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Commercial Airplanes 767 Service Bulletin ALERT Number: 767-53A0265 Original Issue: March 18, 2015 Revision 1: March 18, 2016 ATA System: 5312 5332 5362 SUBJECT: FUSELAGE - Main Frame - Fuselage Frames at Floor Beam and Shear Tie Attachments
- Inspection and Repair Export of this technology is controlled under the United States Export Administration Regulations (EAR) (15 CFR 300-774). 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 © 2015 Boeing.
Unpublished Work. All Rights Reserved.
Treatment of this document and its content is governed by contract with Boeing. Rights to use this document are licensed on a per aircraft basis and such rights may not be transferable. For more information, contact The Boeing Company.
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, KC-46, KDC-10, MD-10, MD-11, MD-80, MD-88, MD-90, P-8, Poseidon and Boeing liveries 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 18, 2015 767-53A0265Revision 1: March 18, 2016 1 of 178
3.0
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: March 18, 2015 767-53A0265Revision 1: March 18, 2016 2 of 178 BOEING SERVICE BULLETIN 767-53A0265
ALERTALERT
BLANK PAGE
Table of Contents
Revision Transmittal Sheet5
S u m m a r y7
1. PLANNING INFORMATION ........................................ 1 1 A . E f f e c t i v i t y ............................................... 1 1
1. Airplanes ............................................ 1 1 2 . S p a r e s A f f e c t e d ........................................ 1 7 B. Concurrent Requirements ...................................... 1 8 C. Reason ................................................ 1 8 D. Description .............................................. 1 8 E. Compliance .............................................. 1 9 F . A p p r o v a l ............................................... 2 1 G. Manpower .............................................. 2 2 H. Weight and Balance Changes .................................... 3 1 I. Electrical Load Data ......................................... 3 1 J . R e f e r e n c e s .............................................. 3 1
1. Existing Data: ......................................... 3 1
2. Data Supplied with this Service Bulletin: ........................... 3 2
3. Installation Drawings Used in the Preparation of this Service Bulletin: ........... 3 2 K. Publications Affected ........................................ 3 4 L. Interchangeability and Intermixability of Parts ........................... 3 5 M. Software Accomplishment Summary ................................ 3 5
2. MATERIAL INFORMATION ........................................ 3 7 A. Material - Price and Availability ................................... 3 7 B. Industry Support Information .................................... 3 7 C. Parts Necessary for Each Airplane ................................. 3 7 1 . K i t s / P a r t s ............................................ 3 7
2. Parts and Materials Supplied by the Operator ........................ 3 7
3. Parts Modified and Reidentified ................................ 3 7
4. Parts Removed and Not Replaced .............................. 3 7 D. Parts Necessary to Change Spares ................................. 3 7 E. Special Tooling - Price and Availability ............................... 3 7 F. Special Tooling Necessary to do this Service Bulletin ....................... 3 7
3. ACCOMPLISHMENT INSTRUCTIONS .................................. 3 9 A. GENERAL INFORMATION ..................................... 3 9 B. WORK INSTRUCTIONS ....................................... 4 1 FIGURE 1: DETAILED AND SURFACE HIGH FREQUENCY EDDY CURRENT INSPECTION OF THE FRAME INNER CHORD AND WEB COMMON TO THE FLOOR BEAM JOINT, SECTION 41 A N D 4 3 , L E F T S I D E ...................................... 7 3 FIGURE 2: DETAILED AND SURFACE HIGH FREQUENCY EDDY CURRENT INSPECTION OF THE FRAME INNER CHORD AND WEB COMMON TO THE FLOOR BEAM JOINT, SECTION 43, LEFT SIDE [Group 1-4] .................................... 7 9 FIGURE 3: DETAILED AND SURFACE HIGH FREQUENCY EDDY CURRENT INSPECTION OF THE FRAME INNER CHORD AND WEB COMMON TO THE FLOOR BEAM JOINT, SECTION 43, L E F T S I D E........................................... 8 5 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: March 18, 2015 767-53A0265Revision 1: March 18, 2016 3 of 178 BOEING SERVICE BULLETIN 767-53A0265
