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Commercial Airplane Group 767 Service Bulletin Number: 767-57A0102 Date: October 25, 2006 Revision 1: November 27, 2007 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BOEING PROPRIETARY, CONFIDENTIAL, AND/OR TRADE SECRET Copyright © 2006 The Boeing Company Unpublished Work - All Rights Reserved Boeing claims copyright in each page of this document only to the extent that the page contains copyrightable subject matter.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, MD-10, MD-11, MD-80, MD-88, MD-90, 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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October 25, 2006 767-57A0102Revision 1: November 27, 2007 1 of 174
8.0
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October 25, 2006 767-57A0102Revision 1: November 27, 2007 2 of 174 BOEING SERVICE BULLETIN 767-57A0102
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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 7 B. Concurrent Requirements ...................................... 1 7 C. Reason ................................................ 1 7 D. Description .............................................. 1 8 E. Compliance .............................................. 2 0 F . Approval ............................................... 2 1 G. Manpower .............................................. 2 1 H. Weight and Balance Changes .................................... 2 8 I. Electrical Load Data ......................................... 2 9 J. References .............................................. 2 9
1. Existing Data: .......................................... 2 9
2. Data supplied with this Service Bulletin: ........................... 2 9
3. Installation Drawings Used in the Preparation of this Service Bulletin: ........... 2 9 K. Publications Affected ......................................... 2 9 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 LESS THAN 1 INCH [Group 1-3] ....................... 5 7 FIGURE 4: GROUP 1 - FRONT SPAR STATION 143 TO STATION 616 - LEFT WING - LOCATION OF THE WIRE BUNDLE CLAMPS [Group 1] ........................... 5 9 FIGURE 5: GROUP 2 - FRONT SPAR STATION 143 TO STATION 616 - LEFT WING - LOCATION OF THE WIRE BUNDLE CLAMPS [Group 2] ........................... 6 4 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
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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] ........................... 6 9 FIGURE 7: GROUP 1 - FRONT SPAR STATION 616 TO STATION 1140 - LEFT WING - LOCATION OF THE WIRE BUNDLE CLAMPS [Group 1] ........................... 7 4 FIGURE 8: GROUP 2 - FRONT SPAR STATION 616 TO STATION 1140 - LEFT WING - LOCATION OF THE WIRE BUNDLE CLAMPS [Group 2] ........................... 8 0 FIGURE 9: GROUP 1 - FRONT SPAR STATION 143 TO STATION 616 - RIGHT WING - LOCATION OF THE WIRE BUNDLE CLAMPS [Group 1] ........................... 8 5 FIGURE 10: GROUP 2 - FRONT SPAR STATION 143 TO STATION 616 - RIGHT WING - LOCATION OF THE WIRE BUNDLE CLAMPS [Group 2] ........................... 9 0 FIGURE 11: GROUP 3 - FRONT SPAR STATION 143 TO STATION 1063 - RIGHT WING - LOCATION OF THE WIRE BUNDLE CLAMPS [Group 3] ........................... 9 5 FIGURE 12: GROUP 1 - FRONT SPAR STATION 616 TO STATION 1140 - RIGHT WING - LOCATION OF THE WIRE BUNDLE CLAMPS [Group 1] ........................... 9 9 FIGURE 13: GROUP 2 - FRONT STATION 616 TO STATION 1140 - RIGHT WING - LOCATION OF THE WIRE BUNDLE CLAMPS [Group 2] ............................. 1 0 5 FIGURE 14: GROUP 1 - FRONT SPAR - FORWARD CARGO COMPARTMENT - LOCATION OF THE WIRE BUNDLE CLAMPS [Group 1] ................................. 1 1 1 FIGURE 15: GROUP 2 - FRONT SPAR - FORWARD CARGO COMPARTMENT - LOCATION OF THE WIRE BUNDLE CLAMPS [Group 2] ................................. 