# Boeing Alert Service Bulletin 767-53A0228: No revision named

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- Pages: 54
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## Text

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### Page 1

Commercial 
Airplanes
767
Service Bulletin
ALERT
Number: 767-53A0228
Original Issue: July 28, 2011
ATA System: 5350
SUBJECT: FUSELAGE - Fuselage Section 45 - Overwing Emergency Exit Hatch Openings - Lower
Main Sill - 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 © 2011 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Unpublished Work - All Rights Reserved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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### Page 3

Table of Contents
Summary ...................................................... 5
1. PLANNING INFORMATION ........................................ 9
A. Effectivity ................................................ 9
1. Airplanes ............................................. 9
2. Spares Affected ........................................ 1 4
B. Concurrent Requirements ...................................... 1 4
C. Reason ................................................ 1 4
D. Description .............................................. 1 4
E. Compliance .............................................. 1 6
F. Approval ............................................... 2 4
G. Manpower .............................................. 2 5
H. Weight and Balance Changes .................................... 2 6
I. Electrical Load Data ......................................... 2 6
J. References .............................................. 2 7
1. Existing Data .......................................... 2 7
2. Data supplied with this Service Bulletin ............................ 2 7
3. Installation Drawings Used in the Preparation of this Service Bulletin ............ 2 7
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 .................................... 2 9
C. Parts Necessary For Each Airplane ................................. 2 9
1. Kits/Parts ............................................ 2 9
2. Parts and Materials Supplied by the Operator ........................ 2 9
3. Parts Modified and Reidentified ................................ 2 9
4. Parts Removed and Not Replaced .............................. 2 9
D. Parts Necessary to Change Spares ................................. 2 9
E. Special Tooling - Price and Availability ............................... 2 9
F. Special Tooling Necessary to do this Service Bulletin ....................... 2 9
3. ACCOMPLISHMENT INSTRUCTIONS .................................. 3 1
A. GENERAL INFORMATION ..................................... 3 1
B. WORK INSTRUCTIONS ....................................... 3 2
FIGURE 1: LEFT SIDE - OVERWING EMERGENCY EXIT HATCH OPENING - LOWER MAIN SILL - STA
883.5 - INSPECTIONS [Group 1; Group 4, Configuration 1] ................. 3 9
FIGURE 2: LEFT SIDE - FORWARD OVERWING EMERGENCY EXIT HATCH OPENING - LOWER MAIN
SILL - STA 883.5 - INSPECTIONS [Group 2; Group 4, Configuration 2] .......... 4 1
FIGURE 3: LEFT SIDE - AFT OVERWING EMERGENCY EXIT HATCH OPENING - LOWER MAIN SILL
- STA 903.5 - INSPECTIONS [Group 2; Group 4, Configuration 2] ............. 4 3
FIGURE 4: LEFT SIDE - OVERWING EMERGENCY EXIT HATCH OPENING - LOWER MAIN SILL - STA
903.5 - INSPECTIONS [Group 3; Group 4, Configuration 3] ................. 4 5
FIGURE 5: RIGHT SIDE - OVERWING EMERGENCY EXIT HATCH OPENING - LOWER MAIN SILL - STA
883.5 - INSPECTIONS [Group 1; Group 4, Configuration 1] ................. 4 7
FIGURE 6: RIGHT SIDE - FORWARD OVERWING EMERGENCY EXIT HATCH OPENING - LOWER MAIN
SILL - STA 883.5 - INSPECTIONS [Group 2; Group 4, Configuration 2] .......... 4 9
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FIGURE 7: RIGHT SIDE - AFT OVERWING EMERGENCY EXIT HATCH OPENING - LOWER MAIN SILL
- STA 903.5 - INSPECTIONS [Group 2; Group 4, Configuration 2] ............. 5 1
FIGURE 8: RIGHT SIDE - OVERWING EMERGENCY EXIT HATCH OPENING - LOWER MAIN SILL - STA
903.5 - INSPECTIONS [Group 3; Group 4, Configuration 3] ................. 5 3
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### Page 5

Commercial 
Airplanes
767
Service Bulletin
ALERT
SummaryNumber: 767-53A0228Original Issue: July 28, 2011
ATA System: 5350
SUBJECT: FUSELAGE - Fuselage Section 45 - Overwing Emergency Exit Hatch Openings - Lower
Main Sill - 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
Cracking has been reported on the lower main sill inner chord of the overwing emergency exit hatch opening
at Body Station (STA) 884, Stringer 18R. The cause of the cracking is fatigue. If cracking exists in the lower
main sill of the overwing emergency exit hatch opening and is not repaired, it could result in reduced structural
integrity of the overwing emergency exit hatch opening and consequent rapid decompression of the airplane.
The problem was discovered on a regular maintenance visit on an airplane that had completed 42,079 flight
cycles.
This service bulletin gives instruction to find and repair cracking of the lower main sill inner chord and surrounding
structure.
Boeing Service Related Problem (SRP) 767-SRP-53-0358 is related to this service bulletin.
Boeing Fleet Team Digest (FTD) 767 FTD 53-10001 is related to this service bulletin.
ACTION
Disarm the off-wing escape system. Remove seats, overwing emergency exit hatches, sidewall panels and
sidewall insulation as necessary to get access to the lower main sills of the overwing emergency exit hatch
openings.
Group 1-2; Group 4, Configuration 1-2:
At STA 883.5, do a surface High Frequency Eddy Current (HFEC) and detailed inspections of the lower main
sill inner chord. Also, do a detailed inspection of the surrounding structure. If any crack, corrosion damage, or
other irregularity is found, do the applicable SRM repair or contact Boeing for repair instructions.
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### Page 6

Group 2-3; Group 4, Configuration 2-3:
At STA 903.5, do a detailed inspections of the lower main sill inner chord and surrounding structure. If any crack,
corrosion damage, or other irregularity is found, do the applicable SRM repair or contact Boeing for repair
instructions.
Install all removed sidewall insulation, sidewall panels, overwing emergency exit hatches and seats. Arm the
off-wing escape system. Put the airplane back to a serviceable condition.
Group 4, Configuration 4:
No work is necessary. This configuration is for airplanes not yet delivered that will have no overwing emergency
exit hatches.
EFFECTIVITY
767-200/-300 series airplanes with overwing emergency exit hatches. Refer to Paragraph 1.A.1., Airplanes, for
the list of affected airplanes.
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 inspection and/or repair procedures given in this service
bulletin.
MANPOWER
WORK PACKAGE 1 - LEFT SIDE
Elapsed HoursTotal Task HoursAirplanes
5.009.00Group 1; Group 4, Configuration 1
7.6513.95Group 2; Group 4, Configuration 2
4.358.35Group 3; Group 4, Configuration 3
WORK PACKAGE 2 - RIGHT SIDE
Elapsed HoursTotal Task HoursAirplanes
5.009.00Group 1; Group 4, Configuration 1
7.6513.95Group 2; Group 4, Configuration 2
4.358.35Group 3; Group 4, Configuration 3
Refer to Paragraph 1.G., Manpower.
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BOEING SERVICE BULLETIN 767-53A0228
ALERT  ALERT
MATERIAL INFORMATION
None.
GROUP 2-3; GROUP 4,
CONFIGURATION 2-3 ONLY:
AFT OVERWING
STA  EMERGENCY EXIT HATCH
933
STA
903.5  GROUP 1-2; GROUP 4,
CONFIGURATION 1-2 ONLY:
STA  FORWARD OVERWING
883.5  EMERGENCY EXIT HATCH
STA
852
GROUP 2-3; GROUP 4, CONFIGURATION 2-3:
DO DETAILED INSPECTION OF INNER
CHORD. IF ANY CRACK IS FOUND, DO SRM
REPAIR. DO DETAILED INSPECTION OF
SURROUNDING STRUCTURE. IF ANY
CRACK IS FOUND, CONTACT BOEING.
GROUP CONCURATIONS AND 3 SMILAR SHOWN.
LEFT SIDE SHOWN
RIGHT SIDE OPPOSITE
' S-18L
GROUP 1-2; GROUP 4, CONFIGURATION 1-2:
DO HFEC AND DETAILED INSPECTIONS
OF INNER CHORD. IF ANY CRACK IS
FOUND, DO SRM REPAIR.
DO DETAILED INSPECTION OF
SURROUNDING STRUCTURE. IF ANY
CRACK IS FOUND, CONTACT BOEING.
Original Issue: July 28, 2011
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### Page 9

