inspections were exempted by Compliance Table 2, Note

(g). Operators that have incorporated the original issue of this service bulletin for the external approved repair inspections must review the REASON FOR REVISION information below, and do additional external approved repair inspections, as necessary, to comply with Revision 1 of this service bulletin.

More work may be required if external feature inspections were exempted by Compliance Table 3, Note (e).

Operators that have incorporated the original issue of this service bulletin for the external feature inspections must review the REASON FOR REVISION information below, and do additional external feature inspections, as necessary, to comply with Revision 1 of this service bulletin.

No more work is required for inspections to decals.

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REASON FOR REVISION This revision is sent to change initial inspection locations and LRTS inspection locations and repeat inspection intervals for skin lap joint inspections. In addition, caution notes are added to advise operators not to blend scribe lines.

These sections were changed:

1. In Paragraph 1.E., Compliance, Table 1 wa s changed to clarify footnote (f).

2. In Paragraph 1.E., Compliance, Table 2 was changed to cl arify footnotes (f) and (g) and added footnote (h).

3. In Paragraph 1.E., Compliance, Table 3 was changed to clarify footnote (e) and added footnote (f).

4. In Paragraph 1.E., Compliance, Table 4 was changed to clarify footnotes (a) and (d) and remove footnotes

(b) and (e).

5. In Paragraph 1.E., Compliance, Tables 5 through 14 were changed for LRTS inspection locations and repeat inspection intervals for skin lap joint inspections.

6. In Paragraph 1.K., Publications Affected, added Damage Tolerance Based Structural Inspection information.

7. In Paragraph 3.A., General Information, Note 16 was added to recommend operators not to blend scribe lines.

8. In Paragraph 3.B., Work Instructio ns, Figures 1 through 36 were changed to reflect changes in affected skin lap joint inspection locations.

9. In Paragraph 3.B., Work Instructions, added a Caut ion to recommend that operators not to blend scribe lines to Figures 1 through 72.

Paragraph 1.A., Effectivity, shows changes of airplane operators. Each operator should examine the Effectivity paragraph for changes.

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 Original Issue: November 25, 2008 Revision 1: April 09, 2009

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ALERT ALERT Commercial Airplanes 767

ALERTALERT Service Bulletin Number: 767-53A0193 Summary Original Issue: November 25, 2008 Revision 1: April 09, 2009 ATA System: 5311 SUBJECT: FUSELAGE - Skins - Inspections of the Fuselage Skin for Scribe Lines

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 This service bulletin gives instructions to inspect for scribe lines in the fuselage skin at skin lap joints, the skin at certain external approved repairs, the skin around external features such as antennas, and the skin at decals.

Fatigue cracks can develop at scribe line locations. Any crack that remains undetected could grow large and cause a rapid decompression.

Thirteen (13) 767 airplanes have been found with scribe line damage by 11 operators. Scribe lines were found at skin lap joints, butt joints, around external repairs and antennas, and at locations where decals were cut.

Many of the scribe lines appear to have been made when sealant was removed as part of preparation of the airplane for repainting. The 767 airplanes had between 6300 flight cycles and 24,600 flight cycles. No cracks as a result of scribe lines on 767 airplanes have been reported to Boeing.

A scribe line is a narrow, shallow, distinct line of damage (typically up to 0.006 inch deep), usually associated with the removal of a fillet or gap seal (lap joints and butt joints, respectively). A more detailed definition of a scribe line is included in Accomplishment Instructions Paragraph 3.B. - Identification of a "Typical" Scribe Line.

A review of fleet activity yields two separate scenarios that are suspected to have caused scribe lines to the fuselage skin.

The first scenario involves the paint stripping and repainting of airplanes. In the process of stripping and preparing the airplane for paint, tools were used to remove sealant and paint buildup at lap joints, at certain external approved repair doublers or door scuff plates, or around external features. Tools like scrapers (steel, wood, hard plastic etc.), knives, or utility knives can damage the skin. Fatigue cracks can develop at scribe line locations.

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The second scenario is decal application on/or removal from the fuselage. To install the decals across lap joint steps or repairs, investigation into maintenance practices has shown that decals have been cut in place, using some form of knife, to allow the decal to lie flush to the skin at these stepped locations. This operation results in scribe lines at the decal cut location. Based on service reports, sharp tools have also been used for close trimming of the decal’s outline. This type of decal trimming has also left scribe lines on the fuselage skin.

The above maintenance operations can each lead to the same type of scribe line damage and subsequent premature fatigue cracks.

Boeing Service Related Problem (SRP) 767-SRP-53-0244 is related to this service bulletin.

ACTION At or before the scribe line inspection thresholds shown in this service bulletin, remove paint and sealant at the applicable locations. Do a detailed inspection of the fuselage skin at applicable skin lap joints, external approved repairs, external features, and decals for any scribe line or any crack. If any crack is found, contact Boeing for repair instructions and do the repair.

When scribe lines are found, they shall be repaired before further flight. As an alternative to immediate repair, for a scribe line that qualifies, the provided Limited Return To Service (LRTS) program may be used to allow airplanes to return to revenue flight for a limited period before scribe lines are repaired. This service bulletin contains a LRTS program.

The LRTS program consists of repeat inspections to detect any crack where scribe lines were found. Total airplane flight cycles, location, and extent of scribe line must meet specific criteria in order for a scribe line to qualify for a LRTS program. Each affected structural location within a LRTS program will be terminated with a repair.

This service bulletin has specific instructions for calculating separate inspection thresholds based on fatigue life for the identified locations. With the use of maintenance records, operators can implement the inspection program based on potential scribe line opportunities in an airplane’s maintenance history. If this maintenance records-based threshold program is not used, then 6,000 flight cycles shall be assigned as the cycle level when potential scribing first occurred.

Since a scribe line can occur at any time during the service life of an airplane and at many locations, this program uses both total flight cycles and structural criticality of location to determine the inspection requirements.

Criticality of location allows this service bulletin to address the most critical areas first and to provide less critical areas with appropriately reduced compliance requirements. Criticality of location determines the inspection thresholds for each location. This service bulletin uses figures and compliance times to address all of the critical locations and ranges of inspection thresholds. Each critical piece of structure susceptible to a scribe line is assigned to a figure. The affected structure for each group of airplanes is identified in individual figures in this service bulletin.

EFFECTIVITY 767-200, -300, -300F, and -400ER Airplanes. Refer to Paragraph 1.A.1., Airplanes for the list of affected airplanes.

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

Refer to Paragraph 1.E., Compliance.

INDUSTRY SUPPORT INFORMATION Boeing warranty remedies are not available for the inspections or repair procedures given in this service bulletin.

MANPOWER

MATERIAL INFORMATION Operator Supplied Parts/Materials.

Refer to Paragraph 2.A., Material - Price and Availability.

Airplanes Total Task Hours Elapsed Hours 767-200, 767-300, 767-300F, and 767-400ER 340.0 50.0

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DO A DETAILED INSPECTION FOR ANY SCRIBE LINE ALONG SKIN

LAP JOINTS, EXTERNAL FEATURES, EXTERNAL APPROVED REPAIRS AND DECALS. IF A SCRIBE LINE IS FOUND, DO A SPECIAL DETAILED INSPECTION FOR ANY CRACK.

1560615

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