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Commercial Airplanes 767 Service Bulletin Number: 767-57A0095 Original Issue: June 02, 2005 Revision 2: December 17, 2009 ATA System: 5740 2781 2811 SUBJECT: WINGS - Leading Edge and Leading Edge Devices - Number 5 and Number 8 Slat Track Housing Drain Tube 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BOEING PROPRIETARY, CONFIDENTIAL, AND/OR TRADE SECRET Copyright © 2005 The Boeing Company Unpublished Work - All Rights Reserved Boeing claims copyright in each page of this document only to the extent that the page contains copyrightable subject matter.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BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.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: June 02, 2005 767-57A0095Revision 2: December 17, 2009 1 of 60
3.0
BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: June 02, 2005 767-57A0095Revision 2: December 17, 2009 2 of 60 BOEING SERVICE BULLETIN 767-57A0095
BLANK PAGE
Table of Contents
Revision Transmittal Sheet5
Summary7
1. PLANNING INFORMATION ........................................ 1 1 A. Effectivity ............................................... 1 1
1. Airplanes ............................................ 1 1
2. Spares Affected ........................................ 1 1 B. Concurrent Requirements ...................................... 1 1 C. Reason ................................................ 1 2 D. Description .............................................. 1 4 E. Compliance .............................................. 1 4 F. Approval ............................................... 1 5 G. Manpower .............................................. 1 5 H. Weight and Balance Changes .................................... 1 6 I. Electrical Load Data ......................................... 1 6 J. References .............................................. 1 6
1. Existing Data: ......................................... 1 6
2. Data supplied with this Service Bulletin: ........................... 1 6
3. Installation Drawings Used in the Preparation of this Service Bulletin: ........... 1 6 K. Publications Affected ........................................ 1 6 L. Interchangeability and Intermixability of Parts ........................... 1 7
2. MATERIAL INFORMATION ........................................ 1 9 A. Material - Price and Availability ................................... 1 9 B. Industry Support Information .................................... 1 9 C. Parts Necessary For Each Airplane ................................. 1 9
1. Kits/Parts: ........................................... 1 9
2. Parts and Materials Supplied by the Operator: ........................ 2 0
3. Parts Modified and Reidentified: ............................... 2 1
4. Parts Removed and Not Replaced: .............................. 2 1 D. Parts Necessary to Change Spares ................................. 2 1 E. Special Tooling - Price and Availability ............................... 2 1 F. Special Tooling Necessary to do this Service Bulletin ....................... 2 3
3. ACCOMPLISHMENT INSTRUCTIONS .................................. 2 5 A. GENERAL INFORMATION ..................................... 2 5 B. WORK INSTRUCTIONS ....................................... 2 6 FIGURE 1: DRAIN TUBE ASSEMBLY AT NUMBER 5 SLAT TRACK HOUSING - REMOVE ..... 2 8 FIGURE 2: DRAIN TUBE ASSEMBLY AT NUMBER 8 SLAT TRACK HOUSING - REMOVE ..... 3 2 FIGURE 3: NEW DRAIN TUBE FOR NUMBER 5 SLAT TRACK HOUSING - PREPARE ....... 3 6 FIGURE 4: NEW DRAIN TUBE FOR NUMBER 8 SLAT TRACK HOUSING - PREPARE ....... 4 0 FIGURE 5: NEW DRAIN TUBE AT NUMBER 5 SLAT TRACK HOUSING - INSTALL ......... 4 4 FIGURE 6: NEW DRAIN TUBE AT NUMBER 8 SLAT TRACK HOUSING - INSTALL ......... 4 9 Appendix A: DRAIN TUBE ROLLER SWAGE INSTRUCTIONS ...................... 5 4
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BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: June 02, 2005 767-57A0095Revision 2: December 17, 2009 4 of 60 BOEING SERVICE BULLETIN 767-57A0095
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Commercial Airplanes 767 Service Bulletin Revision Transmittal SheetNumber: 767-57A0095Original Issue: June 02, 2005 Revision 2: December 17, 2009 ATA System: 5740 2781 2811 SUBJECT: WINGS - Leading Edge and Leading Edge Devices - Number 5 and Number 8 Slat Track Housing Drain Tube Replacement This revision includes all pages of the service bulletin.