Commercial 
Airplanes
767
Service Bulletin
ALERT
Number: 767-53A0228
Original Issue: July 28, 2011
ATA System: 5350
SUBJECT: FUSELAGE - Fuselage Section 45 - Overwing Emergency Exit Hatch Openings - Lower
Main Sill - 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.
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 airplane(s) shown below.
NOTE: This service bulletin is for the airplanes identified below. The effectivity list shown below
is complete for airplanes through line number 1017. At least one airplane after line number
1017 is also affected by this service bulletin, and these airplanes are in Group(s) 2,4.
These airplanes will be added to the service bulletin's MyBoeingFleet.com (MBF) \"get
effectivity\" result when they are added to the MBF Fleet Profile Page.
DESCRIPTIONCONFIGURATIONGROUP
767-200 airplanes through line number 1020 with a single forward
overwing emergency exit hatch on each side of the airplane.
-1
767-200/-300 airplanes through line number 1020 with two overwing
emergency exit hatches on each side of the airplane.
-2
767-300 airplanes through line number 1020 with a single aft overwing
emergency exit hatch on each side of the airplane.
-3
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DESCRIPTIONCONFIGURATIONGROUP
767 airplanes after line number 1020. These airplanes are not yet
delivered and their configuration is unknown.
-4
Airplanes with a single forward overwing emergency exit hatch on
each side of the airplane.
1
Airplanes with two overwing emergency exit hatches on each side
of the airplane.
2
Airplanes with a single aft overwing emergency exit hatch on each
side of the airplane.
3
Airplanes with no overwing emergency exit hatches.4
Airplane Models:
767-200, 767-300
GroupVariable Number
1VA001 - VA020
1VA301 - VA315
1VA501 - VA530
1VA701 - VA719
1VA801 - VA810
1VB001 - VB002
1VB051 - VB055
1VB101 - VB125
1VB201 - VB202
1VB251 - VB253
1VB281 - VB284
2VB301 - VB302
2VB321 - VB332
1VB371 - VB373
1VB401
1VB441 - VB444
1VE001 - VE003
1VE021 - VE023
1VE041 - VE043
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GroupVariable Number
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
2VF101 - VF102
1VF161 - VF162
1VF171 - VF172
1VF180 - VF184
1VF251
2VK001 - VK016
2VK021 - VK022
2VK031 - VK056
2VK081 - VK113
2VK141 - VK148
3VK161 - VK164
2VK171
2VK181
2VK186
3VL001 - VL006
3VL011
2VL701 - VL703
3VL751 - VL755
2VL931 - VL932
2VL941
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GroupVariable Number
2VN001 - VN041
2VN051 - VN064
2VN081 - VN099
2VN151 - VN158
2VN163 - VN168
3VN171 - VN174
2VN191 - VN198
3VN211 - VN212
2VN221 - VN225
3VN231 - VN234
3VN241 - VN243
2VN251 - VN276
2VN291 - VN293
3VN301 - VN314
2VN422 - VN427
2VN436
2VN491 - VN513
3VN634 - VN636
2VN651 - VN658
2VN671 - VN672
2VN676
2VN681 - VN691
2VN731 - VN732
2VN751 - VN753
3VN791 - VN792
2VN811 - VN813
2VN931 - VN936
2VN966 - VN972
1VR051 - VR060
1VR081
1VR084
1VR086 - VR089
1VR106 - VR109
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GroupVariable Number
2VR401
2VR421 - VR423
2VR426
2VR441
2VR461
2VR471 - VR472
3VS061
2VS066 - VS070
2VS073 - VS078
2VS091 - VS104
2VS111 - VS113
2VS131 - VS133
2VS176 - VS177
2VS186 - VS187
2VS196 - VS203
2VS206 - VS208
2VS231
2VS266 - VS274
2VS291 - VS293
2VS301 - VS303
2VS366 - VS367
2VS381 - VS382
2VS391 - VS392
2VS401
2VS466 - VS472
2VS486
3VS496 - VS497
3VS506 - VS507
2VS526
2VS546 - VS549
2VS701 - VS736
2VS751 - VS759
2VS821 - VS825
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GroupVariable Number
2VS841 - VS844
2VS861
2VS896
2VS901 - VS912
2VS921 - VS928
2VS931 - VS933
2VS951 - VS954
2VS961 - VS967
2VS971 - VS975
1VV001
2. Spares Affected
None.
B. Concurrent Requirements
None.
C. Reason
Cracking has been reported on the lower main sill inner chord of the lower main sill of the overwing
emergency exit hatch opening at Body Station (STA) 884, Stringer 18R. The cause of the cracking is
fatigue. If cracking exists in the lower main sill of the overwing emergency exit hatch opening and is
not repaired, it could result in reduced structural integrity of the overwing emergency exit hatch opening
and consequent rapid decompression of the airplane.
The problem was discovered on a regular maintenance visit on an airplane that had completed 42,079
flight cycles.
This service bulletin gives instruction to find and repair cracking of the lower main sill inner chord and
surrounding structure.
Boeing Service Related Problem (SRP) 767-SRP-53-0358 is related to this service bulletin.
Boeing Fleet Team Digest (FTD) 767 FTD 53-10001 is related to this service bulletin.
D. Description
Disarm the off-wing escape system. Remove seats, overwing emergency exit hatches, sidewall panels
and sidewall insulation as necessary to get access to the lower main sills of the overwing emergency
exit hatch openings.
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### Page 15

Group 1-2; Group 4, Configuration 1-2:
At STA 883.5, do a surface High Frequency Eddy Current (HFEC) and detailed inspections of the lower
main sill inner chord. Also, do a detailed inspection of the surrounding structure. If any crack, corrosion
damage, or other irregularity is found, do the applicable SRM repair or contact Boeing for repair
instructions.
Group 2-3; Group 4, Configuration 2-3:
At STA 903.5, do a detailed inspections of the lower main sill inner chord and surrounding structure.
If any crack, corrosion damage, or other irregularity is found, do the applicable SRM repair or contact
Boeing for repair instructions.
Install all removed sidewall insulation, sidewall panels, overwing emergency exit hatches and seats.
Arm the off-wing escape system. Put the airplane back to a serviceable condition.
Group 4, Configuration 4:
No work is necessary. This configuration is for airplanes not yet delivered that will have no overwing
emergency exit hatches.
NOTE: If the damaged area is more than the specified limits, write to Boeing for repair instructions.
Give the size and location of the damage. When possible, send sketches and photographs.
If the damage includes corrosion, send data on the length, width, and largest depth of clean
up.
Send to:
BOEING COMMERCIAL AIRPLANES GROUP
ATTENTION: MANAGER, AIRLINE SUPPORT
The work in this service bulletin is done in the maintenance zone(s) given below.
Group 1:
Affected Maintenance Zones
ZoneModel
241, 242767-200
Group 2,4:
Affected Maintenance Zones
ZoneModel
241, 242767-200, 767-300
Group 3:
Affected Maintenance Zones
ZoneModel
241, 242767-300
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E. 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.
Group 1; Group 4, Configuration 1:
Table 1: Overwing Emergency Exit Hatch Opening - Lower Main Sill - Inspection and Repair - WORK
PACKAGE 1 - LEFT SIDE
Repeat Interval
(Not to Exceed)
Compliance Time
(Whichever Occurs Later)
ActionCondition
-Within 3,000
flight cycles after
the original issue
date of this ser-
vice bulletin
Before
37,500 total
flight cycles
Do a HFEC inspection of the lower
main sill inner chord around STA
883.5 in accordance with Para-
graph 3.B., Work Instructions
WORK PACKAGE 1, Step 2.b.,
and
All airplanes
Do detailed inspections of the
lower main sill inner chord and
surrounding structure around STA
883.5 in accordance with Para-
graph 3.B., Work Instructions
WORK PACKAGE 1, Step 2.b.
3,750 flight cycles
(a)
Within 3,750 flight cycles after
the initial detailed inspection
Repeat the detailed inspections of
the lower main sill inner chord and
surrounding structure around STA
883.5 in accordance with Para-
graph 3.B., Work Instructions
WORK PACKAGE 1, Step 2.b.,
and
No crack, corrosion
damage, or other irreg-
ularity is found
7,500 flight cycles
(a)
Within 7,500 flight cycles after
the initial HFEC inspection
Repeat the HFEC inspection of the
lower main sill inner chord around
STA 883.5 in accordance with
Paragraph 3.B., Work Instructions
WORK PACKAGE 1, Step 2.b.
(a)Before further flightRepair in accordance with Para-
graph 3.B., Work Instructions
WORK PACKAGE 1, Step 2.b.(1)
Any crack is found in
the lower main sill inner
chord
Before further flightContact Boeing for instructions and
do the work instructed by Boeing
Any corrosion damage
or other irregularity is
found in the lower main
sill inner chord
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### Page 17

