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Commercial Airplanes 767 Service Bulletin Number: 767-57A0102 Original Issue: October 25, 2006 Revision 4: September 20, 2011 ATA System: 5710 5720 2811 SUBJECT: WINGS - Center Wing - Outer Wing - Change to Fasteners in Fuel Tank Walls and Change to Wire Bundle Clamps 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BOEING PROPRIETARY, CONFIDENTIAL, AND/OR TRADE SECRET Copyright © 2006 The Boeing Company Unpublished Work - All Rights Reserved Boeing claims copyright in each page of this document only to the extent that the page contains copyrightable subject matter.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.
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Original Issue: October 25, 2006 767-57A0102Revision 4: September 20, 2011 1 of 176
3.0
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Original Issue: October 25, 2006 767-57A0102Revision 4: September 20, 2011 2 of 176 BOEING SERVICE BULLETIN 767-57A0102
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 7 B. Concurrent Requirements ...................................... 1 7 C. Reason ................................................ 1 7 D. Description .............................................. 1 8 E. Compliance .............................................. 2 0 F. Approval ............................................... 2 0 G. Manpower .............................................. 2 1 H. Weight and Balance Changes .................................... 2 9 I. Electrical Load Data ......................................... 2 9 J. References .............................................. 2 9
1. Existing Data: ......................................... 2 9
2. Data supplied with this Service Bulletin: ........................... 3 0
3. Installation Drawings Used in the Preparation of this Service Bulletin: ........... 3 0 K. Publications Affected ........................................ 3 0 L. Interchangeability and Intermixability of Parts ........................... 3 0
2. MATERIAL INFORMATION ........................................ 3 1 A. Material - Price and Availability ................................... 3 1 B. Industry Support Information .................................... 3 2 C. Parts Necessary For Each Airplane ................................. 3 2
1. Kits/Parts: ........................................... 3 2
2. Parts and Materials Supplied by the Operator: ........................ 3 4
3. Parts Modified and Reidentified: ............................... 3 5
4. Parts Removed and Not Replaced: .............................. 3 5 D. Parts Necessary to Change Spares ................................. 3 5 E. Special Tooling - Price and Availability ............................... 3 5 F. Special Tooling Necessary to do this Service Bulletin ....................... 3 5
3. ACCOMPLISHMENT INSTRUCTIONS .................................. 3 7 A. GENERAL INFORMATION ..................................... 3 7 B. WORK INSTRUCTIONS ....................................... 3 8 FIGURE 1: GROUP 1-2 - WIRE BUNDLE CLAMP CONFIGURATION CHANGE - POWER FEEDER WIRE BUNDLES WITH AWG 1/0 AND LARGER WIRES IN THE UNPRESSURIZED AREA [Group 1-2] ............................................... 5 2 FIGURE 2: GROUP 1-3 - WIRE BUNDLE CLAMP CONFIGURATION CHANGE - WIRE BUNDLES WITH A DIAMETER MORE THAN 1 INCH [Group 1-3] ....................... 5 5 FIGURE 3: GROUP 1-3 - WIRE BUNDLE CLAMP CONFIGURATION CHANGE - WIRE BUNDLES WITH A DIAMETER OF 1 INCH OR LESS [Group 1-3] ....................... 5 8 FIGURE 4: GROUP 1 - FRONT SPAR STATION 143 TO STATION 616 - LEFT WING - LOCATION OF THE WIRE BUNDLE CLAMPS [Group 1] ........................... 6 1 FIGURE 5: GROUP 2 - FRONT SPAR STATION 143 TO STATION 616 - LEFT WING - LOCATION OF THE WIRE BUNDLE CLAMPS [Group 2] ........................... 6 6