COMPLIANCE INFORMATION RELATED TO THIS REVISION No more work is necessary on airplanes changed in accordance with the original issue or revision 1 of this service bulletin.
REASON FOR REVISION This revision is sent to add the option for operators to make their own drain tubes and add some optional materials to the service bulletin. A cross reference table is added to the special tooling section to show the equivalent part numbers for operators who want to order special tools from the Boeing Parts Page. This revision also adds a female 3/8 inch square drive socket as an alternative to the wrench. The references to Federal Aviation Administration (FAA) Airworthiness Directive FAA AD 2001-14-19 are removed from the SB. In addition to these changes, the term "as given in/as shown in" is changed to "Refer to, as an accepted procedure" to comply with the latest SB standards on non-FAA approved manuals. Figure references are also updated to say "in accordance with" instead of "as shown in" to comply with latest SB standards.
The changes to this service bulletin are as follows:
– Summary - Compliance - Reference to Federal Aviation Administration (FAA) Airworthiness Directive FAA AD 2001-14-19 is removed. Information related to the future release of Airworthiness Directive related to this service bulletin is updated.
– Paragraph 1.E., Compliance - Reference to Federal Aviation Administration (FAA) Airworthiness Directive FAA AD 2001-14-19 is removed. Information related to the future release of Airworthiness Directive related to this service bulletin is updated.
– Paragraph 1.F., Approval - Alternative Method of Compliance (AMOC) approval paragraph removed.
– Paragraph 1.J.1., Existing Data - Reference to Federal Aviation Administration (FAA) Airworthiness Directive FAA AD 2001-14-19 is removed.
– Paragraph 1.K., Publications Affected - Damage Tolerance Inspections (DTI) information added.
– Paragraph 2.A., Material - Price and Availability - Pricing information updated.
– Paragraph 2.C.1., Kits/Parts - New footnote (d) is added to 015T1772-2 drain tube in top kit table to give operators the option to make the drain tube.
– Paragraph 2.C.2., Parts and Materials Supplied by the Operator - BMS 3-33 is added as an option to BMS
3-24. Also the name for "MIL-C-5541 Class 1A (Alodine 600)" changed to "Alodine 600 (Alodine 1600/1660 Optional)" – Paragraph 2.C.2., Parts and Materials Supplied by the Operator - New footnotes (b) and (c) added.
– Paragraph 2.E., Special Tooling - Price and Availability - Special tooling cross-reference chart added to show the required special tooling part numbers to use when ordering from Boeing Part Page.
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Original Issue: June 02, 2005 767-57A0095Revision 2: December 17, 2009 5 of 60
– Figure 3 and Figure 4, Sheet 2, View A - Tolerance added to the 0.30 dimensions.
– Figure 3 and Figure 4, Step 7 - "MIL-C-5541, Class 1A" is changed to "Alodine 600 (Alodine 1600/1660 Optional)".
– Figure 3 and Figure 4, Footnote (e) - Dimension value 0.30 is added.
– Figure 5 and Figure 6, Step 3 - BMS 3-33 is added as an option to BMS 3-24.
– Figure 5 and Figure 6, Step 5 - BMS 3-33 is added as an option to BMS 3-24.
– Figure 5 and Figure 6, Step 21 - "MIL-C-5541, Class 1A" is changed to "Alodine 600 (Alodine 1600/1660 Optional)".
– Appendix A, Sheet 4 - A female 3/8 inch square drive socket is added to the illustration.
– Appendix A, Sheet 5 - Wrench P/N is changed from ST877W-77A-5 to ST2580-77A-5 in the special tooling table and footnote (e) is added to give tool compatibility information.
– Appendix A, Step 11 - A note is added to show optional automotive engine oils to SAE No 10.
– Appendix A, Step 15 - A female 3/8 inch square drive socket is added as an alternative to the wrench.
– Appendix A, Step 16 - A female 3/8 inch square drive socket is added as an alternative to the wrench.
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 June 02, 2005Original Issue:
December 19, 2006Revision 1:
December 17, 2009Revision 2:
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Original Issue: June 02, 2005 767-57A0095Revision 2: December 17, 2009 6 of 60 BOEING SERVICE BULLETIN 767-57A0095
Commercial Airplanes 767 Service Bulletin SummaryNumber: 767-57A0095Original Issue: June 02, 2005 Revision 2: December 17, 2009 ATA System: 5740 2781 2811 SUBJECT: WINGS - Leading Edge and Leading Edge Devices - Number 5 and Number 8 Slat Track Housing Drain Tube Replacement
CONCURRENT REQUIREMENTS None.