Group 1; Group 4, Configuration 1:
Table 1: Overwing Emergency Exit Hatch Opening - Lower Main Sill - Inspection and Repair - WORK
PACKAGE 1 - LEFT SIDE
Repeat Interval
(Not to Exceed)
Compliance Time
(Whichever Occurs Later)
ActionCondition
-Before further flightContact Boeing for instructions and
do the work instructed by Boeing
Any crack, corrosion
damage, or other irreg-
ularity is found in the
structure other than the
lower main sill inner
chord
(a) Accomplishment of the repair in accordance with Paragraph 3.B., Work Instructions WORK PACKAGE
1, Step 2.b.(1) terminates the inspections in this service bulletin at this location.
Group 1; Group 4, Configuration 1:
Table 2: Overwing Emergency Exit Hatch Opening - Lower Main Sill - Inspection and Repair - WORK
PACKAGE 2 - RIGHT SIDE
Repeat Interval
(Not to Exceed)
Compliance Time
(Whichever Occurs Later)
ActionCondition
-Within 3,000
flight cycles after
the original issue
date of this ser-
vice bulletin
Before
37,500 total
flight cycles
Do a HFEC inspection of the lower
main sill inner chord around STA
883.5 in accordance with Para-
graph 3.B., Work Instructions
WORK PACKAGE 2, Step 2.b.,
and
All airplanes
Do detailed inspections of the
lower main sill inner chord and
surrounding structure around STA
883.5 in accordance with Para-
graph 3.B., Work Instructions
WORK PACKAGE 2, Step 2.b.
3,750 flight cycles
(a)
Within 3,750 flight cycles after
the initial detailed inspection
Repeat the detailed inspections of
the lower main sill inner chord and
surrounding structure around STA
883.5 in accordance with Para-
graph 3.B., Work Instructions
WORK PACKAGE 2, Step 2.b.,
and
No crack, corrosion
damage, or other irreg-
ularity is found
7,500 flight cycles
(a)
Within 7,500 flight cycles after
the initial HFEC inspection
Repeat the HFEC inspection of the
lower main sill inner chord around
STA 883.5 in accordance with
Paragraph 3.B., Work Instructions
WORK PACKAGE 2, Step 2.b.
(a)Before further flightRepair in accordance with Para-
graph 3.B., Work Instructions
WORK PACKAGE 2, Step 2.b.(1)
Any crack is found in
the lower main sill inner
chord
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### Page 18