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FIGURE 4: DETAILED AND SURFACE HIGH FREQUENCY EDDY CURRENT INSPECTION OF THE FRAME INNER CHORD AND WEB COMMON TO THE FLOOR BEAM JOINT, SECTION 43, R I G H T S I D E.......................................... 9 1 FIGURE 5: DETAILED AND SURFACE HIGH FREQUENCY EDDY CURRENT INSPECTION OF THE FRAME INNER CHORD AND WEB COMMON TO THE FLOOR BEAM JOINT, SECTION 43, R I G H T S I D E.......................................... 9 7 FIGURE 6: DETAILED AND SURFACE HIGH FREQUENCY EDDY CURRENT INSPECTION OF THE SECTION 43 FRAMES COMMON TO THE SHEAR TIES, LEFT SIDE .......... 1 0 3 FIGURE 7: DETAILED AND SURFACE HIGH FREQUENCY EDDY CURRENT INSPECTION OF THE SECTION 43 FRAMES COMMON TO THE SHEAR TIES, LEFT SIDE [Group 2-4] . . . 111 FIGURE 8: DETAILED AND SURFACE HIGH FREQUENCY EDDY CURRENT INSPECTION OF THE SECTION 46 FRAMES COMMON TO THE SHEAR TIES, LEFT SIDE .......... 1 1 9 FIGURE 9: DETAILED AND SURFACE HIGH FREQUENCY EDDY CURRENT INSPECTION OF THE SECTION 46 FRAMES COMMON TO THE SHEAR TIES, LEFT SIDE .......... 1 2 7 FIGURE 10: DETAILED AND SURFACE HIGH FREQUENCY EDDY CURRENT INSPECTION OF THE SECTION 46 FRAMES COMMON TO THE SHEAR TIES, LEFT SIDE .......... 1 3 5 FIGURE 11: DETAILED AND SURFACE HIGH FREQUENCY EDDY CURRENT INSPECTION OF THE SECTION 43 FRAMES COMMON TO THE SHEAR TIES, RIGHT SIDE ......... 1 4 3 FIGURE 12: DETAILED AND SURFACE HIGH FREQUENCY EDDY CURRENT INSPECTION OF THE SECTION 46 FRAMES COMMON TO THE SHEAR TIES, RIGHT SIDE ......... 1 5 1 FIGURE 13: DETAILED AND SURFACE HIGH FREQUENCY EDDY CURRENT INSPECTION OF THE SECTION 46 FRAMES COMMON TO THE SHEAR TIES, RIGHT SIDE ......... 1 5 9 FIGURE 14: DETAILED AND SURFACE HIGH FREQUENCY EDDY CURRENT INSPECTION OF THE SECTION 46 FRAMES COMMON TO THE SHEAR TIES, RIGHT SIDE ......... 1 6 7 APPENDIX A: L OGIC DIAGRAM FOR PARAGRAPH 1.E. COMPLIANCE: TABLE 1: DETAILED AND SURFACE
HIGH FREQUENCY EDDY CURRENT INSPECTION OF THE FRAME INNER CHORD AND WEB COMMON TO THE FLOOR BEAM JOINT, SECTION 41 AND 43, LEFT AND RIGHT SIDE ................................................. 1 7 5 APPENDIX B: L OGIC DIAGRAM FOR PARAGRAPH 1.E. COMPLIANCE: TABLE 2: DETAILED AND SURFACE HIGH FREQUENCY EDDY CURRENT INSPECTION OF THE SECTION 43 AND 46 FRAMES C O M M O N T O T H E S H E A R T I E S , L E F T A N D R I G H T S I D E ................ 1 7 7 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: March 18, 2015 767-53A0265Revision 1: March 18, 2016 4 of 178 BOEING SERVICE BULLETIN 767-53A0265
ALERTALERT
Commercial Airplanes 767 Service Bulletin ALERT Revision Transmittal SheetNumber: 767-53A0265Original Issue: March 18, 2015 Revision 1: March 18, 2016 ATA System: 5312 5332 5362 SUBJECT: FUSELAGE - Main Frame - Fuselage Frames at Floor Beam and Shear Tie Attachments
- Inspection and Repair This revision includes all pages of the service bulletin.
COMPLIANCE INFORMATION RELATED TO THIS REVISION The Federal Aviation Administration (FAA) will possibly release an additional 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 AD 2014-14-04 is related to this service bulletin.
The effective date of AD 2014-14-04 is September 5, 2014.
Effects of this Revision on airplanes on which Original Issue was previously done:
None.
Airplanes VS953-VS954, VS972-VS975 and VS983-VS984 were added to Group 2, Airplanes VN130-VN133 were added to Group 4, Airplane VA511 was added to new Group 5, Airplanes VN191-VN197 were added to new Group 6, Airplanes VN791-VN792 were added to new Group 7, Airplanes VN921 and VL806-VL807 were added to new Group 8 and Airplane VS721 was added to new Group 9 of this service bulletin effectivity.
REASON FOR REVISION This revision is sent to add twelve airplanes to the effectivity that were inadvertently omitted from the original issue of this service bulletin, to add new Groups for 767-200 Special Freighter (SF) and 767-300 Boeing Converted Freighter (BCF) airplanes, and to correct footnote references in Paragraph 1.E., Compliance, Tables 1 and 2 and Appendices A and B.