BACKGROUND Accomplishment of this service bulletin prevents cracks in the number 5 and number 8 slat track housing drain tubes. Cracks in these drain tubes could let fuel drain from the main fuel tanks into the dry bay area of the wings.
Fuel from the dry bay areas could subsequently drain on to hot Main Landing Gear (MLG) brakes and possibly result in a fire.
One operator told Boeing of a fuel leak on to the MLG as a result of a cracked drain tube at the number 8 slat track housing, no fire was reported. The crack was in a drain tube on a 767 airplane that had incorporated a re-routed drain tube with a flexible part, as given Boeing service bulletin 767-57A0060. An investigation by Boeing found that the drain tube with a flexible part had cracked as a result of a high intensity engine vibration, which was more than the design of the tube permitted.
Boeing was told of a second occurrence of a cracked drain tube at the number 8 slat track housing. The crack in the flexible part of the drain tube was found after an airplane had a high intensity engine vibration. During flight, an airplane had vibration from the number 2 engine (Pratt & Whitney PW4000) as a result of a second stage turbine blade failure. The engine was subsequently shut-down and the airplane was diverted. After the airplane had landed fuel leakage was seen from the pylon area by maintenance personnel.
This problem affects airplane line numbers 1 thru 921. Airplanes after line number 921 have a production design change which installs the new drain tube without a flexible part.
This service bulletin gives instructions to replace a drain tube assembly which has a flexible part with a new aluminum drain tube without a flexible part, at the number 5 and number 8 slat track housing. Boeing tests have shown that the new aluminum drain tubes are stronger and more resistant to damage during high intensity engine vibrations.
Boeing Service Related Problem (SRP) 767-SRP-57-0160 is related to this service bulletin.
As a part of a service bulletin validation program, the change described in Boeing service bulletin 767-57A0094, which is equivalent to the change given in this service bulletin, was completed on a 767-200ER airplane after the initial release of service bulletin 767-57A0094. The change completed on the 767-200ER airplane is equivalent to the change given in the release of Revision 1 of this service bulletin.
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ACTION (PRR B12901-53S) Defuel the left and right wing main fuel tanks. Open the applicable left and right wing fuel tank access panels to get access to the number 5 and number 8 slat track housing drain tubes. Remove the existing drain tube assemblies that have a flexible part. Prepare and install new aluminum drain tubes without a flexible part at the two locations. Close the left and right wing main tank fuel bay access panels. Refuel the left and right wing main tanks. Inspect the left and right wing main tank dry bay to make sure there is no fuel leakage from the new drain tube installations. Close the left and right wing main tank dry bay access panels.
EFFECTIVITY 767-400ER Airplanes. Refer to Paragraph 1.A.1., Airplanes for the list of affected airplanes.
COMPLIANCE Boeing recommends that this service bulletin is done no later than 24 months after the Revision 1 date of this service bulletin.
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.
INDUSTRY SUPPORT INFORMATION Boeing warranty remedies are not available for the configuration changes given in this service bulletin.
MANPOWER Elapsed HoursTotal Task Hours 2043
MATERIAL INFORMATION Boeing Supplied Kits/Parts.
Refer to Paragraph 2.A., Material - Price and Availability.
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BOEING SERVICE BULLETIN 767-57A0095 SEE A
FRONT SPAR
SLAT TRACK
HOUSING RIB NO. 9 FWD < INBD
REPLACE THE DRAIN TUBE
ASSEMBLY THAT HAS A
FLEXIBLE PART AT THE NUMBER 5 AND NUMBER 8
LOWER SLAT TRACK HOUSING, WITH
SKIN AN ALUMINUM DRAIN TUBE WITHOUT A FLEXIBLE PART.