Group 1; Group 4, Configuration 1:
Table 2: Overwing Emergency Exit Hatch Opening - Lower Main Sill - Inspection and Repair - WORK
PACKAGE 2 - RIGHT SIDE
Repeat Interval
(Not to Exceed)
Compliance Time
(Whichever Occurs Later)
ActionCondition
Before further flightContact Boeing for instructions and
do the work instructed by Boeing
Any corrosion damage
or other irregularity is
found in the lower main
sill inner chord
-Before further flightContact Boeing for instructions and
do the work instructed by Boeing
Any crack, corrosion
damage, or other irreg-
ularity is found in the
structure other than the
lower main sill inner
chord
(a) Accomplishment of the repair in accordance with Paragraph 3.B., Work Instructions WORK PACKAGE
2, Step 2.b.(1) terminates the inspections in this service bulletin at this location.
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Group 2; Group 4, Configuration 2:
Table 3: Overwing Emergency Exit Hatch Openings - Lower Main Sill - Inspection and Repair - WORK
PACKAGE 1 - LEFT SIDE
Repeat Interval
(Not to Exceed)
Compliance Time
(Whichever Occurs Later)
ActionCondition
Within 3,000
flight cycles after
the original issue
date of this ser-
vice bulletin
Before
37,500 total
flight cycles
Do a HFEC inspection of the lower
main sill inner chord around STA
883.5 in accordance with Para-
graph 3.B., Work Instructions
WORK PACKAGE 1, Step 3.b.,
and
All airplanes
Do detailed inspections of the
lower main sill inner chord and
surrounding structure around STA
883.5 in accordance with Para-
graph 3.B., Work Instructions
WORK PACKAGE 1, Step 3.b.
3,750 flight cycles
(a)
Within 3,750 flight cycles after
the initial detailed inspection
Repeat the detailed inspections of
the lower main sill inner chord and
surrounding structure around STA
883.5 in accordance with Para-
graph 3.B., Work Instructions
WORK PACKAGE 1, Step 3.b.,
and
No crack, corrosion
damage, or other irreg-
ularity is found
7,500 flight cycles
(a)
Within 7,500 flight cycles after
the initial HFEC inspection
Repeat the HFEC inspection of the
lower main sill inner chord around
STA 883.5 in accordance with
Paragraph 3.B., Work Instructions
WORK PACKAGE 1, Step 3.b.
(a)Before further flightRepair in accordance with Para-
graph 3.B., Work Instructions
WORK PACKAGE 1, Step 3.b.(1)
Any crack is found in
the lower main sill inner
chord
Before further flightContact Boeing for instructions and
do the work instructed by Boeing
Any corrosion damage
or other irregularity is
found in the lower main
sill inner chord
-Before further flightContact Boeing for instructions and
do the work instructed by Boeing
Any crack, corrosion
damage, or other irreg-
ularity is found in the
structure other than the
lower main sill inner
chord
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Group 2; Group 4, Configuration 2:
Table 3: Overwing Emergency Exit Hatch Openings - Lower Main Sill - Inspection and Repair - WORK
PACKAGE 1 - LEFT SIDE
Repeat Interval
(Not to Exceed)
Compliance Time
(Whichever Occurs Later)
ActionCondition
-Within 3,000
flight cycles after
the original issue
date of this ser-
vice bulletin
Before
37,500 total
flight cycles
Do detailed inspections of the
lower main sill inner chord and
surrounding structure around STA
903.5 in accordance with Para-
graph 3.B., Work Instructions
WORK PACKAGE 1, Step 3.c.
All airplanes
3,750 flight cycles
(b)
Within 3,750 flight cycles after
the initial detailed inspection
Repeat the detailed inspections of
the lower main sill inner chord and
surrounding structure around STA
903.5 in accordance with Para-
graph 3.B., Work Instructions
WORK PACKAGE 1, Step 3.c.
No crack, corrosion
damage, or other irreg-
ularity is found
(b)Before further flightRepair in accordance with Para-
graph 3.B., Work Instructions
WORK PACKAGE 1, Step 3.c.(1)
Any crack is found in
the lower main sill inner
chord
Before further flightContact Boeing for instructions and
do the work instructed by Boeing
Any corrosion damage
or other irregularity is
found in the lower main
sill inner chord
-Before further flightContact Boeing for instructions and
do the work instructed by Boeing
Any crack, corrosion
damage, or other irreg-
ularity is found in the
structure other than the
lower main sill inner
chord
(a) Accomplishment of the repair in accordance with Paragraph 3.B., Work Instructions WORK PACKAGE
1, Step 3.b.(1) terminates the inspections in this service bulletin at this location.
(b) Accomplishment of the repair in accordance with Paragraph 3.B., Work Instructions WORK PACKAGE
1, Step 3.c.(1) terminates the inspections in this service bulletin at this location.
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Group 2; Group 4, Configuration 2:
Table 4: Overwing Emergency Exit Hatch Openings - Lower Main Sill - Inspection and Repair - WORK
PACKAGE 2 - RIGHT SIDE
Repeat Interval
(Not to Exceed)
Compliance Time
(Whichever Occurs Later)
ActionCondition
-Within 3,000
flight cycles after
the original issue
date of this ser-
vice bulletin
Before
37,500 total
flight cycles
Do a HFEC inspection of the lower
main sill inner chord around STA
883.5 in accordance with Para-
graph 3.B., Work Instructions
WORK PACKAGE 2, Step 3.b.,
and
All airplanes
Do detailed inspections of the
lower main sill inner chord and
surrounding structure around STA
883.5 in accordance with Para-
graph 3.B., Work Instructions
WORK PACKAGE 2, Step 3.b.
3,750 flight cycles
(a)
Within 3,750 flight cycles after
the initial detailed inspection
Repeat the detailed inspections of
the lower main sill inner chord and
surrounding structure around STA
883.5 in accordance with Para-
graph 3.B., Work Instructions
WORK PACKAGE 2, Step 3.b.,
and
No crack, corrosion
damage, or other irreg-
ularity is found
7,500 flight cycles
(a)
Within 7,500 flight cycles after
the initial HFEC inspection
Repeat the HFEC inspection of the
lower main sill inner chord around
STA 883.5 in accordance with
Paragraph 3.B., Work Instructions
WORK PACKAGE 2, Step 3.b.
(a)Before further flightRepair in accordance with Para-
graph 3.B., Work Instructions
WORK PACKAGE 2, Step 3.b.(1)
Any crack is found in
the lower main sill inner
chord
Before further flightContact Boeing for instructions and
do the work instructed by Boeing
Any corrosion damage
or other irregularity is
found in the lower main
sill inner chord
-Before further flightContact Boeing for instructions and
do the work instructed by Boeing
Any crack, corrosion
damage, or other irreg-
ularity is found in the
structure other than the
lower main sill inner
chord
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Group 2; Group 4, Configuration 2:
Table 4: Overwing Emergency Exit Hatch Openings - Lower Main Sill - Inspection and Repair - WORK
PACKAGE 2 - RIGHT SIDE
Repeat Interval
(Not to Exceed)
Compliance Time
(Whichever Occurs Later)
ActionCondition
-Within 3,000
flight cycles after
the original issue
date of this ser-
vice bulletin
Before
37,500 total
flight cycles
Do detailed inspections of the
lower main sill inner chord and
surrounding structure around STA
903.5 in accordance with Para-
graph 3.B., Work Instructions
WORK PACKAGE 2, Step 3.c.
All airplanes
3,750 flight cycles
(b)
Within 3,750 flight cycles after
the initial detailed inspection
Repeat the detailed inspections of
the lower main sill inner chord and
surrounding structure around STA
903.5 in accordance with Para-
graph 3.B., Work Instructions
WORK PACKAGE 2, Step 3.c.
No crack, corrosion
damage, or other irreg-
ularity is found
(b)Before further flightRepair in accordance with Para-
graph 3.B., Work Instructions
WORK PACKAGE 2, Step 3.c.(1)
Any crack is found in
the lower main sill inner
chord
Before further flightContact Boeing for instructions and
do the work instructed by Boeing
Any corrosion damage
or other irregularity is
found in the lower main
sill inner chord
-Before further flightContact Boeing for instructions and
do the work instructed by Boeing
Any crack, corrosion
damage, or other irreg-
ularity is found in the
structure other than the
lower main sill inner
chord
(a) Accomplishment of the repair in accordance with Paragraph 3.B., Work Instructions WORK PACKAGE
2, Step 3.b.(1) terminates the inspections in this service bulletin at this location.
(b) Accomplishment of the repair in accordance with Paragraph 3.B., Work Instructions WORK PACKAGE
2, Step 3.c.(1) terminates the inspections in this service bulletin at this location.
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Group 3; Group 4, Configuration 3:
Table 5: Overwing Emergency Exit Hatch Opening - Lower Main Sill - Inspection and Repair - WORK
PACKAGE 1 - LEFT SIDE
Repeat Interval
(Not to Exceed)
Compliance Time
(Whichever Occurs Later)
ActionCondition
-Within 3,000
flight cycles after
the original issue
date of this ser-
vice bulletin
Before
37,500 total
flight cycles
Do detailed inspections of the
lower main sill inner chord and
surrounding structure around STA
903.5 in accordance with Para-
graph 3.B., Work Instructions
WORK PACKAGE 1, Step 4.b.
All airplanes
3,750 flight cycles
(a)
Within 3,750 flight cycles after
the initial detailed inspection
Repeat the detailed inspections of
the lower main sill inner chord and
surrounding structure around STA
903.5 in accordance with Para-
graph 3.B., Work Instructions
WORK PACKAGE 1, Step 4.b.
No crack, corrosion
damage, or other irreg-
ularity is found
(a)Before further flightRepair in accordance with Para-
graph 3.B., Work Instructions
WORK PACKAGE 1, Step 4.b.(1)
Any crack is found in
the lower main sill inner
chord
Before further flightContact Boeing for instructions and
do the work instructed by Boeing
Any corrosion damage
or other irregularity is
found in the lower main
sill inner chord
-Before further flightContact Boeing for instructions and
do the work instructed by Boeing
Any crack, corrosion
damage, or other irreg-
ularity is found in the
structure other than the
lower main sill inner
chord
(a) Accomplishment of the repair in accordance with Paragraph 3.B., Work Instructions WORK PACKAGE
1, Step 4.b.(1) terminates the inspections in this service bulletin at this location.
Group 3; Group 4, Configuration 3:
Table 6: Overwing Emergency Exit Hatch Opening - Lower Main Sill - Inspection and Repair - WORK
PACKAGE 2 - RIGHT SIDE
Repeat Interval
(Not to Exceed)
Compliance Time
(Whichever Occurs Later)
ActionCondition
-Within 3,000
flight cycles after
the original issue
date of this ser-
vice bulletin
Before
37,500 total
flight cycles
Do detailed inspections of the
lower main sill inner chord and
surrounding structure around STA
903.5 in accordance with Para-
graph 3.B., Work Instructions
WORK PACKAGE 2, Step 4.b.
All airplanes
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Group 3; Group 4, Configuration 3:
Table 6: Overwing Emergency Exit Hatch Opening - Lower Main Sill - Inspection and Repair - WORK
PACKAGE 2 - RIGHT SIDE
Repeat Interval
(Not to Exceed)
Compliance Time
(Whichever Occurs Later)
ActionCondition
3,750 flight cycles
(a)
Within 3,750 flight cycles after
the initial detailed inspection
Repeat the detailed inspections of
the lower main sill inner chord and
surrounding structure around STA
903.5 in accordance with Para-
graph 3.B., Work Instructions
WORK PACKAGE 2, Step 4.b.
No crack, corrosion
damage, or other irreg-
ularity is found
(a)Before further flightRepair in accordance with Para-
graph 3.B., Work Instructions
WORK PACKAGE 2, Step 4.b.(1)
Any crack is found in
the lower main sill inner
chord
Before further flightContact Boeing for instructions and
do the work instructed by Boeing
Any corrosion damage
or other irregularity is
found in the lower main
sill inner chord
-Before further flightContact Boeing for instructions and
do the work instructed by Boeing
Any crack, corrosion
damage, or other irreg-
ularity is found in the
structure other than the
lower main sill inner
chord
(a) Accomplishment of the repair in accordance with Paragraph 3.B., Work Instructions WORK PACKAGE
2, Step 4.b.(1) terminates the inspections in this service bulletin at this location.
Group 4, Configuration 4:
No work is necessary.
F. Approval
This service bulletin was examined by the Federal Aviation Administration (FAA). The changes specified
in this service bulletin comply with the applicable regulations and are FAA approved, as well as European
Aviation Safety Agency (EASA)/Joint Aviation Authorities (JAA) approved for all EASA/JAA approved
airplanes listed in the service bulletin effectivity. This service bulletin and its approval were based on
the airplane in its original Boeing delivery configuration or as modified by other approved Boeing
changes.
If an airplane has a non-Boeing modification or repair that affects a component or system also affected
by this service bulletin, the operator is responsible for obtaining appropriate regulatory agency approval
before incorporating this service bulletin.
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G. Manpower
The table below shows an estimate of the task hours necessary to do this service bulletin for each
airplane. This estimate is for direct labor only, done by an experienced crew. Adjust the estimate with
operator task hour data if necessary. The estimate does not include lost time. These are some examples
of lost time:
 Time to adjust to the workplace
 Time to schedule the work
 Time to inspect the work
 Time to cure the materials
 Time to make the parts
 Time to find the tools.
Group 1; Group 4, Configuration 1:
WORK PACKAGE 1 - LEFT SIDE
Elapsed HoursTask HoursNumber of PersonsTask
2.004.002Open Access
1.001.001FIGURE 1
2.004.002Close Access
5.009.00TOTAL FOR EACH AIRPLANE
Group 1; Group 4, Configuration 1:
WORK PACKAGE 2 - RIGHT SIDE
Elapsed HoursTask HoursNumber of PersonsTask
2.004.002Open Access
1.001.001FIGURE 5
2.004.002Close Access
5.009.00TOTAL FOR EACH AIRPLANE
Group 2; Group 4, Configuration 2:
WORK PACKAGE 1 - LEFT SIDE
Elapsed HoursTask HoursNumber of PersonsTask
3.156.302Open Access
1.001.001FIGURE 2
0.350.351FIGURE 3
3.156.302Close Access
7.6513.95TOTAL FOR EACH AIRPLANE
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Group 2; Group 4, Configuration 2:
WORK PACKAGE 2 - RIGHT SIDE
Elapsed HoursTask HoursNumber of PersonsTask
3.156.302Open Access
1.001.001FIGURE 6
0.350.351FIGURE 7
3.156.302Close Access
7.6513.95TOTAL FOR EACH AIRPLANE
Group 3; Group 4, Configuration 3:
WORK PACKAGE 1 - LEFT SIDE
Elapsed HoursTask HoursNumber of PersonsTask
2.004.002Open Access
0.350.351FIGURE 4
2.004.002Close Access
4.358.35TOTAL FOR EACH AIRPLANE
Group 3; Group 4, Configuration 3:
WORK PACKAGE 2 - RIGHT SIDE
Elapsed HoursTask HoursNumber of PersonsTask
2.004.002Open Access
0.350.351FIGURE 8
2.004.002Close Access
4.358.35TOTAL FOR EACH AIRPLANE
H. Weight and Balance Changes
None.
I. Electrical Load Data
Not changed.
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J. References
1. Existing Data
a. Boeing Service Letter 767-SL-51-036
b. Boeing Service Related Problem (SRP) 767-SRP-53-0358
c. 767 Aircraft Maintenance Manual (AMM) 25-21-01, 25-21-05, 25-25-01, 25-65-00, 52-21-01
d. 767 Fleet Team Digest (FTD) 53-10001
e. 767 Non-Destructive Testing (NDT) Manual Part 6, 51-00-01, Part 6, 51-00-19
f. 767-200 Structural Repair Manual (SRM) 53-50-07
g. 767-300 Structural Repair Manual (SRM) 53-50-07
h. 767-300BCF Structural Repair Manual (SRM) 53-50-07
2. Data supplied with this Service Bulletin
None.
3. Installation Drawings Used in the Preparation of this Service Bulletin
This drawing was used to prepare this service bulletin. This drawing is not necessary to make the
specified changes, and is not supplied with this service bulletin. This drawing may not be applicable
to all airplane configurations or operators.
TitleDrawing Number
SILL INSTL - LOWER EMERGENCY EXIT145T8310
K. Publications Affected
1. Publications:
None.
2. Damage Tolerance Based Structural Inspections:
Boeing has evaluated the repairs and/or changes in this service bulletin for effects on Fatigue
Critical Structure (FCS) and for changes to Damage Tolerance Inspections (DTI) required in the
Maintenance Program. This service bulletin affects FCS. DTI requirements for the structure affected
are contained in Paragraph 1.E., Compliance of this service bulletin.
L. Interchangeability and Intermixability of Parts
Accomplishment of this service bulletin does not affect interchangeability or intermixability of parts.
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### Page 29

