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Commercial Airplanes 767 Service Bulletin ALERT Number: 767-57A0126 Original Issue: August 12, 2011 Revision 2: March 12, 2012 ATA System: 5710 5350 SUBJECT: Wing - Center Wing - Lower Underwing Longeron Fitting at FWD Intersection of Fuselage and Wing Skin - Inspection 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BOEING PROPRIETARY, CONFIDENTIAL, AND/OR TRADE SECRET Copyright © 2011 The Boeing Company Unpublished Work - All Rights Reserved Boeing claims copyright in each page of this document only to the extent that the page contains copyrightable subject matter.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BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.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: August 12, 2011 767-57A0126Revision 2: March 12, 2012 1 of 116
3.0
BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: August 12, 2011 767-57A0126Revision 2: March 12, 2012 2 of 116 BOEING SERVICE BULLETIN 767-57A0126
ALERTALERT
BLANK PAGE
Table of Contents
Revision Transmittal Sheet5
Summary9
1. PLANNING INFORMATION ........................................ 1 3 A. Effectivity ............................................... 1 3
1. Airplanes ............................................ 1 3
2. Spares Affected ........................................ 2 0 B. Concurrent Requirements ...................................... 2 0 C. Reason ................................................ 2 0 D. Description .............................................. 2 1 E. Compliance .............................................. 2 2 F. Approval ............................................... 2 4 G. Manpower .............................................. 2 4 H. Weight and Balance Changes .................................... 2 8 I. Electrical Load Data ......................................... 2 8 J. References .............................................. 2 8
1. Existing Data .......................................... 2 8
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 ........................... 2 9
2. MATERIAL INFORMATION ........................................ 3 1 A. Material - Price and Availability ................................... 3 1 B. Industry Support Information .................................... 3 1 C. Parts Necessary For Each Airplane ................................. 3 2
1. Kits/Parts ............................................ 3 2
2. Parts and Materials Supplied by the Operator ........................ 3 5
3. Parts Modified and Reidentified ................................ 3 6
4. Parts Removed and Not Replaced .............................. 3 6 D. Parts Necessary to Change Spares ................................. 3 6 E. Special Tooling - Price and Availability ............................... 3 6 F. Special Tooling Necessary to do this Service Bulletin ....................... 3 6
3. ACCOMPLISHMENT INSTRUCTIONS .................................. 3 7 A. GENERAL INFORMATION ..................................... 3 7 B. WORK INSTRUCTIONS ....................................... 3 8 FIGURE 1: UNDERWING LONGERON FITTING INSPECTION, LH ................... 4 4 FIGURE 2: UNDERWING LONGERON FITTING INSPECTION, RH .................. 4 7 FIGURE 3: TENSION BOLT HOLE AND FRONT SPAR LOWER CHORD INSPECTION, LH [Group 1, 3-4] .................................................. 5 0 FIGURE 4: TENSION BOLT HOLE AND FRONT SPAR LOWER CHORD INSPECTION, RH [Group 1, 3-4] .................................................. 5 6 FIGURE 5: TENSION BOLT HOLE AND FRONT SPAR LOWER CHORD INSPECTION, LH [Group 2] . 62 FIGURE 6: TENSION BOLT HOLE AND FRONT SPAR LOWER CHORD INSPECTION, RH [Group 2] . 68 FIGURE 7: TENSION BOLT, INTERNAL BATHTUB FITTING AND UNDERWING LONGERON FITTING INSTALL - LH [Group 1, 3-4] .................................. 7 4 FIGURE 8: TENSION BOLT, INTERNAL BATHTUB FITTING AND UNDERWING LONGERON FITTING INSTALL, RH [Group 1, 3-4] .................................. 8 2
BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: August 12, 2011 767-57A0126Revision 2: March 12, 2012 3 of 116 BOEING SERVICE BULLETIN 767-57A0126
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FIGURE 9: TENSION BOLT, INTERNAL BATHTUB FITTING AND UNDERWING LONGERON FITTING INSTALL, LH [Group 2] .................................... 9 0 FIGURE 10: TENSION BOLT, INTERNAL BATHTUB FITTING AND UNDERWING LONGERON FITTING INSTALL, RH [Group 2] .................................... 9 8 FIGURE 11: SEAL RETAINER REMOVAL, LH [Group 1-2; Group 4, Configuration 1] ......... 1 0 6 FIGURE 12: SEAL RETAINER REMOVAL, RH [Group 1-2; Group 4, Configuration 1] ......... 1 0 8 FIGURE 13: SEAL RETAINER INSTALL, LH [Group 1-2; Group 4, Configuration 1] .......... 1 1 0 FIGURE 14: SEAL RETAINER INSTALL, RH [Group 1-2; Group 4, Configuration 1] .......... 1 1 2 APPENDIX A: ................................................. 1 1 4
BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: August 12, 2011 767-57A0126Revision 2: March 12, 2012 4 of 116 BOEING SERVICE BULLETIN 767-57A0126
ALERTALERT
Commercial Airplanes 767 Service Bulletin ALERT Revision Transmittal SheetNumber: 767-57A0126Original Issue: August 12, 2011 Revision 2: March 12, 2012 ATA System: 5710 5350 SUBJECT: Wing - Center Wing - Lower Underwing Longeron Fitting at FWD Intersection of Fuselage and Wing Skin - Inspection and Replacement This revision includes all pages of the service bulletin.
COMPLIANCE INFORMATION RELATED TO THIS REVISION Federal Aviation Administration (FAA) Notice of Proposed Rule Making NPRM 2011-NM-211-AD, is related to this service bulletin.
No more work is necessary on the airplanes changed in accordance with the Original Issue or Revision 1 of this service bulletin. However, these airplanes should continue to accomplish the Part 1 inspections within the compliance time in Paragraph 1.E., Compliance and do the follow-on actions in Paragraph 1.E., Compliance.
Airplanes VS928, VS968, VS974, VS975, and VS981 were added to Group 1 of this service bulletin effectivity.
In addition, all airplanes after line number 1020 are also affected by this service bulletin.
REASON FOR REVISION This revision is sent to:
1. Add airplanes VS928, VS968, VS974, VS975, and VS981 to Group 1 Airplanes. These airplanes were inadvertantly omitted from the original issue and Revision 1 of this service bulletin. In addition all airplanes after line number 1020 are also affected by this service bulletin. These airplanes will be added to the service bulletin's MyBoeingFleet.com (MBF) "get effectivity" result when they are added to the MBF FleetProfile Page.
2. Add reference to FAA NPRM 2011-NM-211-AD.
3. Show tension bolt and related hardware do not need to be kept as new parts are included in the kits as the hole needs to be oversized.
4. Correct various typographical errors in the figures.
5. Clarify inspection areas.
6. Update service bulletin to latest requirements.
These sections were changed:
BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: August 12, 2011 767-57A0126Revision 2: March 12, 2012 5 of 116
1. Summary - Added reference to FAA NPRM 2011-NM-211-AD to compliance paragraph.
2. Paragraph 1.C., Reason - Added reason for Revision 1 and Revision 2.
3. Paragraph 1.D., Description - Added compliance information related to Revision 1 and Revision 2.
4. Paragraph 1.E., Compliance - Added reference to FAA NPRM 2011-NM-211-AD.
5. Paragraph 3.A., General Information - Deleted General Note 1 and revised General Note 5 to bring service bulletin to current standards.
6. Paragraph 3.B., Work Instructions:
a. FIGURE 1 - Clarify part being inspected in view B and section A-A.
b. FIGURE 2 - Clarify part being inspected in view B and section A-A.
c. FIGURE 3:
(1) Clarify inspection area in view B.