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FIGURE 6: GROUP 3 - FRONT SPAR STATION 143 TO STATION 1063 - LEFT WING - LOCATION OF THE WIRE BUNDLE CLAMPS [Group 3] ........................... 7 1 FIGURE 7: GROUP 1 - FRONT SPAR STATION 616 TO STATION 1140 - LEFT WING - LOCATION OF THE WIRE BUNDLE CLAMPS [Group 1] ........................... 7 6 FIGURE 8: GROUP 2 - FRONT SPAR STATION 616 TO STATION 1140 - LEFT WING - LOCATION OF THE WIRE BUNDLE CLAMPS [Group 2] ........................... 8 2 FIGURE 9: GROUP 1 - FRONT SPAR STATION 143 TO STATION 616 - RIGHT WING - LOCATION OF THE WIRE BUNDLE CLAMPS [Group 1] ........................... 8 7 FIGURE 10: GROUP 2 - FRONT SPAR STATION 143 TO STATION 616 - RIGHT WING - LOCATION OF THE WIRE BUNDLE CLAMPS [Group 2] ........................... 9 2 FIGURE 11: GROUP 3 - FRONT SPAR STATION 143 TO STATION 1063 - RIGHT WING - LOCATION OF THE WIRE BUNDLE CLAMPS [Group 3] ........................... 9 7 FIGURE 12: GROUP 1 - FRONT SPAR STATION 616 TO STATION 1140 - RIGHT WING - LOCATION OF THE WIRE BUNDLE CLAMPS [Group 1] .......................... 1 0 1 FIGURE 13: GROUP 2 - FRONT STATION 616 TO STATION 1140 - RIGHT WING - LOCATION OF THE WIRE BUNDLE CLAMPS [Group 2] ............................. 1 0 7 FIGURE 14: GROUP 1 - FRONT SPAR - FORWARD CARGO COMPARTMENT - LOCATION OF THE WIRE BUNDLE CLAMPS [Group 1] ................................. 1 1 3 FIGURE 15: GROUP 2 - FRONT SPAR - FORWARD CARGO COMPARTMENT - LOCATION OF THE WIRE BUNDLE CLAMPS [Group 2] ................................. 1 1 5 FIGURE 16: GROUP 1-2 - REAR SPAR - MAIN WHEEL WELL - LOCATION OF THE WIRE BUNDLE CLAMPS [Group 1-2] ..................................... 1 1 7 FIGURE 17: GROUP 1-3 - SEAL OF THE FASTENER [Group 1-3] ................... 1 1 9 FIGURE 18: GROUP 1 - FRONT SPAR - LEFT WING - MAIN FUEL TANK - LOCATION OF THE FASTENERS [Group 1] ............................................ 1 2 1 FIGURE 19: GROUP 1 - FRONT SPAR - LEFT WING - SURGE TANK - LOCATION OF THE FASTENERS [Group 1] ............................................ 1 2 8 FIGURE 20: GROUP 2 - FRONT SPAR - LEFT WING - MAIN FUEL TANK - LOCATION OF THE FASTENERS [Group 2] ............................................ 1 3 1 FIGURE 21: GROUP 2 - FRONT SPAR - LEFT WING - SURGE TANK - LOCATION OF THE FASTENERS [Group 2] ............................................ 1 4 0 FIGURE 22: GROUP 1 - FRONT SPAR - RIGHT WING - MAIN FUEL TANK - LOCATION OF THE FASTENERS [Group 1] .................................... 1 4 3 FIGURE 23: GROUP 1 - FRONT SPAR - RIGHT WING - SURGE TANK - LOCATION OF THE FASTENERS [Group 1] ............................................ 1 5 0 FIGURE 24: GROUP 2 - FRONT SPAR - RIGHT WING - MAIN FUEL TANK - LOCATION OF THE FASTENERS [Group 2] .................................... 1 5 3 FIGURE 25: GROUP 2 - FRONT SPAR - RIGHT WING - SURGE TANK - LOCATION OF THE FASTENERS [Group 2] ............................................ 1 6 2 FIGURE 26: GROUP 3 - FRONT SPAR - LEFT WING - MAIN FUEL TANK - LOCATION OF THE FASTENERS [Group 3] ............................................ 1 6 5 FIGURE 27: GROUP 3 - FRONT SPAR - RIGHT WING - MAIN FUEL TANK - LOCATION OF THE FASTENERS [Group 3] .................................... 1 6 8 FIGURE 28: GROUP 2 - CENTER BAY - AUXILIARY FUEL TANK - LOCATION OF THE FASTENERS [Group 2] ............................................ 1 7 1 FIGURE 29: GROUP 1 - CENTER BAY - AUXILIARY FUEL TANK - LOCATION OF THE FASTENERS [Group 1] ............................................ 1 7 4
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Original Issue: October 25, 2006 767-57A0102Revision 4: September 20, 2011 4 of 176 BOEING SERVICE BULLETIN 767-57A0102
Commercial Airplanes 767 Service Bulletin Revision Transmittal SheetNumber: 767-57A0102Original Issue: October 25, 2006 Revision 4: September 20, 2011 ATA System: 5710 5720 2811 SUBJECT: WINGS - Center Wing - Outer Wing - Change to Fasteners in Fuel Tank Walls and Change to Wire Bundle Clamps This revision includes all pages of the service bulletin.