2.    MATERIAL INFORMATION
A. Material - Price and Availability
None.
B. Industry Support Information
Boeing warranty remedies are not available for the inspection and/or repair procedures given in this
service bulletin.
C. Parts Necessary For Each Airplane
1. Kits/Parts
None.
2. Parts and Materials Supplied by the Operator
None.
3. Parts Modified and Reidentified
None.
4. Parts Removed and Not Replaced
None.
D. Parts Necessary to Change Spares
None.
E. Special Tooling - Price and Availability
None.
F. Special Tooling Necessary to do this Service Bulletin
No special tools or equipment are necessary to do the change in this service bulletin. But, maintenance
and overhaul tools in the manuals given in Paragraph 1.J., References, can be necessary. Examine
operator tool supply to make sure all necessary tools are available.
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### Page 31

3.    ACCOMPLISHMENT INSTRUCTIONS
A. GENERAL INFORMATION
CAUTION: KEEP THE WORK AREA, WIRES AND ELECTRICAL BUNDLES CLEAN OF METAL
PARTICLES OR CONTAMINATION WHEN YOU USE TOOLS. UNWANTED MATERIAL,
METAL PARTICLES OR CONTAMINATION CAUGHT IN WIRE BUNDLES CAN CAUSE
DAMAGE TO THE BUNDLES. DAMAGED WIRE BUNDLES CAN CAUSE SPARKS OR
OTHER ELECTRICAL DAMAGE.
NOTE: 1. The instructions identified in Paragraph 3.B., Work Instructions and the Figure(s)
give the recommended sequence of steps. The sequence of steps to do this service
bulletin can be changed.
2. Manual titles are referred to by acronyms. Refer to Paragraph 1.J., References, for
definition of the acronyms.
3. Obey all of the warnings and cautions given in the specified manual sections.
4. The work instructions are divided into work packages. Task Hours and Elapsed Hours
for each package are given in Paragraph 1.G., Manpower. You can do each work
package independently.
5. Unless shown differently, these dimensions and tolerances are used:
– Linear dimensions are in inches
– Tolerance on linear dimensions, other than rivet and bolt edge margins, is plus
or minus 0.03 inch
6. Use the approved fastener and process material substitutions in accordance with
SRM Chapter 51. Alternate fasteners are listed in SRM Chapter 51 and Boeing
Drawing 012W6100.
7. A Detailed Inspection is defined as: An intensive examination of a specific item,
installation, or assembly to detect damage, failure, or irregularity. Available lighting
is normally supplemented with a direct source of good lighting at an intensity deemed
appropriate. Inspection aids such as mirrors, magnifying lenses, etc. may be
necessary. Surface cleaning and elaborate procedures may be required.
8. These work instructions refer to procedures included in other Boeing documents.
When the words "refer to" are used and the operator has an accepted alternative
procedure, the accepted alternative procedure can be used. When the words "in
accordance with" are included in the instruction, the procedure in the Boeing document
must be used.
9. Boeing Service Letter 767-SL-51-036, Damage Reporting and Repair Plan/Design
Guidelines, is an acceptable procedure to request information from Boeing for
additional structural repair instructions. The Service Letter describes what information
must be provided to Boeing before a structural repair can be provided.
10. If it is necessary to remove more parts for access, you can remove those parts. If
you can get access without removing identified parts, it is not necessary to remove
all of the identified parts. Jacking and shoring limitations must be observed.
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B. WORK INSTRUCTIONS
Group 1-3; Group 4, Configuration 1-3:
WORK PACKAGE 1 - LEFT SIDE
1. Disarm the off-wing escape system. Refer to 767 AMM 25-65-00 as an accepted procedure.
2. Group 1; Group 4, Configuration 1:
a. Do the following steps as necessary to get access to the lower main sill of the overwing
emergency exit hatch opening around the frame at Body Station (STA) 883.5 (immediately
aft of the overwing emergency exit hatch):
(1) Remove seats within 6 inches forward and aft of the frame. Refer to 767 AMM 25-25-01
as an accepted procedure.
(2) Remove the overwing emergency exit hatch. Refer to 767 AMM 52-21-01 as an accepted
procedure.
(3) Remove sidewall panels within 6 inches forward and aft of the frame. Refer to 767 AMM
25-21-01 as an accepted procedure.
(4) Remove or fold back sidewall insulation within 6 inches forward and aft of the frame and
4 inches above and below the lower main sill. Refer to 767 AMM 25-21-05 as an accepted
procedure.
b. Do High Frequency Eddy Current (HFEC) and detailed inspections of the lower main sill
around STA 883.5 in accordance with FIGURE 1.
(1) If any crack is found in the lower main sill inner chord, repair in accordance with 767-200
SRM 53-50-07 REPAIR 1.
(2) If any corrosion damage or other irregularity is found in the lower main sill inner chord,
contact Boeing for repair instructions and do the work instructed by Boeing.
(3) If any crack, corrosion damage, or other irregularity is found in structure other than the
lower main sill inner chord, contact Boeing for repair instructions and do the work instructed
by Boeing.
c. Do the following to close access to the lower main sill of the overwing emergency exit hatch
opening around the frame at STA 883.5:
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(1) Install removed sidewall insulation. Refer to 767 AMM 25-21-05 as an accepted procedure.
(2) Install removed sidewall panels. Refer to 767 AMM 25-21-01 as an accepted procedure.
(3) Install removed overwing emergency exit hatch. Refer to 767 AMM 52-21-01 as an
accepted procedure.
(4) Install removed seats. Refer to 767 AMM 25-25-01 as an accepted procedure.
3. Group 2; Group 4, Configuration 2:
a. Do the following steps as necessary to get access to the lower main sill of the overwing
emergency exit hatch openings around the frames at STA 883.5 (immediately aft of the forward
overwing emergency exit hatch) and STA 903.5 (immediately forward of the aft overwing
emergency exit hatch):
(1) Remove seats within 6 inches forward and aft of the frames. Refer to 767 AMM 25-25-01
as an accepted procedure.
(2) Remove the overwing emergency exit hatches. Refer to 767 AMM 52-21-01 as an accepted
procedure.
(3) Remove sidewall panels within 6 inches forward and aft of the frames. Refer to 767 AMM
25-21-01 as an accepted procedure.
(4) Remove or fold back sidewall insulation within 6 inches forward and aft of the frames and
4 inches above and below the lower main sill. Refer to 767 AMM 25-21-05 as an accepted
procedure.
b. Do HFEC and detailed inspections of the lower main sill around STA 883.5 in accordance
with FIGURE 2.
(1) If any crack is found in the lower main sill inner chord, repair in accordance with 767-200
SRM 53-50-07 REPAIR 2, 767-300 SRM 53-50-07 REPAIR 2 or 767-300BCF SRM
53-50-07 REPAIR 2.
(2) If any corrosion damage or other irregularity is found in the lower main sill inner chord,
contact Boeing for repair instructions and do the work instructed by Boeing.
(3) If any crack, corrosion damage, or other irregularity is found in structure other than the
lower main sill inner chord, contact Boeing for repair instructions and do the work instructed
by Boeing.
c. Do detailed inspections of the lower main sill around STA 903.5 in accordance with FIGURE
3.
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(1) If any crack is found in the lower main sill inner chord, repair in accordance with 767-200
SRM 53-50-07 REPAIR 2, 767-300 SRM 53-50-07 REPAIR 2 or 767-300BCF SRM
53-50-07 REPAIR 2.
(2) If any corrosion damage or other irregularity is found in the lower main sill inner chord,
contact Boeing for repair instructions and do the work instructed by Boeing.
(3) If any crack, corrosion damage, or other irregularity is found in structure other than the
lower main sill inner chord, contact Boeing for repair instructions and do the work instructed
by Boeing.
d. Do the following to close access to the lower main sill of the overwing emergency exit hatch
openings around the frames at STA 883.5 and STA 903.5:
(1) Install removed sidewall insulation. Refer to 767 AMM 25-21-05 as an accepted procedure.
(2) Install removed sidewall panels. Refer to 767 AMM 25-21-01 as an accepted procedure.
(3) Install removed overwing emergency exit hatch. Refer to 767 AMM 52-21-01 as an
accepted procedure.
(4) Install removed seats. Refer to 767 AMM 25-25-01 as an accepted procedure.
4. Group 3; Group 4, Configuration 3:
a. Do the following steps as necessary to get access to the lower main sill of the overwing
emergency exit hatch opening around the frame at STA 903.5 (immediately forward of the
overwing emergency exit hatch):
(1) Remove seats within 6 inches forward and aft of the frame. Refer to 767 AMM 25-25-01
as an accepted procedure.
(2) Remove the overwing emergency exit hatch. Refer to 767 AMM 52-21-01 as an accepted
procedure.
(3) Remove sidewall panels within 6 inches forward and aft of the frame. Refer to 767 AMM
25-21-01 as an accepted procedure.
(4) Remove or fold back sidewall insulation within 6 inches forward and aft of the frame and
4 inches above and below the lower main sill. Refer to 767 AMM 25-21-05 as an accepted
procedure.
b. Do detailed inspections of the lower main sill around STA 903.5 in accordance with FIGURE
4.
BOEING PROPRIETARY -
Copyright © Unpublished Work - See page 1 for details.
Original Issue: July 28, 2011
767-53A0228
34 of 54
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ALERTALERT

