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Commercial Airplanes 767 Service Bulletin ALERT Number: 767-54A0101 Original Issue: September 23, 1999 Revision 5: June 29, 2010 ATA System: 5451 SUBJECT: NACELLES/PYLONS - Attach Fittings - Midspar Fitting Inspection, Rework, and Replacement 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BOEING PROPRIETARY, CONFIDENTIAL, AND/OR TRADE SECRET Copyright © 1999 The Boeing Company Unpublished Work - All Rights Reserved Boeing claims copyright in each page of this document only to the extent that the page contains copyrightable subject matter.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.
BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: September 23, 1999 767-54A0101Revision 5: June 29, 2010 1 of 49
4.0
BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: September 23, 1999 767-54A0101Revision 5: June 29, 2010 2 of 49 BOEING SERVICE BULLETIN 767-54A0101
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Table of Contents
Revision Transmittal Sheet5
Summary7
1. PLANNING INFORMATION ........................................ 1 1 A. Effectivity ............................................... 1 1
1. Airplanes ............................................ 1 1
2. Spares Affected ........................................ 1 5 B. Concurrent Requirements ...................................... 1 5 C. Reason ................................................ 1 5 D. Description .............................................. 1 8 E. Compliance .............................................. 2 0 F. Approval ............................................... 2 0 G. Manpower .............................................. 2 0 H. Weight and Balance Changes .................................... 2 2 I. Electrical Load Data ......................................... 2 2 J. References .............................................. 2 2
1. Existing Data: ......................................... 2 2
2. Data supplied with this Service Bulletin: ........................... 2 2
3. Installation Drawings Used in the Preparation of this Service Bulletin: ........... 2 2 K. Publications Affected ........................................ 2 3 L. Interchangeability and Intermixability of Parts ........................... 2 3
2. MATERIAL INFORMATION ........................................ 2 5 A. Material - Price and Availability ................................... 2 5 B. Industry Support Information .................................... 2 5 C. Parts Necessary For Each Airplane ................................. 2 6
1. Kits/Parts: ........................................... 2 6
2. Parts and Materials Supplied by the Operator: ........................ 2 6
3. Parts Modified and Reidentified: ............................... 2 7
4. Parts Removed and Not Replaced: .............................. 2 7 D. Parts Necessary to Change Spares ................................. 2 8 E. Special Tooling - Price and Availability ............................... 2 8 F. Special Tooling Necessary to do this Service Bulletin ....................... 2 8
3. ACCOMPLISHMENT INSTRUCTIONS .................................. 2 9 A. GENERAL INFORMATION ..................................... 2 9 B. WORK INSTRUCTIONS ....................................... 3 0 FIGURE 1: INSPECTION THRESHOLD AND REINSPECTION INTERVALS .............. 3 7 FIGURE 2: MIDSPAR FITTING INSPECTION (DETAILED) ....................... 4 1 FIGURE 3: MIDSPAR FITTING FASTENER HOLE INSPECTION (HFEC) ............... 4 4 FIGURE 4: MIDSPAR FITTING FASTENER HOLE REWORK ...................... 4 6
BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: September 23, 1999 767-54A0101Revision 5: June 29, 2010 3 of 49 BOEING SERVICE BULLETIN 767-54A0101
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BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: September 23, 1999 767-54A0101Revision 5: June 29, 2010 4 of 49 BOEING SERVICE BULLETIN 767-54A0101
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Commercial Airplanes 767 Service Bulletin ALERT Revision Transmittal SheetNumber: 767-54A0101Original Issue: September 23, 1999 Revision 5: June 29, 2010 ATA System: 5451 SUBJECT: NACELLES/PYLONS - Attach Fittings - Midspar Fitting Inspection, Rework, and Replacement This revision includes all pages of the service bulletin.
COMPLIANCE INFORMATION RELATED TO THIS REVISION More work is necessary on the airplanes changed in accordance with previous revisions of this service bulletin.
