Boeing ASB 767-54A0074: Revision 1, text

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ALERT ALERT Commercial Airplane Group 767

ALERTALERT Service Bulletin Number: 767-54A0074 Date: March 27, 1997 Revision 1: April 24, 2008 ATA System: 5451 SUBJECT: NACELLE/PYLON - Strut Attach Fuse Pins - Upper Link Fuse Pin Inspection/ Replacement

BOEING PROPRIETARY, CONFIDENTIAL, AND/OR TRADE SECRET Copyright © 1997 The Boeing Company Unpublished Work - All Rights Reserved Boeing claims copyright in each page of this document only to the extent that the page contains copyrightable subject matter. Boeing also claims copyright in this document as a compilation and/or collective work.

This document includes proprietary information owned by The Boeing Company and/or one or more third parties. Treatment of the document and the information it contains is governed by contract with Boeing. For more information, contact The Boeing Company, P.O. Box 3707, Seattle, Washington 98124.

Boeing, 707, 717, 727, 737, 747, 757, 767, 777, BBJ, BOEING BUSINESS JET, DC-8, DC-9, DC-10, MD-10, MD-11, MD-80, MD-90, the Boeing logo and the Boeing livery are among the trademarks owned by Boeing or its subsidiaries. No intellectual property license (express or implied) is granted in connection with this document or otherwise.

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Table of Contents Revision Transmittal Sheet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

1. PLANNING INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 A. Effectivity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

1. Airplanes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

2. Spares Affected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 B. Concurrent Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 C. Reason . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 D. Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 E. Compliance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 F. Approval . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 G. Manpower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 H. Weight and Balance Changes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 I. Electrical Load Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 J. References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

1. Existing Data: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

2. Data supplied with this Service Bulletin: . . . . . . . . . . . . . . . . . . . . . . . . . 24

3. Installation Drawings Used in the Preparation of this Service Bulletin: . . . . . . . . . . 24 K. Publications Affected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 L. Interchangeability and Intermixability of Parts . . . . . . . . . . . . . . . . . . . . . . . . . 24

2. MATERIAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 A. Material - Price and Availability. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 B. Industry Support Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 C. Parts Necessary For Each Airplane . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

1. Kits/Parts: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

2. Parts and Materials Supplied by the Operator: . . . . . . . . . . . . . . . . . . . . . . 25

3. Parts Modified and Reidentified: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

4. Parts Removed and Not Replaced: . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 D. Parts Necessary to Change Spares . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 E. Special Tooling - Price and Availability. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 F. Special Tooling Necessary to do this Service Bulletin . . . . . . . . . . . . . . . . . . . . . 26

3. ACCOMPLISHMENT INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 A. GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 B. WORK INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 FIGURE 1: INSPECTION INTERVALS AND MAINTENANCE ALTERNATIVES . . . . . . . . . . . . 30 FIGURE 2: DETAILED INSPECTION OF THE UPPER LINK FUSE PIN . . . . . . . . . . . . . . . 32

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ALERT ALERT Commercial Airplane Group 767

ALERTALERT Service Bulletin Number: 767-54A0074 Revision Transmittal Sheet Date: March 27, 1997 Revision 1: April 24, 2008 ATA System: 5451 SUBJECT: NACELLE/PYLON - Strut Attach Fuse Pins - Upper Link Fuse Pin Inspection/ Replacement This Revision includes all pages of the service bulletin.

COMPLIANCE INFORMATION RELATED TO THIS REVISION No more work is necessary on airplanes inspected as shown in the original issue of this service bulletin.

However, continued repeat inspections are necessary at an increased frequency. Additionally, initial inspections on JT9D airplanes are required at a reduced threshold.

REASON FOR REVISION This revision is sent to update the initial and repeat inspection intervals for early detection of cracks in the upper link fuse pin. The Boeing analysis of in-service fractured pins from two operators has found that the previous inspection intervals given in the original issue of this service bulletin are not sufficient to find fatigue cracks in the fuse pin. A change to the inspection intervals is necessary to ensure that cracks are detected before the failure of the fuse pin.

These sections were changed:

1. Summary Background and Paragraph 1.C., Reason, were changed to add new information on the fatigue damage found by two operators.

2. Summary Action, clarified the inspection procedure, and moved the terminating action information to Summary Compliance.

3. Summary Illustration, revised the text to match the work instructions.

4. Paragraph 1.D., Description, clarified the inspection procedure, deleted the request for inspection results, and moved the terminating action information to Paragraph 1.E., Compliance.

5. Paragraph 1.J., References, was updated to show the correct references.

6. Paragraph 2.C., Parts and Materials Supplied by the Operator, item 2, corrected the cotter pin part number.

7. Paragraph 3.A., General Information, added caution information and clarified the inspection definition.

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8. Paragraph 3.B., Work Instructions, item 4, clarified the inspection procedure.

9. Figure 1, changed the initial and repeat inspection intervals for the upper link fuse pin, and added terminating action information.

10. Figure 2, clarified the cleaning procedure.

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

Vertical lines are put on the left edge of each page, except in Paragraph 1.A., Effectivity, to show the location of important changes.

Pages with no vertical lines have no important changes.

REVISION HISTORY Original Issue: March 27, 1997 Revision 1: April 24, 2008

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ALERT ALERT Commercial Airplane Group 767

ALERTALERT Service Bulletin Number: 767-54A0074 Summary Date: March 27, 1997 Revision 1: April 24, 2008 ATA System: 5451 SUBJECT: NACELLE/PYLON - Strut Attach Fuse Pins - Upper Link Fuse Pin Inspection/ 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 fuse pin inspection will permit early detection of cracks in the upper link fuse pin. Cracks in the fuse pin could result in a fractured fuse pin. A fractured fuse pin can result in reduced structural capability of the nacelle strut, and possible separation of the strut and engine from the airplane during flight.

