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Original Issue: April 14, 1994 Revision 6: November 05, 2009 767-54A0062 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 1 of 66
ALERT ALERT Commercial Airplanes 767
ALERTALERT Service Bulletin Number: 767-54A0062 Original Issue: April 14, 1994 Revision 6: November 05, 2009 ATA System: 5451 SUBJECT: NACELLES / PYLONS - Strut Attach Fuse Pins - Midspar Fuse Pin Inspection and Replacement
BOEING PROPRIETARY, CONFIDENTIAL, AND/OR TRADE SECRET Copyright © 1994 The Boeing Company Unpublished Work - All Rights Reserved Boeing claims copyright in each page of this document only to the extent that the page contains copyrightable subject matter.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.
BLANK PAGE Original Issue: April 14, 1994 Revision 6: November 05, 2009 767-54A0062 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 2 of 66 BOEING SERVICE BULLETIN 767-54A0062
ALERT ALERT
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Table of Contents Original Issue: April 14, 1994 Revision 6: November 05, 2009 767-54A0062 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 3 of 66 BOEING SERVICE BULLETIN 767-54A0062
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Table of Contents Revision Transmittal Sheet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
1. PLANNING INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 A. Effectivity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
1. Airplanes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
2. Spares Affected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 B. Concurrent Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 C. Reason . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 D. Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 E. Compliance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 F. Approval . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 G. Manpower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 H. Weight and Balance Changes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 I. Electrical Load Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 J. References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
1. Existing Data: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
2. Data supplied with this Service Bulletin: . . . . . . . . . . . . . . . . . . . . . . . . . 35
3. Installation Drawings Used in the Preparation of this Service Bulletin: . . . . . . . . . . 35 K. Publications Affected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 L. Interchangeability and Intermixability of Parts . . . . . . . . . . . . . . . . . . . . . . . . . 36
2. MATERIAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 A. Material - Price and Availability. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 B. Industry Support Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 C. Parts Necessary For Each Airplane . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
1. Kits/Parts: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
2. Parts and Materials Supplied by the Operator: . . . . . . . . . . . . . . . . . . . . . . 38
3. Parts Modified and Reidentified: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
4. Parts Removed and Not Replaced: . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 D. Parts Necessary to Change Spares . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 E. Special Tooling - Price and Availability. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 F. Special Tooling Necessary to do this Service Bulletin . . . . . . . . . . . . . . . . . . . . . 40
3. ACCOMPLISHMENT INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41 A. GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41 B. WORK INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42 FIGURE 1: DELETED - REFER TO PARAGRAPH 1.E. - COMPLIANCE . . . . . . . . . . . . . . . 48 FIGURE 2: MIDSPAR FUSE PIN ACCESS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49 FIGURE 3: ON WING MIDSPAR FUSE PIN INSPECTION . . . . . . . . . . . . . . . . . . . . . . 51 FIGURE 4: OFF WING MIDSPAR FUSE PIN INSPECTION. . . . . . . . . . . . . . . . . . . . . . 55 FIGURE 5: MIDSPAR FUSE PIN REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . 58 FIGURE 6: OFF WING MIDSPAR FUSE PIN MAGNETIC PARTICLE INSPECTION . . . . . . . . . 60 FIGURE 7: MIDSPAR FUSE PIN FINISH RESTORATION . . . . . . . . . . . . . . . . . . . . . . 61 APPENDIX A: APPROVED REPAIRS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Table of Contents Original Issue: April 14, 1994 Revision 6: November 05, 2009 767-54A0062 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 4 of 66 BOEING SERVICE BULLETIN 767-54A0062
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Original Issue: April 14, 1994 Revision 6: November 05, 2009 767-54A0062 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 5 of 66
ALERT ALERT Commercial Airplanes 767
ALERTALERT Service Bulletin Number: 767-54A0062 Revision Transmittal Sheet Original Issue: April 14, 1994 Revision 6: November 05, 2009 ATA System: 5451 SUBJECT: NACELLES / PYLONS - Strut Attach Fuse Pins - Midspar Fuse Pin Inspection and Replacement
This Revision includes all pages of the service bulletin.
COMPLIANCE INFORMATION RELATED TO THIS REVISION Federal Aviation Administration (FAA) Airworthiness Directives (AD) 94-11-02 and 2003-03-02 are related to this service bulletin.
More work is necessary on airplanes that have not been changed in accordance with either service bulletin 767- 54-0069, or the applicable 767 SIP service bulletin 767-54-0080, 767-54-0081 or 767-54-0082. Continued inspections of the midspar fuse pins are required at reduced thresholds and repeat intervals in accordance with Paragraph 1.E., Compliance.
No more work is necessary on airplanes that have been changed in accordance with either service bulletin 767- 54-0069, or the applicable 767 Strut Improvement Program (SIP) service bulletin 767-54-0080, 767-54-0081 or 767-54-0082. Accomplishment of either service bulletin 767-54-0069 or the applicable 767 SIP service bulletin 767-54-0080, 767-54-0081 or 767-54-0082 is terminating action for this service bulletin.