Operators must do Part 1 inspection at the reduced threshold and repeat intervals in accordance with Paragraph
1. E., Compliance.
Federal Aviation Administration (FAA) Airworthiness Directive AD 2005-19-23 is related to this service bulletin.
REASON FOR REVISION This revision is sent to:
1. Revise Part 1 inspection threshold and repeat intervals. The inspection threshold reduction is based on fleet history. Subsequent to the release of Revision 4 of this service bulletin, one operator reported two incidents of cracks in the midspar fitting tangs. The first report found severed upper and lower tangs at the aft two fastener locations in the Number 1 pylon inboard midspar fitting. The cracks were found during a routine check of a 767-300 airplane at approximately 92,205 flight hours and 14,969 cycles. This airplane had incurred 408 flight cycles from the previous inspection. The second report found cracks in the Number 1 pylon inboard midspar fitting lower tang, between the aft two fastener holes, on a 767-300 airplane at approximately 94176 flight hours and 15405 cycles. This airplane had incurred 830 cycles from the previous inspection.
2. Delete the requirement for cap sealing the fasteners in the outboard midspar fitting after performing the detailed inspection.
3. Update the service bulletin to the current format.
These sections were changed:
BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: September 23, 1999 767-54A0101Revision 5: June 29, 2010 5 of 49
1. In Summary Compliance and paragraph 1.E., Compliance, added compliance information for Federal Aviation Administration (FAA) Airworthiness Directive, and updated the affected maintenance zones and the reference to FAA Airworthiness Directive AD 2005-19-23.
2. In Summary Industry Support Information, updated the reference to Program Letter BPL 6-1151-757/767PGM-120 R4.
3. In Summary Background and paragraph 1.C, Reason, updated the reference to Service Related Problem (SRP) 767-SRP-54-0133.
4. In Paragraph 3.A., General Information, added new general notes.
5. In Paragraph 3.B, Work Instructions, Part 2 - Open Hole HFEC Inspection, made the strut removal optional.
6. In Figure 1, changed the inspection threshold and repeat interval for Part 1 inspection, and deleted the MPD references in Table 1, flag note 1.
7. In Figure 2 and Figure 4, deleted the requirement for cap sealing the bolts at the outboard midspar fitting, and added requirement for the application of plating and primer to the bare surfaces, as required.
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 September 23, 1999Original Issue:
February 03, 2000Revision 1:
January 10, 2002Revision 2:
September 05, 2002Revision 3:
February 10, 2005Revision 4:
June 29, 2010Revision 5:
BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: September 23, 1999 767-54A0101Revision 5: June 29, 2010 6 of 49 BOEING SERVICE BULLETIN 767-54A0101
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Commercial Airplanes 767 Service Bulletin ALERT SummaryNumber: 767-54A0101Original Issue: September 23, 1999 Revision 5: June 29, 2010 ATA System: 5451 SUBJECT: NACELLES/PYLONS - Attach Fittings - Midspar Fitting Inspection, Rework, 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 For Part 4 - Terminating Action the related service bulletins are 767-54-0080, 767-54-0081, 767-54-0052, 767-54-0061, 767-54A0062, 767-54-0069, 767-57-0063, 767-54-0072, 767-54-0074, 767-54A0094.
BACKGROUND Accomplishment of this service bulletin will ensure early detection of cracks in the horizontal tangs of the strut midspar fitting. A cracked midspar fitting could result in a fractured fitting which could lead to strut and engine separation.
One operator has reported a cracked inboard midspar fitting on a number two pylon of a General Electric powered airplane. The crack was found during a midspar fitting bushing replacement. The airplane had accumulated 21,375 hours and 11,563 cycles. This crack was due to fatigue and occurred much earlier than predicted by Boeing analysis.