1 1 3 FIGURE 16: GROUP 1-2 - REAR SPAR - MAIN WHELL WELL - LOCATION OF THE WIRE BUNDLE CLAMPS [Group 1-2] ..................................... 1 1 5 FIGURE 17: GROUP 1-3 - SEAL OF THE FASTENER [Group 1-3] ................... 1 1 7 FIGURE 18: GROUP 1 - FRONT SPAR - LEFT WING - MAIN FUEL TANK - LOCATION OF THE FASTENERS [Group 1] ............................................ 1 1 9 FIGURE 19: GROUP 1 - FRONT SPAR - LEFT WING - SURGE TANK - LOCATION OF THE FASTENERS [Group 1] ............................................ 1 2 6 FIGURE 20: GROUP 2 - FRONT SPAR - LEFT WING - MAIN FUEL TANK - LOCATION OF THE FASTENERS [Group 2] ............................................ 1 2 9 FIGURE 21: GROUP 2 - FRONT SPAR - LEFT WING - SURGE TANK - LOCATION OF THE FASTENERS [Group 2] ............................................ 1 3 8 FIGURE 22: GROUP 1 - FRONT SPAR - RIGHT WING - MAIN FUEL TANK - LOCATION OF THE FASTENERS [Group 1] .................................... 1 4 1 FIGURE 23: GROUP 1 - FRONT SPAR - RIGHT WING - SURGE TANK - LOCATION OF THE FASTENERS [Group 1] ............................................ 1 4 8 FIGURE 24: GROUP 2 - FRONT SPAR - RIGHT WING - MAIN FUEL TANK - LOCATION OF THE FASTENERS [Group 2] .................................... 1 5 1 FIGURE 25: GROUP 2 - FRONT SPAR - RIGHT WING - SURGE TANK - LOCATION OF THE FASTENERS [Group 2] ............................................ 1 6 0 FIGURE 26: GROUP 3 - FRONT SPAR - LEFT WING - MAIN FUEL TANK - LOCATION OF THE FASTENERS [Group 3] ............................................ 1 6 3 FIGURE 27: GROUP 3 - FRONT SPAR - RIGHT WING - MAIN FUEL TANK - LOCATION OF THE FASTENERS [Group 3] .................................... 1 6 6 FIGURE 28: GROUP 2 - CENTER BAY - AUXILIARY FUEL TANK - LOCATION OF THE FASTENERS [Group 2] ............................................ 1 6 9 FIGURE 29: GROUP 1 - CENTER BAY - AUXILIARY FUEL TANK - LOCATION OF THE FASTENERS [Group 1] ............................................ 1 7 2 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
October 25, 2006 767-57A0102Revision 1: November 27, 2007 4 of 174 BOEING SERVICE BULLETIN 767-57A0102
Commercial Airplane Group 767 Service Bulletin Revision Transmittal SheetNumber: 767-57A0102Date: October 25, 2006 Revision 1: November 27, 2007 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 as shown in the original issue of this service bulletin. Refer to Work Package 10, 11 and 12 for work instructions.
REASON FOR REVISION This revision is sent to correct the specified location of fasteners that must be sealed on the rear spar in the auxiliary fuel tank, correct the specified location of fasteners that must be sealed at rib 28 on the front spar, add Work Packages for airplanes that accomplished the original issue of this service bulletin, add references to more access doors that are necessary to get access to the fuel tanks and to specify permitted alternative fuel tank sealants.
New Work Packages are necessary because the original issue of this service bulletin specified the incorrect locations for certain fasteners on the rear spar of the auxiliary fuel tank and the front spar of the main wing. The new Work Packages do a general visual inspection of certain fasteners in the fuel tanks for sealant and seals the fasteners if they are not sealed already. If the correct fasteners are not sealed, there is a risk that arcing from a short can enter the fuel tank and be an ignition source.
These sections were changed:
1. In Planning Information, Paragraph 1.G, updated the manpower estimates.
2. In Material Information - Parts Necessary for Each Airplane, Paragraph 2.C., added permitted alternative fuel tank sealants specified in 767 AMM 28-11-00.