These sections were changed:
1. Summary, Background: Planning data table has been updated.
2. Paragraph 1.A., Effectivity: Airplanes VS953-VS954, VS972-VS975 and VS983-VS984 were added to Group 2, Airplanes VN130-VN133 were added to Group 4, Airplane VA511 was added to new Group 5, Airplanes VN191-VN197 were added to new Group 6, Airplanes VN791-VN792 were added to new Group 7, Airplanes VN921 and VL806-VL807 were added to new Group 8 and Airplane VS721 was added to new Group 9 of this service bulletin effectivity.
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: March 18, 2015 767-53A0265Revision 1: March 18, 2016 5 of 178
3. Paragraph 1.C., Reason: Added the reason for this revision.
4. Paragraph 1.D., Description: Added the effects of this revision on airplanes on which Original Issue was previously done.
5. Paragraph 1.E., Compliance: Clarified repeat inspection requirements in Tables 1 and 2 and added footnote references to Tables 1 and 2.
6. Paragraph 1.F., Approval: Revised the Alternative Method of Compliance (AMOC) statement.
7. Paragraph 1.G., Manpower: Added manpower information for new Groups.
8. Paragraph 1.J., References: Added reference to Federal Aviation Administration (FAA) Airworthiness Directive (AD) reference, 767-200SF Structural Repair Manual and 767-300BCF Structural Repair Manual.
9. Paragraph 3.A., General Information: Updated note 18 and added new note 19.
10. Paragraph 3.B., Work Instructions: Revised the work instructions, clarified work instructions for repeat inspections for areas that have not been repaired.
11. Figures 1-5: Revised the illustrations.
12. Figures 1-14: Added note to illustrations and revised step table footnotes.
13. Appendix A: Logic diagram has been updated.
14. Appendix B: Logic diagram has been updated.
Vertical lines are put on the left edge of each page, except in Paragraph 1.A., Effectivity and format changes, to show the location of all content changes.
Pages with no vertical lines have no changes.
REVISION HISTORY March 18, 2015Original Issue:
March 18, 2016Revision 1:
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: March 18, 2015 767-53A0265Revision 1: March 18, 2016 6 of 178 BOEING SERVICE BULLETIN 767-53A0265
ALERTALERT
Commercial Airplanes 767 Service Bulletin ALERT SummaryNumber: 767-53A0265Original Issue: March 18, 2015 Revision 1: March 18, 2016 ATA System: 5312 5332 5362 SUBJECT: FUSELAGE - Main Frame - Fuselage Frames at Floor Beam and Shear Tie Attachments
- Inspection and Repair
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 Widespread Fatigue Damage (WFD) analysis of the 767, as required by 14 CFR 26.21(b), has resulted in the conclusion that existing 767 MPD Section 9, Airworthiness Limitation Item (ALI) inspection program is not sufficient to preclude the occurrence of WFD in the frame to floor beam joint and frame at shear tie at specified locations of fuselage structure as the airplane ages. The multiple similar adjacent frame to floor beam and frame to shear tie attachment locations have the potential for Multiple Element Damage (MED) and the potential for WFD. 14 CFR 26.21 requires evaluation of such designs for the potential for WFD and implementation of the appropriate service actions to ensure that WFD is precluded before the Limit of Validity (LOV). Boeing has not received any cracking reports from 767 fleet in the frame to floor beam or frame to shear tie attachment locations.
Fatigue cracking was found at a few locations affected by this service bulletin on the full scale fatigue test article.
If Widespread Fatigue cracking is not found and repaired, the cracks could result in loss of structural integrity of the airplane.
The frame to floor beam and frame to shear tie attachment locations affected by this service bulletin have been determined to be structure that is susceptible to Widespread Fatigue Damage (WFD).
Boeing Service Related Problem (SRP) 767-SRP-53-0465 is related to this service bulletin.
This table is provided to operators for planning purposes only. Refer to the applicable sections for more information.
ReferenceAffectedPlanning Data Paragraph 1.A.2., Spares AffectedNoSpares Affected Paragraph 1.E., Compliance and Paragraph
1.F., Approval YesAD Related Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: March 18, 2015 767-53A0265Revision 1: March 18, 2016 7 of 178
ReferenceAffectedPlanning Data Paragraph 1.H., Weight and Balance ChangesNoWeight and Balance Change Paragraph 1.I., Electrical Load DataNoElectrical Load Changed Paragraph 1.K., Publications AffectedNoPublications Affected Paragraph 1.K., Publications AffectedNoAirplane Flight Operations Affected (Flight Crew Operations Manual and/or FAA Approved Airplane Flight Manual) Paragraph 2.C.1., Kits/PartsNoKits/Parts Required Paragraph 2.C.2., Parts and Materials Supplied by the Operator NoOperator Supplied Parts/Material Paragraph 2.F., Special Tooling Necessary to do this Service Bulletin NoSpecial Tooling Required ACTION Inspect the fuselage frames for any crack at the floor beam attachment between S-20 and S-21, and at the shear tie attachment between S-17 and S-23 at specified frame station location in accordance with this Service Bulletin. If any crack is found, do the repair in accordance with this Service Bulletin. If no crack is found, do repetitive inspection at the repeat interval in accordance with this Service Bulletin.