COMPLIANCE INFORMATION RELATED TO THIS REVISION More work is necessary on airplanes changed in accordance with the original issue of this service bulletin. Refer to Work Packages 10, 11 and 12 for work instructions.
More work is necessary on airplanes changed in accordance with the original issue, Revision 1 or Revision 2 of this service bulletin. Refer to Work Package 13 for work instructions.
No more work is necessary on airplanes changed in accordance with Revision 3 of this service bulletin.
Airplane VV001 was added to Group 1 of this service bulletin effectivity.
Federal Aviation Administration (FAA) Airworthiness Directive AD 2009-18-02 is related to this service bulletin.
REASON FOR REVISION This revision is sent to add VV001 to the service bulletin effectivity and to correct the quantity of the fasteners in Figure 20 and Figure 24 view C-C. Also clarification was added to show that Figure 17 is a typical view of a fastener that was intended to apply to rivets or bolts with collars.
These sections were changed:
1. In Manpower, added a table to Work Package 12 to have a table for Group 1 and another table for Group
2. Figure 24 was eliminated from Group 1 and Figure 22 was eliminated from Group 2.
2. In Manpower, added applicability for Work Package 13.
3. In the Parts and Materials Supplied by the Operator, added footnote (d) to all the tables to provide the pre shrink diameter of the TFE-2X Standard Wall sleeve.
4. In Work Package 1, added the word left for clarification and consistency.
5. In Work Package 2, added the word right for clarification and consistency.
6. In Work Package 5, change access doors 532DB, 532EB, and 532FB to 533AB.
7. In Work Package 6, change access doors 632DB, 632EB, and 632FB to 633 AB.
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8. In Work Package 13, added applicability of Group 1-2.
9. In Figure 1, added footnote (a) to step 6. Also added the text each power feeder wire to footnotes (a) and
(b). The TFE-2X STANDARD WALL sleeve was added as an optional part for the 005W3281-() sleeve.
10. In Figure 2, added footnote (a) to step 4. The TFE-2X STANDARD WALL sleeve was added as an optional part for the 005W3281-() sleeve.
11. In Figure 3, added footnote (a) to step 4. The TFE-2X STANDARD WALL sleeve was added as an optional part for the 005W3281-() sleeve.
12. In Figure 17, added the text rivet or bolt with a collar to the illustration and to footnotes (a), (c), (d), and (e).
13. In Figure 20, updated the illustration text of view C-C to specify 16 locations and updated the total fastener quantity in the table.
14. In Figure 24, updated the illustration text of view C-C to specify 16 locations and updated the total fastener quantity in the table.