REASON FOR REVISION This revision is sent to reduce the midspar fuse pin inspection threshold and repeat intervals based on an operator report of a cracked midspar fuse pin, after the Revision 5 date of this service bulletin.
These sections were changed:
1. Summary: Added statement of consequences of not accomplishing the service bulletin; added/changed references; added service history; changed Action paragraph; changed effectivity statement; added FAA AD statement; changed illustration.
2. Paragraph 1.A., Effectivity: Added Group/Configuration table
3. Paragraph 1.C., Reason: Added statement of consequences of not accomplishing the service bulletin;
added/changed references; added service history; added Revision 6 changes information.
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4. Paragraph 1.D., Description: Changed reference; added note; deleted Group descriptions; added Revision 6 change information.
5. Paragraph 1.E., Compliance: Added/deleted references; added/changed compliance table; added ferry flight information.
6. Paragraph 1.F., Approval: Added references.
7. Paragraph 1.G., Manpower: Changed task names
8. Paragraph 1.J.1., Existing Data: Added/changed/deleted references
9. Paragraph 1.K., Publications Affected: Added paragraph
10. Paragraph 2.C., Material - Price and Availability: Updated price and availability data
11. Paragraph 2.C.2., Parts and Materials Supplied by the Operator: Changed part number; deleted materials;
revised notes.
12. Paragraph 3.A., General Instructions: Added instructions; added inspection information; revised referenced procedures information; added serviceable pin criteria.
13. Paragraph 3.B., Work Instructions: Changed instructions to CONDITION/Option format; added/changed/ deleted instructions; deleted torque stripe requirement.
14. Figure 1: Deleted figure
15. Figure 2: Changed title; changed illustration; changed step numbers; added/changed references.
16. Figure 3: Changed/added illustration; added/changed steps; added/changed/deleted references; added corrosion information.
17. Figure 4: Added/changed illustration; added/changed steps; changed reference; added option for Magnetic Particle Inspection; added corrosion information.
18. Figure 5: Changed illustration; changed/deleted steps; changed reference.
19. Figure 6: Completely revised figure
20. Figure 7: New Figure
21. Appendix A: New Appendix 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.
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ALERT ALERT
REVISION HISTORY Original Issue: April 14, 1994 Revision 1: May 11, 1994 Revision 2: December 21, 1994 Revision 3: June 15, 1995 Revision 4: May 7, 1998 Revision 5: November 11, 2002 Revision 6: November 5, 2009
Original Issue: April 14, 1994 Revision 6: November 05, 2009 767-54A0062 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 8 of 66 BOEING SERVICE BULLETIN 767-54A0062
ALERT ALERT
BLANK PAGE
Original Issue: April 14, 1994 Revision 6: November 05, 2009 767-54A0062 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 9 of 66
ALERT ALERT Commercial Airplanes 767
ALERTALERT Service Bulletin Number: 767-54A0062 Summary Original Issue: April 14, 1994 Revision 6: November 05, 2009 ATA System: 5451 SUBJECT: NACELLES / PYLONS - Strut Attach Fuse Pins - Midspar Fuse Pin Inspection and Replacement
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 inspection/replacement program will permit early detection of cracks in the midspar fuse pin on the inboard and outboard sides of the number one and number two pylons. Midspar fuse pin cracks can result in the loss of structural integrity of the midspar fuse pins and cause an engine breakaway from the airplane.
There have been eight reports involving a total of fourteen midspar fuse pins suspected of having longitudinal cracks. Of these fuse pins, seven pins were confirmed cracked. The cracked pins were from one operator on airplanes with 15,628 to 23,056 flight cycles. Both airplanes are equipped with CF6-80A engines.
The first pins suspected of being cracked were found during midspar bushing migration rework. The cracks were found by a detailed visual inspection. The cracking was confirmed by magnetic particle inspection with the pins removed. The second cracked pin was found using eddy current inspection on the inner bore of the fuse pin with the engine installed. Subsequent inspections of at least sixty-nine additional fuse pins from the same engine type have revealed no cracks. These additional pins were on airplanes with as many as 23,007 flight cycles.
These cracks are believed to be caused by stresses due to ovalization of the fuse pin. Because this strut has redundant load paths, one pin can fail without affecting flight safety. Boeing testing of similar fuse pins showed no significant reduction in shear strength with longitudinal cracks up to 1 inch.
An all base message M-7240-94-0006 was sent to inform operators of the development of this service bulletin and of Delta Airlines involvement as the “Lead the Fleet” airline.
Original Issue: April 14, 1994 Revision 6: November 05, 2009 767-54A0062 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 10 of 66 BOEING SERVICE BULLETIN 767-54A0062
ALERT ALERT
Subsequent to the release of Revision 4 of this service bulletin one operator has reported a fractured midspar fuse pin. The fractured midspar fuse pin was found during routine maintenance on the outboard side of the number one pylon. Further inspection of the inboard side of the number one pylon, revealed the midspar fuse pin to have corrosion within the bore and on the pin surface. The 767-ER airplane was equipped with RB211 engines and had accumulated 9,456 flight cycles. Service bulletin 767-54-0069 to replace the midspar fuse pins and service bulletin 767-54-0082 to modify the nacelle strut and wing structure had not been incorporated on this airplane.