EFFECTIVITY 767-200/-300 Airplanes. 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.
Federal Aviation Administration (FAA) Airworthiness Directive AD 2014-14-04 is related to this service bulletin.
The effective date of AD 2014-14-04 is September 5, 2014.
This service bulletin affects SSI 53-10-I08B/C, 53-30-I24A/B/C, 53-60-I08A/C of MPD 622T001-9 Section 9, which is mandated by AD 2014-14-04.
Refer to Paragraph 1.E., Compliance.
INDUSTRY SUPPORT INFORMATION Boeing warranty remedies are not available for the inspection given in this service bulletin.
MANPOWER Refer to Paragraph 1.G., Manpower.
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: March 18, 2015 767-53A0265Revision 1: March 18, 2016 8 of 178 BOEING SERVICE BULLETIN 767-53A0265
ALERTALERT
BOEING SERVICE BULLETIN 767-53A0265
ALERT ALERT
MATERIAL INFORMATION None.
INSPECT THE FUSELAGE
FRAMES FOR ANY CRACK
AT THE FLOOR BEAM
ATTACHMENT BETWEEN STRINGER S-20 AND S-21,
AND AT THE SHEAR TIE
ATTACHMENT BETWEEN / STRINGER S-17 AND S-23.
SECTION 46 SECTION 43 SECTION 41 S-17L S-18L S-19L S-20L S-21L - S-22L S-23L FRAME 2394888 (TYPICAL) Original Issue: March 18, 2015 Revision 1: March 18, 2016 PROPRIETARY - Copyright © Unpublished Export Controlled ECCN: 9E991 - BOEING 767-53A0265 Work - See page 1 for details. 9 of 178
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: March 18, 2015 767-53A0265Revision 1: March 18, 2016 10 of 178 BOEING SERVICE BULLETIN 767-53A0265
ALERTALERT
BLANK PAGE
Commercial Airplanes 767 Service Bulletin ALERT Number: 767-53A0265 Original Issue: March 18, 2015 Revision 1: March 18, 2016 ATA System: 5312 5332 5362 SUBJECT: FUSELAGE - Main Frame - Fuselage Frames at Floor Beam and Shear Tie Attachments
- Inspection and Repair
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 This service bulletin is applicable to 767-200 and 300 Airplanes in 9 Groups. The Variable Numbers and Group Information for the applicable airplanes is given below.
Refer to Service Bulletin Index D624T001 Part 3 for Airplane Variable Number, Line Number, and Serial Number data.
NOTE: The Variable Number table below includes all affected airplanes up to Line Number 1068.
Affected airplanes after Line Number 1068 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 passenger airplanes.-1 767-300 passenger airplanes with no Type A door in Section 43 and no Type 1 door in Section 46 on each side of airplane.
-2 767-300 passenger airplanes with Type A door in Section 43 and no Type 1 door in Section 46 on each side of airplane.
-3 767-300 passenger airplanes with Type A door in Section 43 and Type 1 door in Section 46 on each side of airplane.
-4 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: March 18, 2015 767-53A0265Revision 1: March 18, 2016 11 of 178
DESCRIPTIONCONFIGURATIONGROUP 767-200 Special Freighter (SF) airplane, line number 109.-5 767-300 Boeing Converted Freighter (BCF) airplanes with a large section 43 crown doubler, with no Type A door in Section 43 and no Type 1 door in Section 46 on each side of airplane, line numbers 269, 285, 379, 432, 463, 556 and 645.
-6 767-300 Boeing Converted Freighter (BCF) airplanes with Type A door in Section 43 and no Type 1 door in Section 46 on each side of airplane, line number 434 and 438.
-7 767-300 Boeing Converted Freighter (BCF) airplanes with Type A door in Section 43 and Type 1 door in Section 46 on each side of airplane, line number 484, 635 and 650.
-8 767-300 Boeing Converted Freighter (BCF) airplanes with no Type A door in Section 43 and no Type 1 door in Section 46 on each side of airplane, line number 877.
-9 Airplane Models:
767-200, 767-300 GroupVariable Number 1VA002 - VA020 1VA301 - VA315 1VA501 - VA510 5VA511 1VA512 - VA530 1VA701 - VA719 1VA801 - VA810 1VB001 - VB002 1VB051 - VB055 1VB101 - VB125 1VB201 - VB202 1VB251 - VB253 1VB281 - VB284 1VB301 - VB302 1VB321 - VB332 1VB371 - VB373 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: March 18, 2015 767-53A0265Revision 1: March 18, 2016 12 of 178 BOEING SERVICE BULLETIN 767-53A0265