The midspar fittings are part of the redundant strut-to-wing load path. More frequent inspections of the midspar fittings are necessary to ensure the structural integrity required for damage tolerance. Without early detection, a cracked midspar fitting could eventually result in separation of an engine and strut.
Subsequent to the initial release of this service bulletin, six operators have reported finding cracks in seven midspar fittings on airplanes with approximately 27,914 to 61,347 hours and 11,640 to 23,826 flight cycles. One of the cracks was next to the third row of fasteners in the upper tang of a midspar fitting. Therefore, the inspection and rework requirements have changed to include the aft most eight (8) fastener locations common to the upper and lower tangs of the midspar fittings, instead of the aft most two (2) fastener locations. The Federal Aviation Administration (FAA) has issued an Airworthiness Directive (AD) which requires incorporation of this service bulletin.
Subsequent to the release of Revision 3 of this service bulletin, one operator has reported finding a crack in the closeout angle common to the aft most row of fasteners for the midspar fitting. An eddy current inspection of the fastener holes revealed that the midspar fitting lower tang was also cracked in the area under the closeout angle.
BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: September 23, 1999 767-54A0101Revision 5: June 29, 2010 7 of 49
Subsequent to the release of Revision 4 of this service bulletin, one operator reported two incidents of cracks in the midspar fitting tangs. The first report found severed upper and lower tangs at the aft two fastener locations in the Number 1 pylon inboard midspar fitting. The cracks were found during a routine check of a 767-300 airplane at approximately 92,205 flight hours and 14,969 cycles. This airplane had incurred 408 flight cycles from the previous inspection. The second report found cracks in the Number 1 pylon inboard midspar fitting lower tang, between the aft two fastener holes, on a 767-300 airplane at approximately 94176 flight hours and 15405 cycles. This airplane had incurred 830 cycles from the previous inspection.
Boeing Service Related Problems (SRP) 767-SRP-54-0107 and 767-SRP-54-0133 are related to this service bulletin.
ACTION For each midspar fitting, do a Detailed Inspection of the tangs at the aft most eight (8) fastener locations for cracks. Also do a surface High Frequency Eddy Current (HFEC) Inspection of the close out angle around the two fasteners common to the closeout angle and the midspar fitting. If no cracks are found, repeat the inspection at the intervals specified in Figure 1. If cracks are found in the closeout angle, remove the two fasteners common to the closeout angle and the midspar fitting, and do the PART 2 - OPEN HOLE HFEC INSPECTION. Contact Boeing for repair instructions if cracks are only found in the closeout angle.
Optional to Detailed Inspection: Do a HFEC Inspection of the fastener holes. If no cracks are found, rework the holes as necessary and repeat the inspection at the intervals specified in Figure 1. If cracks are found or any of the fastener holes are larger than 0.5322 inch, do Part 4 - Terminating Action or contact Boeing for rework instructions.
The terminating action for this service bulletin is to do Part 4, which replaces the midspar fittings as specified by the 767 Strut Improvement Program (SIP) service bulletins or contact Boeing for additional inspection instructions.
EFFECTIVITY All 767 airplanes line numbers 1 to 663 powered by General Electric and Pratt-Whitney engines.
COMPLIANCE The Federal Aviation Administration (FAA) will possibly release an Airworthiness Directive related to Revision 5 of this service bulletin. The Airworthiness Directive will make the compliance tasks and times given in Revision 5 of this service bulletin mandatory.
See Figure 1 for compliance recommendations and maintenance alternatives.
Federal Aviation Administration (FAA) Airworthiness Directive AD 2005-19-23 is related to this service bulletin.
INDUSTRY SUPPORT INFORMATION Boeing warranty remedies are not available for the inspection or repair procedures given in this service bulletin.
The inspection and repair procedures given in this service bulletin are not covered by Program Letter BPL 6-1151-757/767PGM-120 R4 .
MANPOWER Refer to Paragraph 1.G., Manpower.
BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: September 23, 1999 767-54A0101Revision 5: June 29, 2010 8 of 49 BOEING SERVICE BULLETIN 767-54A0101
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BOEING SERVICE BULLETIN 767-54A0101
ALERT ALERT
MATERIAL INFORMATION Operator Supplied Parts/Materials for Part 3 - Hole Rework.
Boeing Supplied Kits for Part 4 - Terminating Action. Refer to Paragraph 2.A., Material - Price and Availability.
SEE A
LEFT STRUT SHOWN
RIGHT STRUT SIMILAR
GENERAL ELECTRIC STRUT SHOWN
PRATT-WHITNEY STRUT SIMILAR FWD C
POSSIBLE CRACK
LOCATIONS
DO A DETAILED INSPECTION WITH
SURFACE HIGH FREQUENCY EDDY CURRENT
POSSIBLE CRACK (HFEC) INSPECTION - OR - DO AN OPEN
LOCATIONS HOLE HFEC INSPECTION OF THE MIDSPAR
FITTING AFT MOST EIGHT HOLES FOR CRACKS. IF CRACKS ARE FOUND, DO THE
STRUT IMPROVEMENT PROGRAM (SIP)
SERVICE BULLETINS OR REPLACE THE CRACKED FITTING.
POSSIBLE CRACK
LOCATIONS V02877 Original Issue: September 23, 1999 Revision 5: June 29, 2010 767-54A0101
BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 9 of 49
BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: September 23, 1999 767-54A0101Revision 5: June 29, 2010 10 of 49 BOEING SERVICE BULLETIN 767-54A0101
ALERTALERT
BLANK PAGE
Commercial Airplanes 767 Service Bulletin ALERT Number: 767-54A0101 Original Issue: September 23, 1999 Revision 5: June 29, 2010 ATA System: 5451 SUBJECT: NACELLES/PYLONS - Attach Fittings - Midspar Fitting Inspection, Rework, 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.
1. PLANNING INFORMATION A. Effectivity
1. Airplanes Refer to Service Bulletin Index Document D6-24T001 Part 3 for Airplane Variable Number, Line Number, and Serial Number data.
This service bulletin is for the airplanes shown below.
DESCRIPTIONCONFIGURATIONGROUP 767-200 airplanes, line numbers 1 thru 123, powered by Pratt and Whitney JT9D engines.
-1 767-200 and -300 airplanes, line numbers 124 thru 379, powered by Pratt and Whitney JT9D engines.
-2 767-200 and -300 airplanes, line numbers 165 thru 663, powered by Pratt and Whitney PW4000 engines.
-3 767-200 airplanes, line numbers 6 thru 123, powered by General Electric CF6-80A engines.
-4 767-200 and -300 airplanes, line numbers 124 thru 427, powered by General Electric CF6-80A engines.
-5
BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: September 23, 1999 767-54A0101Revision 5: June 29, 2010 11 of 49
DESCRIPTIONCONFIGURATIONGROUP 767-200, -300, and -300F airplanes, line numbers 158 thru 663, powered by General Electric CF6-80C2 engines.
-6 Airplane Models:
767-200, 767-300, 767-300F GroupVariable Number 1VA001 - VA020 4VA301 - VA315 4VA501 - VA513 5VA514 - VA530 1VA701 - VA712 2VA713 - VA719 1VA801 - VA810 1VB001 - VB002 4VB051 - VB055 4VB101 - VB121 5VB122 - VB125 1VB201 - VB202 4VB251 - VB253 1VB281 - VB284 1VB301 - VB302 4VB321 - VB324 5VB325 - VB330 6VB331 - VB332 1VB371 - VB373 5VB401 6VB441 - VB444 1VE001 - VE002 2VE003 1VE021 - VE023 2VE041 - VE043 1VE061 - VE062
BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: September 23, 1999 767-54A0101Revision 5: June 29, 2010 12 of 49 BOEING SERVICE BULLETIN 767-54A0101