Reduced thresholds for the inspections given in this service bulletin will provide early detection of cracks and ensure the structural integrity of the number one and two pylons.
An all base message M-7200-02-01708 was sent to inform operators of the development of revision 5 of this service bulletin.
After the Revision 5 date of this service bulletin, one operator of a 767-300 airplane with CF6-80C2 engines reported a fractured midspar fuse pin. The airplane had accumulated 16,054 flight cycles and neither service bulletin 767-54-0069 nor 767 Strut Improvement Program (SIP) service bulletin 767-54-0081 had been incorporated. The fractured midspar fuse pin was found during routine maintenance on the outboard side of the number one pylon, prior to the next scheduled midspar fuse pin inspection in accordance with Revision 5 of this service bulletin. Further inspection revealed a cracked midspar fuse pin on the inboard side of the number one pylon. Subsequent inspection of both midspar fuse pins revealed discrepant circumferential machining grooves on the fuse pin main bore surface, in addition to longitudinal cracks. Eddy Current Inspection (ECI) of the midspar fuse pins in accordance with the requirements of Revision 5 of this service bulletin will not reveal the presence of the discrepant machining grooves. The roughness of the discrepant machining grooves exceeded the maximum allowable roughness of the fuse pin main bore surface. Metallurgical analysis determined the fuse pin fracture or crack origins coincided with the discrepant machining groove locations, in all cases. Stresses due to pin ovalization contributed to the longitudinal cracking of the midspar fuse pins.
Multi-Operator Message (MOM) 1-1171248586 was sent to inform operators of the development of Revision 6 of this service bulletin.
Reduced inspection thresholds and repeat intervals in accordance with Revision 6 of this service bulletin will provide early detection of cracks due to discrepant circumferential machining grooves and will ensure the structural integrity of the number one and two pylons.
Boeing Service Related Problems (SRP) 767-SRP-54-0093 and 767-SRP-54-0131 are related to this service bulletin.
ACTION Do either Part 1 - On Wing Midspar Fuse Pin Inspection or Part 2 - Off Wing Midspar Fuse Pin Inspection or Part 3 - Midspar Fuse Pin Replacement of each inboard and outboard midspar fuse pin on the number one and two pylons, for any crack and any corrosion.
— If any crack is found on the midspar fuse pin, replace the fuse pin.
— If any corrosion is only found on a non-critical midspar fuse pin surface, remove the corrosion and continue the fuse pin inspection or replace the fuse pin.
— If any corrosion is found on any midspar fuse pin surface except a non-critical surface, either contact Boeing for repair instructions and do the repair or replace the fuse pin.
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ALERT ALERT
— If no crack is found and no corrosion is found on the midspar fuse pin, install the fuse pin (if removed) or replace the fuse pin.
Repeat either Part 1 - On Wing Midspar Fuse Pin Inspection or Part 2 - Off Wing Midspar Fuse Pin Inspection or Part 3 - Midspar Fuse Pin Replacement of each inboard and outboard midspar fuse pin on the number one and two pylons, in accordance with Paragraph 1.E., Compliance.
Accomplishment of either service bulletin 767-54-0069 or the applicable 767 SIP service bulletin 767-54-0080, 767-54-0081 or 767-54-0082 is terminating action for this service bulletin.
EFFECTIVITY 767-200, 767-300 and 767-300F 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 Revision 6 of this service bulletin. The Airworthiness Directive will make the compliance tasks and times given in this service bulletin mandatory.
FAA Airworthiness Directives (AD) 94-11-02 and 2003-03-02 are related to this service bulletin.
See Service Bulletin Paragraph 1.E. for compliance information.
INDUSTRY SUPPORT INFORMATION This service bulletin was first released before October of 1994. Thus industry support for affected airplanes depends upon whether you ever filed a warranty claim with Boeing on this service bulletin.
MANPOWER See the table in the Manpower section.
MATERIAL INFORMATION Operator Supplied Parts/Materials.
Refer to Paragraph 2.A., Material - Price and Availability.
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PIN COTTER
DETAIL I SEESEE
DETAIL I WING
FITTING WASHER
MIDSPAR
FITTING WASHER
SELF-LOCKING NUT (2 LOCATIONS)
DETAIL I
TYPICAL MIDSPAR FITTING
DO A DETAILED AND EDDY CURRENT (MAGNETIC PARTICLE OPTIONAL, OFF WING) INSPECTION OF THE MIDSPAR FUSE PIN FOR ANY CRACK AND ANY CORROSION.
REPLACE FUSE PIN IF ANY CRACK OR ANY CORROSION IS FOUND, EXCEPT ON NON-CRITICAL SURFACES. REMOVE CORROSION ON NON-CRITICAL SURFACES OR REPLACE FUSE PIN. DO REPEAT INSPECTIONS.