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 October 25, 2006Original Issue:
November 27, 2007Revision 1:
January 07, 2010Revision 2:
December 02, 2010Revision 3:
September 20, 2011Revision 4:
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Commercial Airplanes 767 Service Bulletin SummaryNumber: 767-57A0102Original Issue: October 25, 2006 Revision 4: September 20, 2011 ATA System: 5710 5720 2811 SUBJECT: WINGS - Center Wing - Outer Wing - Change to Fasteners in Fuel Tank Walls and Change to Wire Bundle Clamps
CONCURRENT REQUIREMENTS None.
BACKGROUND Accomplishment of the modifications within this service bulletin will help prevent possible ignition sources in the auxiliary fuel tank, main fuel tanks, and surge tanks caused by a wiring short. An ignition source in a fuel tank could result in a fire or an explosion.
A safety assessment by Boeing identified a certain type of fastener that penetrates the fuel tank wall and has an insufficient electrical bond to the fuel tank structure. These fasteners can be a path for electrical energy to enter the fuel tank if a wiring short occurs in a wire bundle installed along the fuel tank boundary structure. The electrical energy from the wiring short can go through these fasteners because they have an insufficient bond to the fuel tank structure. This energy can be sufficient to cause arcing at the ends of these fasteners in the fuel tank. If arcing occurs it can be an ignition source in a fuel tank.
This Service Bulletin makes these changes where a high energy short can occur and certain fasteners are installed: Installs a polytetraflouroethylene (TFE) sleeve on the wire bundles where the wire bundle clamp is installed to give more protection from chafing, replaces the wire bundle clamps with a different design that has better protection on its metal edges, and seals the ends of the fasteners in the fuel tanks to contain the electrical energy from a wiring short. These changes make sure that the risk of an ignition source in the fuel tank from a short is kept to a minimum.
This service bulletin is the result of the safety assessments conducted by Boeing under SFAR 88, "Fuel Tank System Fault Tolerance Evaluation Requirements".
ACTION (PRR B13421-11) This service bulletin is divided into work packages that are related to the different areas of the airplane.
Work Package 1 - Get access to the left front spar of the outer wing and change the clamp configurations at the specified locations.
Work Package 2 - Get access to the right front spar of the outer wing and change the clamp configurations at the specified locations.
Work Package 3 - Get access to the front spar of the center wing in the forward cargo area and change the clamp configurations at the specified locations.
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Work Package 4 - Get access to the rear spar of the center wing in the main wheel well on the right side and change the clamp configurations at the specified locations.
Work Package 5 - Prepare the main fuel tank and surge tank in the left wing for entry. Get access to the fasteners and seal the fasteners and certain stiffeners at the specified locations in the fuel tank. Close access to the main fuel tank and the surge tank.
Work Package 6 - Prepare the main fuel tank and surge tank in the right wing for entry. Get access to the fasteners and seal the fasteners and certain stiffeners at the specified locations in the fuel tank. Close access to the main fuel tank and the surge tank.
Work Package 7 - Prepare the center bay of the auxiliary fuel tank for entry. Get access to the fasteners and seal the fasteners at the specified locations in the fuel tank. Close access to the auxiliary fuel tank.
Work Package 8 - Get access to the main fuel tank in the left wing. Get access to the fasteners and seal the fasteners and certain stiffeners at the specified locations in the fuel tank. Close access to the main fuel tank.
Work Package 9 - Prepare the main fuel tank in the right wing. Get access to the fasteners and seal the fasteners and certain stiffeners at the specified locations in the fuel tank. Close access to the main fuel tank.
Work Package 10 - Prepare the center bay of the auxiliary fuel tank for entry. Get access to the fasteners on the rear spar at the specified locations. Do a General Visual Inspection of the fasteners at the specified locations.
If the fasteners are not sealed, seal the fasteners at the specified locations. Close access to the auxiliary fuel tank.
Work Package 11 - Prepare the left main fuel tank for entry. Get access to the fasteners at rib 28. Do a General Visual Inspection of the fasteners for sealant. If the fasteners are not sealed, seal the fasteners at the specified locations at rib 28. Close access to the left main fuel tank.