(2) Revised Step 1 to show tension bolt and related hardware do not need to be kept.
d. FIGURE 4:
(1) Clarify inspection area in view B.
(2) Revised Step 1 to show tension bolt and related hardware do not need to be kept.
e. FIGURE 5 - Clarify inspection area in view B.
f. FIGURE 6 - Clarify inspection area in view B.
g. FIGURE 7:
(1) Corrected typographical errors for: 1) The Circle Note for Shim "D"; 2) The Circle Note for fastener cap seal; and 3) The Fastener Code at radius filler "F".
(2) Corrected typographical errors for Shim "C" Identification in Steps 1, 4, and 8.
(3) Add Fastener code explanation illustration to bring fastener code table up to current requirements.
h. FIGURE 8:
(1) Corrected typographical errors for: 1) The Circle Note for Shim "D"; and 2) The Circle Note for fastener cap seal.
(2) Corrected typographical errors for Shim "C" Identification in Steps 1, 4, and 8.
(3) Add Fastener code explanation illustration to bring fastener code table up to current requirements.
i. FIGURE 9:
BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: August 12, 2011 767-57A0126Revision 2: March 12, 2012 6 of 116 BOEING SERVICE BULLETIN 767-57A0126
ALERTALERT
(1) Corrected typographical errors for: 1) The Circle Note for Shim "D"; 2) The Circle Note for fastener cap seal; and 3) The Fastener Code at radius filler "F".
(2) Corrected typographical errors for Shims "A", "B", and "C" Identification in Steps 1, 4, and 8.
(3) Add Fastener code explanation illustration to bring fastener code table up to current requirements.
j. FIGURE 10:
(1) Corrected typographical errors for: 1) The Circle Note for Shim "D"; and 2) The Circle Note for fastener cap seal.
(2) Corrected typographical errors for Shims "A", "B", and "C" Identification in Steps 1, 4, and 8.
(3) Add Fastener code explanation illustration to bring fastener code table up to current requirements.
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 August 12, 2011Original Issue:
November 09, 2011Revision 1:
March 12, 2012Revision 2:
BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: August 12, 2011 767-57A0126Revision 2: March 12, 2012 7 of 116 BOEING SERVICE BULLETIN 767-57A0126
ALERTALERT
BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: August 12, 2011 767-57A0126Revision 2: March 12, 2012 8 of 116 BOEING SERVICE BULLETIN 767-57A0126
ALERTALERT
BLANK PAGE
Commercial Airplanes 767 Service Bulletin ALERT SummaryNumber: 767-57A0126Original Issue: August 12, 2011 Revision 2: March 12, 2012 ATA System: 5710 5350 SUBJECT: Wing - Center Wing - Lower Underwing Longeron Fitting at FWD Intersection of Fuselage and Wing Skin - Inspection 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 None.
BACKGROUND The underwing longeron fittings must be inspected by High Frequency Eddy Current (HFEC) inspection to detect cracks in each underwing longeron fitting. If any crack is found in an underwing longeron fitting, that fitting must be replaced, and the tension bolt hole and the front spar lower chord adjacent to the underwing longeron fitting must be inspected for cracks. Further repair may be required. The underwing longeron fittings must be inspected periodically for cracks over the service life of the airplane. If you do not do this service bulletin, then cracks in the underwing longeron fitting could go undetected, potentially leading to a loss of the primary load path between the fuselage and the wing box. The loss of the primary load path could result in catastrophic damage to the wing box.
An operator reported finding cracks in the left and right wing center section underwing longeron fittings. The cracks found were in the same location on both fittings and appeared to run through the entire thickness of the forward edge of the fitting at the radius corner of the vertical/horizontal flange. The lengths of cracks were approximately 0.300 to 0.375 inches long. The airplane had accumulated 37,000 flight-cycles.
Similar cracks were found on a fatigue test airplane at these locations. Boeing estimates that it would take 25,000 cycles for the cracks to grow from 0.375 inches to 1.8 inches.