3. In Accomplishment Instructions, Paragraph 3.B, added access doors 541FB, 541JB, 542BB, 542CB, and 532AZ to Work Package 5 to gain access to the fuel tank.
4. In Accomplishment Instructions, Paragraph 3.B, added access doors 641FB, 641JB, 642BB, 642CB, and 632AZ to Work Package 6 to gain access to the fuel tank.
5. In Accomplishment Instructions, Paragraph 3.B, added access doors 134BZ, 134CZ, 134DZ, 134EZ, 134FZ, and 134GZ are added to Work Package 7 to gain access to the fuel tank.
6. In Accomplishment Instructions, Paragraph 3.B, added Work Package 10, 11, and 12 to show more work for airplanes changed as shown in the original issue of this service bulletin.
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October 25, 2006 767-57A0102Revision 1: November 27, 2007 5 of 174
7. In Figure 2 and 3, revised the procedure to install the sleeve to make it more clear.
8. In Figure 17, 18, 20, 22, 24, 26, and 27, added a reference to the AMM for permitted alternative fuel tank sealants.
9. In Figure 18, revised the location of the fasteners that must be sealed from rib 27 to rib 28.
10. In Figure 22, revised the location of the fasteners that must be sealed from rib 27 to rib 28.
11. In Figure 24, revised the location of the fasteners that must be sealed from rib 27 to rib 28.
12. In Figure 25, revised the orientation of the structure to show the right side view.
13. In Figure 28, revised the illustration to show the correct locator and BBL references that show the location of the fasteners that must be sealed on the rear spar in the auxiliary fuel tank.
14. In Figure 29, revised the illustration to show the correct locator and BBL references that show the location of the fasteners that must be sealed on the rear spar in the auxiliary fuel tank.
The data given in Information Notice 767-57A0102 IN 01 is included in this revision.
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 October 25, 2006Original Issue:
November 27, 2007Revision 1:
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October 25, 2006 767-57A0102Revision 1: November 27, 2007 6 of 174 BOEING SERVICE BULLETIN 767-57A0102
Commercial Airplane Group 767 Service Bulletin SummaryNumber: 767-57A0102Date: October 25, 2006 Revision 1: November 27, 2007 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 - Prepare the main fuel 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.
Work Package 9 - Prepare the main fuel 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.
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.
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 Airplanes. See Service Bulletin Paragraph 1.A.1 for effectivity.
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.
Boeing recommends that this service bulletin be incorporated within 5 years after the date on this service bulletin.
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INDUSTRY SUPPORT INFORMATION Boeing warranty remedies are not available for the configuration changes given in this service bulletin.
MANPOWER Elapsed HoursTotal Task HoursAirplanes
109.00329.01Group 1
275.79967.89Group 2
30.5460.10Group 3
13.4523.20Group 1, Configuration 2
22.1536.40Group 2, Configuration 2
MATERIAL INFORMATION Boeing Supplied Kits/Parts.
Refer to Paragraph 2.A., Material - Price and Availability.
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Commercial Airplane Group 767 Service Bulletin Number: 767-57A0102 Date: October 25, 2006 Revision 1: November 27, 2007 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:
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767-200, 767-300, 767-300F , 767-400ER GroupVariable Number 1VA001 - VA012 1VA014 - VA020 1VA301 - VA315 1VA501 - VA525 1VA527 - VA530 1VA701 - VA719 1VA801 1VA803 - VA804 1VA806 - VA810 1VB001 - VB002 1VB051 1VB053 - VB055 1VB101 - VB123 1VB125 1VB201 - VB202 1VB281 - VB284 1VB301 - VB302 1VB321 - VB323 1VB325 - VB332 1VB371 - VB373 1VB441 - VB444 1VE001 - VE002 1VE021 - VE023 1VE041 1VE061 1VE063 - VE064 1VE066 - VE069 1VE083 - VE086 1VE101 - VE104 1VE116 - VE118 1VE121 - VE126 1VE141 - VE149 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
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