(NUMBER 8 SLAT TRACK HOUSING OPPOSITE) NUMBER 5 SLAT TRACK HOUSING SHOWN 423043 Original Issue: June 02, 2005 Revision 2: December 17, 2009 767-57A0095
BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 9 of 60
BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: June 02, 2005 767-57A0095Revision 2: December 17, 2009 10 of 60 BOEING SERVICE BULLETIN 767-57A0095
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Commercial Airplanes 767 Service Bulletin Number: 767-57A0095 Original Issue: June 02, 2005 Revision 2: December 17, 2009 ATA System: 5740 2781 2811 SUBJECT: WINGS - Leading Edge and Leading Edge Devices - Number 5 and Number 8 Slat Track Housing Drain Tube Replacement
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 airplanes shown below. An equivalent change is on subsequent production airplanes. Refer to PRR B12901-53S for data about this change.
DESCRIPTIONCONFIGURATIONGROUP 767-400ER airplanes, Line Numbers 758 thru 878, that have a drain tube with a flexible part installed at the no.5 and no.8 slat track housing. Two doublers are installed at rib no.9 and there is a 2 jumper electrostatic bond configuration -1 Airplane Models:
767-400ER GroupVariable Number 1VQ001 - VQ021 1VQ071 - VQ086
2. Spares Affected None.
B. Concurrent Requirements None.
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C. Reason Accomplishment of this service bulletin prevents cracks in the number 5 and number 8 slat track housing drain tubes. Cracks in these drain tubes could let fuel drain from the main fuel tanks into the dry bay area of the wings. Fuel from the dry bay areas could subsequently drain on to hot Main Landing Gear (MLG) brakes and possibly result in a fire.
One operator told Boeing of a fuel leak on to the MLG as a result of a cracked drain tube at the number 8 slat track housing, no fire was reported. The crack was in a drain tube on a 767 airplane that had incorporated a re-routed drain tube with a flexible part, as given Boeing service bulletin 767-57A0060.
An investigation by Boeing found that the drain tube with a flexible part had cracked as a result of a high intensity engine vibration, which was more than the design of the tube permitted.
Boeing was told of a second occurrence of a cracked drain tube at the number 8 slat track housing.
The crack in the flexible part of the drain tube was found after an airplane had a high intensity engine vibration. During flight, an airplane had vibration from the number 2 engine (Pratt & Whitney PW4000) as a result of a second stage turbine blade failure. The engine was subsequently shut-down and the airplane was diverted. After the airplane had landed fuel leakage was seen from the pylon area by maintenance personnel.
This problem affects airplane line numbers 1 thru 921. Airplanes after line number 921 have a production design change which installs the new drain tube without a flexible part.
This service bulletin gives instructions to replace a drain tube assembly which has a flexible part with a new aluminum drain tube without a flexible part, at the number 5 and number 8 slat track housing.
Boeing tests have shown that the new aluminum drain tubes are stronger and more resistant to damage during high intensity engine vibrations.
Boeing Service Related Problem (SRP) 767-SRP-57-0160 is related to this service bulletin.
As a part of a service bulletin validation program, the change described in Boeing service bulletin 767-57A0094, which is equivalent to the change given in this service bulletin, was completed on a 767-200ER airplane after the initial release of service bulletin 767-57A0094. The change completed on the 767-200ER airplane is equivalent to the change given in Revision 1 of this service bulletin.
Revision 1 of this service bulletin was sent to change the sequence of the work instructions and to change the safety wire part number, as a result of the airplane validation. The validation found that the step to close the main wing tank access panels was incorrectly located after the refuel step. The validation also found that the minimum fuel quantity note was incorrectly located after the dry bay inspection step. Special tools required to roller swage the drain tubes onto the ferrules, are specified in this revision.
The changes to this service bulletin are as follows:
— The Summary, Background paragraph and Paragraph 1.C., Reason, are changed to include the airplane validation data.
— The Summary, Compliance paragraph and Paragraph 1.E., Compliance, are revised to change the recommended compliance time from 24 months after the initial release of this service bulletin, to 24 months after the Revision 1 release of this service bulletin. The compliance time is changed due to the special roller swage tools required to accomplish this service bulletin, and the difficulty operators have experienced with special roller swage tool procurement.
— Paragraph 1.G., Manpower, is changed to agree with the resequenced steps to close the main wing tank fuel bay access panels prior to the refuel step, in Paragraph 3.B., Work Instructions.
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Original Issue: June 02, 2005 767-57A0095Revision 2: December 17, 2009 12 of 60 BOEING SERVICE BULLETIN 767-57A0095