### Page 35

(1) If any crack is found in the lower main sill inner chord, repair in accordance with 767-300
SRM 53-50-07 REPAIR 3 or 767-300BCF SRM 53-50-07 REPAIR 3.
(2) If any corrosion damage or other irregularity is found in the lower main sill inner chord,
contact Boeing for repair instructions and do the work instructed by Boeing.
(3) If any crack, corrosion damage, or other irregularity is found in structure other than the
lower main sill inner chord, contact Boeing for repair instructions and do the work instructed
by Boeing.
c. Do the following to close access to the lower main sill of the overwing emergency exit hatch
opening around the frame at STA 903.5:
(1) Install removed sidewall insulation. Refer to 767 AMM 25-21-05 as an accepted procedure.
(2) Install removed sidewall panels. Refer to 767 AMM 25-21-01 as an accepted procedure.
(3) Install removed overwing emergency exit hatch. Refer to 767 AMM 52-21-01 as an
accepted procedure.
(4) Install removed seats. Refer to 767 AMM 25-25-01 as an accepted procedure.
5. Arm the off-wing escape system. Refer to 767 AMM 25-65-00 as an accepted procedure.
6. Put the airplane back to a serviceable condition.
Group 1-3; Group 4, Configuration 1-3:
WORK PACKAGE 2 - RIGHT SIDE
1. Disarm the off-wing escape system. Refer to 767 AMM 25-65-00 as an accepted procedure.
2. Group 1; Group 4, Configuration 1:
a. Do the following steps as necessary to get access to the lower main sill of the overwing
emergency exit hatch opening around the frame at STA 883.5 (immediately aft of the overwing
emergency exit hatch):
(1) Remove seats within 6 inches forward and aft of the frame. Refer to 767 AMM 25-25-01
as an accepted procedure.
(2) Remove the overwing emergency exit hatch. Refer to 767 AMM 52-21-01 as an accepted
procedure.
(3) Remove sidewall panels within 6 inches forward and aft of the frame. Refer to 767 AMM
25-21-01 as an accepted procedure.
(4) Remove or fold back sidewall insulation within 6 inches forward and aft of the frame and
4 inches above and below the lower main sill. Refer to 767 AMM 25-21-05 as an accepted
procedure.
b. Do High Frequency Eddy Current (HFEC) and detailed inspections of the lower main sill
around STA 883.5 in accordance with FIGURE 5.
BOEING PROPRIETARY -
Copyright © Unpublished Work - See page 1 for details.
Original Issue: July 28, 2011
767-53A0228
35 of 54
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ALERTALERT

### Page 36

(1) If any crack is found in the lower main sill inner chord, repair in accordance with 767-200
SRM 53-50-07 REPAIR 1.
(2) If any corrosion damage or other irregularity is found in the lower main sill inner chord,
contact Boeing for repair instructions and do the work instructed by Boeing.
(3) If any crack, corrosion damage, or other irregularity is found in structure other than the
lower main sill inner chord, contact Boeing for repair instructions and do the work instructed
by Boeing.
c. Do the following to close access to the lower main sill of the overwing emergency exit hatch
opening around the frame at STA 883.5:
(1) Install removed sidewall insulation. Refer to 767 AMM 25-21-05 as an accepted procedure.
(2) Install removed sidewall panels. Refer to 767 AMM 25-21-01 as an accepted procedure.
(3) Install removed overwing emergency exit hatch. Refer to 767 AMM 52-21-01 as an
accepted procedure.
(4) Install removed seats. Refer to 767 AMM 25-25-01 as an accepted procedure.
3. Group 2; Group 4, Configuration 2:
a. Do the following steps as necessary to get access to the lower main sill of the overwing
emergency exit hatch openings around the frames at STA 883.5 (immediately aft of the forward
overwing emergency exit hatch) and STA 903.5 (immediately forward of the aft overwing
emergency exit hatch):
(1) Remove seats within 6 inches forward and aft of the frames. Refer to 767 AMM 25-25-01
as an accepted procedure.
(2) Remove the overwing emergency exit hatch. Refer to 767 AMM 52-21-01 as an accepted
procedure.
(3) Remove sidewall panels within 6 inches forward and aft of the frames. Refer to 767 AMM
25-21-01 as an accepted procedure.
(4) Remove or fold back sidewall insulation within 6 inches forward and aft of the frames and
4 inches above and below the lower main sill. Refer to 767 AMM 25-21-05 as an accepted
procedure.
b. Do HFEC and detailed inspections of the lower main sill around STA 883.5 in accordance
with FIGURE 6.
BOEING PROPRIETARY -
Copyright © Unpublished Work - See page 1 for details.
Original Issue: July 28, 2011
767-53A0228
36 of 54
BOEING SERVICE BULLETIN 767-53A0228
ALERTALERT

### Page 37

(1) If any crack is found in the lower main sill inner chord, repair in accordance with 767-200
SRM 53-50-07 REPAIR 2, 767-300 SRM 53-50-07 REPAIR 2 or 767-300BCF SRM
53-50-07 REPAIR 2.
(2) If any corrosion damage or other irregularity is found in the lower main sill inner chord,
contact Boeing for repair instructions and do the work instructed by Boeing.
(3) If any crack, corrosion damage, or other irregularity is found in structure other than the
lower main sill inner chord, contact Boeing for repair instructions and do the work instructed
by Boeing.
c. Do detailed inspections of the lower main sill around STA 903.5 in accordance with FIGURE
7.
(1) If any crack is found in the lower main sill inner chord, repair in accordance with 767-200
SRM 53-50-07 REPAIR 2, 767-300 SRM 53-50-07 REPAIR 2 or 767-300BCF SRM
53-50-07 REPAIR 2.
(2) If any corrosion damage or other irregularity is found in the lower main sill inner chord,
contact Boeing for repair instructions and do the work instructed by Boeing.
(3) If any crack, corrosion damage, or other irregularity is found in structure other than the
lower main sill inner chord, contact Boeing for repair instructions and do the work instructed
by Boeing.
d. Do the following to close access to the lower main sill of the overwing emergency exit hatch
openings around the frames at STA 883.5 and STA 903.5:
(1) Install removed sidewall insulation. Refer to 767 AMM 25-21-05 as an accepted procedure.
(2) Install removed sidewall panels. Refer to 767 AMM 25-21-01 as an accepted procedure.
(3) Install removed overwing emergency exit hatch. Refer to 767 AMM 52-21-01 as an
accepted procedure.
(4) Install removed seats. Refer to 767 AMM 25-25-01 as an accepted procedure.
4. Group 3; Group 4, Configuration 3:
a. Do the following steps as necessary to get access to the lower main sill of the overwing
emergency exit hatch opening around the frame at STA 903.5 (immediately forward of the
overwing emergency exit hatch):
BOEING PROPRIETARY -
Copyright © Unpublished Work - See page 1 for details.
Original Issue: July 28, 2011
767-53A0228
37 of 54
BOEING SERVICE BULLETIN 767-53A0228
ALERTALERT