No operators have reported cracks in the upper link fuse pins. Cracks were found in an upper link fuse pin at Boeing during testing of a RB211 Strut.

As part of the service bulletin validation program, this inspection was completed on airplane VB051 by Service Bulletin Validation Copy 1 before the initial release of this service bulletin. The inspection completed on VB051 by Service Bulletin Validation Copy 1 is equivalent to the initial release of this service bulletin.

After the original issue of this service bulletin, two operators reported cracked upper link fuse pins. The two airplanes had PW4000 engines with 11,573 flight cycles and 14,780 flight cycles. Boeing analysis found cracks in the longitudinal direction of the fuse pins. The longitudinal cracks were the result of fatigue loads. No material anomalies were found. Further Boeing analysis has found that the previous inspection intervals given in the original issue of this service bulletin are not sufficient to find fatigue cracks in the fuse pin. As a result, a change to the inspection intervals is necessary to ensure that cracks are detected before the failure of the fuse pin.

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ACTION Remove the strut underwing fairings. Remove the end caps and corrosion preventive compound from the upper link fuse pin and clean the inside surface of the upper link fuse pin. Do a detailed inspection of the inside surface of the upper link fuse pin in place, without engine removal and strut removal, for corrosion. If corrosion is found in the base metal of the fuse pin, or if any crack is found, replace the fuse pin with a new fuse pin with the same part number. If no corrosion is found, do a High Frequency Eddy Current (HFEC) inspection. If crack is detected, remove the upper link fuse pin and do a Magnetic Particle inspection on the inside surface of the upper link fuse pin. If crack is found in the upper link fuse pin, replace the fuse pin with a new fuse pin with the same part number. Apply the corrosion preventive compound on the upper link fuse pin and install the end caps.

Install the strut underwing fairings.

EFFECTIVITY 767-200/-300/-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 this service bulletin. The Airworthiness Directive will make the compliance tasks and times given in this service bulletin mandatory.

See Figure 1 for compliance recommendations and maintenance alternatives.

Terminating action for this service bulletin is the accomplishment of the modification of the nacelle strut and wing structure for Pratt and Whitney, General Electric and Rolls Royce powered airplanes, in accordance with Service Bulletin 767-54-0080, Original Issue or Revision 1; or 767-54-0081, Original Issue or Revision 1; or 767-54-0082, Original Issue, Revision 1 or Revision 3, as applicable.

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

MANPOWER Total Man-hours - 6 for each strut Elapsed Time - 4 Hours

MATERIAL INFORMATION Operator Supplied PartsRefer to Paragraph 2.A., Material - Price and Availability.

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FUSE PIN

END CAP

END CAP COMPOUND FROM THE FUSE PIN.

DO A DETAILED INSPECTION OF

THE INNER SURFACE OF THE FUSE PIN.

CORROSION PREVENTIVE

REMOVE THE END CAPS AND

UPPER LINK STRUT

TYPICAL LEFT STRUT SHOWN

RIGHT STRUT OPPOSITE FWD UP R85906

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ALERT ALERT Commercial Airplane Group 767

1. PLANNING INFORMATION A. Effectivity

1. Airplanes Refer to Service Bulletin Index Document D6-D624T001, Part 3 for Airplane Variable Number, Line Number, and Serial Number data.

This service bulletin is for the airplanes shown below.

Airplane models:

767-200 767-300 767-300F

IDENTIFICATION BY CUSTOMER, CUSTOMER CODE, GROUP AND VARIABLE NUMBER AA 767 LLC (SVX) 1V E 0 6 7

ABX AIR (ABX) 1 VA301 VA303–VA306 VA309–VA315 VA508 VA803 VA807–VA809 VB101–VB123 VB125 VB302

GROUP CONFIGURATION DESCRIPTION 1 - 767 airplanes, line numbers 1 through 663, that have not accomplished service bulletins 767-54- 0080, 767-54-0081 or 767-54-0082.

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AEROFLOT (ARO) 1 VL896–VL897 VN471–VN472

AEROMEXICO (AMX) 1 VF071 VF093 VF162

AEROSVIT (UKA) 1 VN154–VN155 VN157

AEROTURBINE (AUB) 1 VB051 VB054–VB055 VB321

AIR ALGERIE (ALG) 1 VK131–VK133

AIR ASTANA (AKZ) 1 VL899–VL900

AIR CANADA (ACN) 1 VA701–VA709 VA711–VA719 VB001–VB002 VB201–VB202 VN051–VN054 VN056–VN062 VN531 VN541 VN546–VN547 VN751–VN752 VN811–VN812 VN931–VN936

AIR CHINA (BEJ) 1 VE064 VE083 VE085–VE086 VK161–VK164

AIR EUROPA (ARE) 1V N 6 3 8

AIR ITALY (RIT) 1 VL913

AIR MADAGASCAR (MAD) 1V N 1 6 7 V N 7 3 1

AIR NEW ZEALAND (ANZ) 1 VN653 VN655–VN657

AIR PACIFIC (APC) 1V N 6 7 6

AIR SEYCHELLES (ASY) 1 VL941

AIR TRANSPORT INTERNATIONAL (TIN) 1 VA509–VA513

AIR ZIMBABWE (ZMB) 1 VF061–VF062

ALITALIA (ALI) 1 VL701–VL702 VN422–VN427 VN732 VN813

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