Another operator reported finding a crack in the left wing center section underwing longeron fitting during normal maintenance. The length of crack was approximately one inch long and started from the radius of the fitting flange. The airplane had accumulated 16,655 flight-cycles.
If you do this service bulletin you will prevent a possible loss of a primary load path due to the subject mode of crack development.
Boeing Service Related Problem (SRP) 767-SRP-57-0240 is related to this service bulletin.
BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: August 12, 2011 767-57A0126Revision 2: March 12, 2012 9 of 116
This area is the subject of Maintenance Planning Document (MPD) 767 MPD 8 53-622-00 and 767 MPD 8 53-632-00.
ACTION Part 1 - UNDERWING LONGERON FITTING INSPECTION – Do a HFEC inspection of the underwing longeron fitting for any crack.
– If no crack is detected, repeat Part 1 within the compliance time in accordance with Paragraph 1.E., Compliance.
– If any crack is detected, do Part 2 - TENSION BOLT HOLE, FRONT SPAR LOWER CHORD INSPECTION AND UNDERWING LONGERON FITTING REPLACEMENT.
Part 2 - TENSION BOLT HOLE, FRONT SPAR LOWER CHORD INSPECTION AND UNDERWING LONGERON FITTING REPLACEMENT.
– Do a HFEC inspection of the tension bolt hole and the front spar lower chord for any crack.
– If no crack is detected in the tension bolt hole or in the front spar lower chord, install the new underwing longeron fitting.
– If any crack is detected in the tension bolt hole or in the front spar lower chord, contact The Boeing Company for repair instructions and do the repair.
– Repeat Part 1 UNDERWING LONGERON FITTING INSPECTION within the compliance time in accordance with Paragraph 1.E., Compliance.
EFFECTIVITY All 767-200/ -300/ -300F/ -400ER airplanes. Refer to Paragraph 1.A., Effectivity.
COMPLIANCE Federal Aviation Administration (FAA) Notice of Proposed Rule Making NPRM 2011-NM-211-AD, is related to this service bulletin.
Refer to Paragraph 1.E., Compliance.
INDUSTRY SUPPORT INFORMATION Boeing warranty remedies are not available for the inspection,and/or repair procedures given in this service bulletin.
MANPOWER Refer to Paragraph 1.G., Manpower.
MATERIAL INFORMATION Refer to Paragraph 2.A., Material - Price and Availability.
BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: August 12, 2011 767-57A0126Revision 2: March 12, 2012 10 of 116 BOEING SERVICE BULLETIN 767-57A0126
ALERTALERT
BOEING SERVICE BULLETIN 767-57A0126
ALERT ALERT
JACK PAD (193EL-LEF I SIDE) (194ER-RIGHT SIDE) (193KL-LEFT SIDE) (194KR-RIGHT SIDE) STA
783.04 BODY
UPPER DRAG SKIN FRONT SPAR
SPLICE ANGLE LOWER DRAG оббо UNDERWING
SPLICE ANGLE LONGERON
FORWARD FASTENERS (3 LOCATIONS) LEFT SIDE (3 LOCATIONS) RIGHT SIDE PART 1:
DO A HFEC INSPECTION OF
THE UNDERWING LONGERON
FITTING FOR ANY CRACK PART 2: DO A HFEC INSPECTION OF FWD
THE TENSION BOLT HOLE AND UNDERWING LONGERON
THE FRONT SPAR LOWER (LEFT SIDE SHOWN, RIGHT SIDE OPPOSITE) CHORD FOR ANY CRACK, AND 2029426
REPLACE THE UNDERWING
LONGERON FITTING Original Issue: August 12, 2011 Revision 2: March 12, 2012 767-57A0126
BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 11 of 116
BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: August 12, 2011 767-57A0126Revision 2: March 12, 2012 12 of 116 BOEING SERVICE BULLETIN 767-57A0126