### Page 38

(1) Remove seats within 6 inches forward and aft of the frame. Refer to 767 AMM 25-25-01
as an accepted procedure.
(2) Remove the overwing emergency exit hatch. Refer to 767 AMM 52-21-01 as an accepted
procedure.
(3) Remove sidewall panels within 6 inches forward and aft of the frame. Refer to 767 AMM
25-21-01 as an accepted procedure.
(4) Remove or fold back sidewall insulation within 6 inches forward and aft of the frame and
4 inches above and below the lower main sill. Refer to 767 AMM 25-21-05 as an accepted
procedure.
b. Do detailed inspections of the lower main sill around STA 903.5 in accordance with FIGURE
8.
(1) If any crack is found in the lower main sill inner chord, repair in accordance with 767-300
SRM 53-50-07 REPAIR 3 or 767-300BCF SRM 53-50-07 REPAIR 3.
(2) If any corrosion damage or other irregularity is found in the lower main sill inner chord,
contact Boeing for repair instructions and do the work instructed by Boeing.
(3) If any crack, corrosion damage, or other irregularity is found in structure other than the
lower main sill inner chord, contact Boeing for repair instructions and do the work instructed
by Boeing.
c. Do the following to close access to the lower main sill of the overwing emergency exit hatch
opening around the frame at STA 903.5:
(1) Install removed sidewall insulation. Refer to 767 AMM 25-21-05 as an accepted procedure.
(2) Install removed sidewall panels. Refer to 767 AMM 25-21-01 as an accepted procedure.
(3) Install removed overwing emergency exit hatch. Refer to 767 AMM 52-21-01 as an
accepted procedure.
(4) Install removed seats. Refer to 767 AMM 25-25-01 as an accepted procedure.
5. Arm the off-wing escape system. Refer to 767 AMM 25-65-00 as an accepted procedure.
6. Put the airplane back to a serviceable condition.
Group 4, Configuration 4:
AIRPLANES WITH NO OVERWING EMERGENCY EXIT HATCHES
1. No work is necessary.
BOEING PROPRIETARY -
Copyright © Unpublished Work - See page 1 for details.
Original Issue: July 28, 2011
767-53A0228
38 of 54
BOEING SERVICE BULLETIN 767-53A0228
ALERTALERT

### Page 39 (OCR)

BOEING SERVICE BULLETIN 767-53A0228
ALERT  ALERT
This Figure applies only to: Group 1; Group 4, Configuration 1.
00000000
STA
889
S-18L
2024217
FIGURE 1: LEFT SIDE - OVERWING EMERGENCY EXIT HATCH OPENING - LOWER MAIN SILL - STA
883.5 - INSPECTIONS
(SHEET 1 OF 2)
Original Issue: July 28, 2011
BOEING PROPRIETARY -  767-53A0228
Copyright © Unpublished Work - See page 1 for details.  39 of 54

### Page 40

The step numbers shown below agree with the numbers shown in the circle symbols in the figure.
MORE DATAQTYIDENTIFICATIONNAMETASKSTEP
(b)--LOWER MAIN SILL IN-
NER CHORD
Inspect1
(a)--LOWER MAIN SILL IN-
NER CHORD
Inspect2
(c)--STRUCTUREInspect3
(a) Do a surface HFEC inspection of the upper surface of the lower main sill inner chord for cracks in accor-
dance with 767 NDT Part 6, 51-00-01 or 767 NDT Part 6, 51-00-19.
(b) Do a detailed inspection of the upper surface of the lower main sill inner chord for cracks, corrosion
damage, or other irregularity. Use 5-10x magnification.
(c) Do a detailed inspection of all visible surfaces of the structure within 2 inches in all directions around the
lower main sill inspection area shown in step 1. This inspection is to detect cracks, corrosion damage, or
other irregularity.
FIGURE 1: LEFT SIDE - OVERWING EMERGENCY EXIT HATCH OPENING - LOWER MAIN SILL - STA
883.5 - INSPECTIONS
(SHEET 2 OF 2)
BOEING PROPRIETARY -
Copyright © Unpublished Work - See page 1 for details.
Original Issue: July 28, 2011
767-53A0228
40 of 54
BOEING SERVICE BULLETIN 767-53A0228
ALERTALERT

### Page 41 (OCR)

BOEING SERVICE BULLETIN 767-53A0228
ALERT  ALERT
This Figure applies only to: Group 2; Group 4, Configuration 2.
903.5
STA
883.5
STA
852
S-18L
2024219
FIGURE 2: LEFT SIDE - FORWARD OVERWING EMERGENCY EXIT HATCH OPENING - LOWER MAIN
SILL - STA 883.5 - INSPECTIONS
(SHEET 1 OF 2)
Original Issue: July 28, 2011
767-53A0228
BOEING PROPRIETARY -
Copyright © Unpublished  Work - See page 1 for details.  41 of 54

### Page 42

The step numbers shown below agree with the numbers shown in the circle symbols in the figure.
MORE DATAQTYIDENTIFICATIONNAMETASKSTEP
(b)--LOWER MAIN SILL IN-
NER CHORD
Inspect1
(a)--LOWER MAIN SILL IN-
NER CHORD
Inspect2
(c)--STRUCTUREInspect3
(a) Do a surface HFEC inspection of the upper surface of the lower main sill inner chord for cracks in accor-
dance with 767 NDT Part 6, 51-00-01 or 767 NDT Part 6, 51-00-19.
(b) Do a detailed inspection of the upper surface of the lower main sill inner chord for cracks, corrosion
damage, or other irregularity. Use 5-10x magnification.
(c) Do a detailed inspection of all visible surfaces of the structure within 2 inches in all directions around the
lower main sill inspection area shown in step 1. This inspection is to detect cracks, corrosion damage, or
other irregularity.
FIGURE 2: LEFT SIDE - FORWARD OVERWING EMERGENCY EXIT HATCH OPENING - LOWER MAIN
SILL - STA 883.5 - INSPECTIONS
(SHEET 2 OF 2)
BOEING PROPRIETARY -
Copyright © Unpublished Work - See page 1 for details.
Original Issue: July 28, 2011
767-53A0228
42 of 54
BOEING SERVICE BULLETIN 767-53A0228
ALERTALERT

### Page 43 (OCR)

BOEING SERVICE BULLETIN 767-53A0228
ALERT  ALERT
This Figure applies only to: Group 2; Group 4, Configuration 2.
000000
903.5
STA
883.5
STA
852
S-18L
2024221
FIGURE 3: LEFT SIDE - AFT OVERWING EMERGENCY EXIT HATCH OPENING - LOWER MAIN SILL -
STA 903.5 - INSPECTIONS
(SHEET 1 OF 2)
Original Issue: July 28, 2011
BOEING PROPRIETARY -  767-53A0228
Copyright © Unpublished  Work - See page 1 for details.  43 of 54

### Page 44

The step numbers shown below agree with the numbers shown in the circle symbols in the figure.
MORE DATAQTYIDENTIFICATIONNAMETASKSTEP
(a)--LOWER MAIN SILL IN-
NER CHORD
Inspect1
(b)--STRUCTUREInspect2
(a) Do a detailed inspection of the upper surface of the lower main sill inner chord for cracks, corrosion
damage, or other irregularity. Use 5-10x magnification.
(b) Do a detailed inspection of all visible surfaces of the structure within 2 inches in all directions around the
lower main sill inspection area shown in step 1. This inspection is to detect cracks, corrosion damage, or
other irregularity.
FIGURE 3: LEFT SIDE - AFT OVERWING EMERGENCY EXIT HATCH OPENING - LOWER MAIN SILL -
STA 903.5 - INSPECTIONS
(SHEET 2 OF 2)
BOEING PROPRIETARY -
Copyright © Unpublished Work - See page 1 for details.
Original Issue: July 28, 2011
767-53A0228
44 of 54
BOEING SERVICE BULLETIN 767-53A0228
ALERTALERT

### Page 45 (OCR)

BOEING SERVICE BULLETIN 767-53A0228
ALERT  ALERT
This Figure applies only to: Group 3; Group 4, Configuration 3.
STA
933
STA
903.5
STA
883.5
STA
852
S-18L
2024223
FIGURE 4: LEFT SIDE - OVERWING EMERGENCY EXIT HATCH OPENING - LOWER MAIN SILL - STA
903.5 - INSPECTIONS
(SHEET 1 OF 2)
Original Issue: July 28, 2011
767-53A0228
Copyright © Unpublished  BOEING  • PROPRIETARY -  Work - See page 1 for details.  45 of 54