Work Package 12 - Prepare the right main fuel tank for entry. Get access to the fasteners at rib 28. Do a General Visual Inspection of the fasteners at the specified locations. If the fasteners are not sealed, seal the fasteners at the specified locations at rib 28. Close access to the right main fuel tank.
Work Package 13 - Get access to the right wheel well. Do a General Visual Inspection of the clamp location on the rear spar. If a TFE sleeve is not installed between the clamp and the plastic convoluted tubing, install a TFE sleeve between the clamp and the plastic convoluted tubing. Close access to the right wheel well.
Return the airplane to a serviceable condition.
Service bulletin 767-57A0100 has common access and defuel requirements. This bulletin can be incorporated at the same time or separately. Service Bulletin 767-57A0100 is separate from this bulletin because it corrects a design deficiency and has warranty remedies.
EFFECTIVITY 767-200/-300/-300F/-400ER Airplanes. Refer to Paragraph 1.A.1., Airplanes, for the list of affected airplanes.
COMPLIANCE Federal Aviation Administration (FAA) Airworthiness Directive FAA AD 2009-18-02 is related to this service bulletin.
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Boeing recommends that this service bulletin be incorporated within 60 months from the effective date of FAA AD 2009-18-02.
INDUSTRY SUPPORT INFORMATION Boeing warranty remedies are not available for the configuration changes given in this service bulletin.
MANPOWER Elapsed HoursTotal Task HoursAirplanes
110.87330.88Group 1
277.66969.76Group 2
26.4149.97Group 3
15.3225.07Group 1, Configuration 2
24.0238.27Group 2, Configuration 2
MATERIAL INFORMATION Boeing Supplied Kits/Parts.
Refer to Paragraph 2.A., Material - Price and Availability.
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Commercial Airplanes 767 Service Bulletin Number: 767-57A0102 Original Issue: October 25, 2006 Revision 4: September 20, 2011 ATA System: 5710 5720 2811 SUBJECT: WINGS - Center Wing - Outer Wing - Change to Fasteners in Fuel Tank Walls and Change to Wire Bundle Clamps
1. PLANNING INFORMATION A. Effectivity
1. Airplanes This service bulletin is for the airplanes shown below. An equivalent change is on subsequent production airplanes. Refer to PRRB13421-11 for data about this change.
Refer to Service Bulletin Index Document D624T001 Part 3 for Airplane Variable Number, Line Number, and Serial Number data.
DESCRIPTIONCONFIGURATIONGROUP 767-200, 767-300, 767-300F-1 767-200/300/300F airplanes that have not accomplished the original issue of Boeing Service Bulletin 767-57A0102 1 767-200/300/300F airplanes that have accomplished the original issue of Boeing Service Bulletin 767-57A0102 2 767-400ER-2 767-400ER airplanes that have not accomplished the original issue of Boeing Service Bulletin 767-57A0102 1 767-400ER airplanes that have accomplished the original issue of Boeing Service Bulletin 767-57A0102 2 767-300 airplanes that need wire bundle clamp changes at limited locations on the front spar of the wings and sealant applied at limited locations in the main fuel tanks -3 Airplane Models:
767-200, 767-300, 767-300F, 767-400ER
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GroupVariable Number 1VA001 - VA020 1VA301 - VA315 1VA501 - VA530 1VA701 - VA719 1VA801 - VA810 1VB001 - VB002 1VB051 - VB055 1VB101 - VB125 1VB201 - VB202 1VB251 - VB253 1VB281 - VB284 1VB301 - VB302 1VB321 - VB332 1VB371 - VB373 1VB401 1VB441 - VB444 1VE001 - VE003 1VE021 - VE023 1VE041 - VE043 1VE061 - VE069 1VE083 - VE086 1VE101 - VE104 1VE116 - VE118 1VE121 - VE126 1VE141 - VE152 1VE171 - VE172 1VF001 - VF002 1VF041 - VF042 1VF051 1VF061 - VF062 1VF071 - VF072 1VF091 - VF093
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