### Page 46

The step numbers shown below agree with the numbers shown in the circle symbols in the figure.
MORE DATAQTYIDENTIFICATIONNAMETASKSTEP
(a)--LOWER MAIN SILL IN-
NER CHORD
Inspect1
(b)--STRUCTUREInspect2
(a) Do a detailed inspection of the upper surface of the lower main sill inner chord for cracks, corrosion
damage, or other irregularity. Use 5-10x magnification.
(b) Do a detailed inspection of all visible surfaces of the structure within 2 inches in all directions around the
lower main sill inspection area shown in step 1. This inspection is to detect cracks, corrosion damage, or
other irregularity.
FIGURE 4: LEFT SIDE - OVERWING EMERGENCY EXIT HATCH OPENING - LOWER MAIN SILL - STA
903.5 - INSPECTIONS
(SHEET 2 OF 2)
BOEING PROPRIETARY -
Copyright © Unpublished Work - See page 1 for details.
Original Issue: July 28, 2011
767-53A0228
46 of 54
BOEING SERVICE BULLETIN 767-53A0228
ALERTALERT

### Page 47 (OCR)

BOEING SERVICE BULLETIN 767-53A0228
ALERT  ALERT
This Figure applies only to: Group 1; Group 4, Configuration 1.
STA
889
STA
852
S-18R -
2024225
FIGURE 5: RIGHT SIDE - OVERWING EMERGENCY EXIT HATCH OPENING - LOWER MAIN SILL - STA
883.5 - INSPECTIONS
(SHEET 1 OF 2)
Original Issue: July 28, 2011
767-53A0228
BOEING PROPRIETARY -
Copyright © Unpublished Work - See page 1 for details.  47 of 54

### Page 48

The step numbers shown below agree with the numbers shown in the circle symbols in the figure.
MORE DATAQTYIDENTIFICATIONNAMETASKSTEP
(b)--LOWER MAIN SILL IN-
NER CHORD
Inspect1
(a)--LOWER MAIN SILL IN-
NER CHORD
Inspect2
(c)--STRUCTUREInspect3
(a) Do a surface HFEC inspection of the upper surface of the lower main sill inner chord for cracks in accor-
dance with 767 NDT Part 6, 51-00-01 or 767 NDT Part 6, 51-00-19.
(b) Do a detailed inspection of the upper surface of the lower main sill inner chord for cracks, corrosion
damage, or other irregularity. Use 5-10x magnification.
(c) Do a detailed inspection of all visible surfaces of the structure within 2 inches in all directions around the
lower main sill inspection area shown in step 1. This inspection is to detect cracks, corrosion damage, or
other irregularity.
FIGURE 5: RIGHT SIDE - OVERWING EMERGENCY EXIT HATCH OPENING - LOWER MAIN SILL - STA
883.5 - INSPECTIONS
(SHEET 2 OF 2)
BOEING PROPRIETARY -
Copyright © Unpublished Work - See page 1 for details.
Original Issue: July 28, 2011
767-53A0228
48 of 54
BOEING SERVICE BULLETIN 767-53A0228
ALERTALERT

### Page 49 (OCR)

BOEING SERVICE BULLETIN 767-53A0228
ALERT  ALERT
This Figure applies only to: Group 2; Group 4, Configuration 2.
000
STA
933
STA
903.5
STA
852
S-18R
2024227
FIGURE 6: RIGHT SIDE - FORWARD OVERWING EMERGENCY EXIT HATCH OPENING - LOWER MAIN
SILL - STA 883.5 - INSPECTIONS
(SHEET 1 OF 2)
Original Issue: July 28, 2011
BOEING PROPRIETARY -  767-53A0228
Copyright © Unpublished Work - See page 1 for details.  49 of 54

### Page 50

The step numbers shown below agree with the numbers shown in the circle symbols in the figure.
MORE DATAQTYIDENTIFICATIONNAMETASKSTEP
(b)--LOWER MAIN SILL IN-
NER CHORD
Inspect1
(a)--LOWER MAIN SILL IN-
NER CHORD
Inspect2
(c)--STRUCTUREInspect3
(a) Do a surface HFEC inspection of the upper surface of the lower main sill inner chord for cracks in accor-
dance with 767 NDT Part 6, 51-00-01 or 767 NDT Part 6, 51-00-19.
(b) Do a detailed inspection of the upper surface of the lower main sill inner chord for cracks, corrosion
damage, or other irregularity. Use 5-10x magnification.
(c) Do a detailed inspection of all visible surfaces of the structure within 2 inches in all directions around the
lower main sill inspection area shown in step 1. This inspection is to detect cracks, corrosion damage, or
other irregularity.
FIGURE 6: RIGHT SIDE - FORWARD OVERWING EMERGENCY EXIT HATCH OPENING - LOWER MAIN
SILL - STA 883.5 - INSPECTIONS
(SHEET 2 OF 2)
BOEING PROPRIETARY -
Copyright © Unpublished Work - See page 1 for details.
Original Issue: July 28, 2011
767-53A0228
50 of 54
BOEING SERVICE BULLETIN 767-53A0228
ALERTALERT

### Page 51 (OCR)

BOEING SERVICE BULLETIN 767-53A0228
ALERT  ALERT
This Figure applies only to: Group 2; Group 4, Configuration 2.
000
STA
933
STA
903.5
STA
883.5
STA
852
S-18R
2024229
FIGURE 7: RIGHT SIDE - AFT OVERWING EMERGENCY EXIT HATCH OPENING - LOWER MAIN SILL -
STA 903.5 - INSPECTIONS
(SHEET 1 OF 2)
Original Issue: July 28, 2011
767-53A0228
Copyright © Unpublished Work - See page 1 for details.  BOEING PROPRIETARY -  51 of 54

### Page 52

The step numbers shown below agree with the numbers shown in the circle symbols in the figure.
MORE DATAQTYIDENTIFICATIONNAMETASKSTEP
(a)--LOWER MAIN SILL IN-
NER CHORD
Inspect1
(b)--STRUCTUREInspect2
(a) Do a detailed inspection of the upper surface of the lower main sill inner chord for cracks, corrosion
damage, or other irregularity. Use 5-10x magnification.
(b) Do a detailed inspection of all visible surfaces of the structure within 2 inches in all directions around the
lower main sill inspection area shown in step 1. This inspection is to detect cracks, corrosion damage, or
other irregularity.
FIGURE 7: RIGHT SIDE - AFT OVERWING EMERGENCY EXIT HATCH OPENING - LOWER MAIN SILL -
STA 903.5 - INSPECTIONS
(SHEET 2 OF 2)
BOEING PROPRIETARY -
Copyright © Unpublished Work - See page 1 for details.
Original Issue: July 28, 2011
767-53A0228
52 of 54
BOEING SERVICE BULLETIN 767-53A0228
ALERTALERT

### Page 53 (OCR)

BOEING SERVICE BULLETIN 767-53A0228
ALERT  ALERT
This Figure applies only to: Group 3; Group 4, Configuration 3.
000
STA
933
STA
903.5
STA
883.5
STA
852
S-18R
2024232
FIGURE 8: RIGHT SIDE - OVERWING EMERGENCY EXIT HATCH OPENING - LOWER MAIN SILL - STA
903.5 - INSPECTIONS
(SHEET 1 OF 2)
Original Issue: July 28, 2011
BOEING PROPRIETARY -  767-53A0228
Copyright © Unpublished Work - See page 1 for details.  53 of 54

### Page 54

The step numbers shown below agree with the numbers shown in the circle symbols in the figure.
MORE DATAQTYIDENTIFICATIONNAMETASKSTEP
(a)--LOWER MAIN SILL IN-
NER CHORD
Inspect1
(b)--STRUCTUREInspect2
(a) Do a detailed inspection of the upper surface of the lower main sill inner chord for cracks, corrosion
damage, or other irregularity. Use 5-10x magnification.
(b) Do a detailed inspection of all visible surfaces of the structure within 2 inches in all directions around the
lower main sill inspection area shown in step 1. This inspection is to detect cracks, corrosion damage, or
other irregularity.
FIGURE 8: RIGHT SIDE - OVERWING EMERGENCY EXIT HATCH OPENING - LOWER MAIN SILL - STA
903.5 - INSPECTIONS
(SHEET 2 OF 2)
BOEING PROPRIETARY -
Copyright © Unpublished Work - See page 1 for details.
Original Issue: July 28, 2011
767-53A0228
54 of 54
BOEING SERVICE BULLETIN 767-53A0228
ALERTALERT

---
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