Original Issue: April 14, 1994 Revision 6: November 05, 2009 767-54A0062 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 1 of 66 ALERT ALERT 

### Commercial **Airplanes** 

# 767

**ALERT ALERT**  

# Service Bulletin

**Number: 767-54A0062** Original Issue: April 14, 1994 Revision 6: November 05, 2009 ATA System: 5451 **SUBJECT:** NACELLES / PYLONS - Strut Attach Fuse Pins - Midspar Fuse Pin Inspection and Replacement 

## BOEING PROPRIETARY, CONFIDENTIAL, AND/OR TRADE SECRET Copyright © 1994 The Boeing Company Unpublished Work - All Rights Reserved Boeing claims copyright in each page of this document only to the extent that the page contains copyrightable subject matter.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.**BLANK PAGE** Original Issue: April 14, 1994 Revision 6: November 05, 2009 767-54A0062 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 2 of 66 

### BOEING SERVICE BULLETIN 767-54A0062 **ALERT ALERT**

BLANK PAGE**Table of Contents** Original Issue: April 14, 1994 Revision 6: November 05, 2009 767-54A0062 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 3 of 66 

### BOEING SERVICE BULLETIN 767-54A0062 **ALERT ALERT Table of Contents**  Revision Transmittal Sheet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 1. PLANNING INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 A. Effectivity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 1. Airplanes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 2. Spares Affected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 B. Concurrent Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 C. Reason . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 D. Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 E. Compliance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 F. Approval . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 G. Manpower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 H. Weight and Balance Changes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 I. Electrical Load Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 J. References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 1. Existing Data: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 2. Data supplied with this Service Bulletin: . . . . . . . . . . . . . . . . . . . . . . . . . 35 3. Installation Drawings Used in the Preparation of this Service Bulletin: . . . . . . . . . . 35 K. Publications Affected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 L. Interchangeability and Intermixability of Parts . . . . . . . . . . . . . . . . . . . . . . . . . 36 2. MATERIAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 A. Material - Price and Availability. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 B. Industry Support Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 C. Parts Necessary For Each Airplane . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 1. Kits/Parts: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 2. Parts and Materials Supplied by the Operator: . . . . . . . . . . . . . . . . . . . . . . 38 3. Parts Modified and Reidentified: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 4. Parts Removed and Not Replaced: . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 D. Parts Necessary to Change Spares . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 E. Special Tooling - Price and Availability. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 F. Special Tooling Necessary to do this Service Bulletin . . . . . . . . . . . . . . . . . . . . . 40 3. ACCOMPLISHMENT INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41 A. GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41 B. WORK INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42 FIGURE 1: DELETED - REFER TO PARAGRAPH 1.E. - COMPLIANCE . . . . . . . . . . . . . . . 48 FIGURE 2: MIDSPAR FUSE PIN ACCESS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49 FIGURE 3: ON WING MIDSPAR FUSE PIN INSPECTION . . . . . . . . . . . . . . . . . . . . . . 51 FIGURE 4: OFF WING MIDSPAR FUSE PIN INSPECTION. . . . . . . . . . . . . . . . . . . . . . 55 FIGURE 5: MIDSPAR FUSE PIN REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . 58 FIGURE 6: OFF WING MIDSPAR FUSE PIN MAGNETIC PARTICLE INSPECTION . . . . . . . . . 60 FIGURE 7: MIDSPAR FUSE PIN FINISH RESTORATION . . . . . . . . . . . . . . . . . . . . . . 61 APPENDIX A: APPROVED REPAIRS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62**Table of Contents** Original Issue: April 14, 1994 Revision 6: November 05, 2009 767-54A0062 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 4 of 66 

### BOEING SERVICE BULLETIN 767-54A0062 **ALERT ALERT**

BLANK PAGEOriginal Issue: April 14, 1994 Revision 6: November 05, 2009 767-54A0062 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 5 of 66 ALERT ALERT 

### Commercial **Airplanes** 

# 767

**ALERT ALERT**  

# Service Bulletin

**Number: 767-54A0062** 

### Revision Transmittal Sheet Original Issue: April 14, 1994 Revision 6: November 05, 2009 ATA System: 5451 **SUBJECT:** NACELLES / PYLONS - Strut Attach Fuse Pins - Midspar Fuse Pin Inspection and Replacement

This Revision includes all pages of the service bulletin.

**COMPLIANCE INFORMATION RELATED TO THIS REVISION** Federal Aviation Administration (FAA) Airworthiness Directives (AD) 94-11-02 and 2003-03-02 are related to this service bulletin. More work is necessary on airplanes that have not been changed in accordance with either service bulletin 767- 54-0069, or the applicable 767 SIP service bulletin 767-54-0080, 767-54-0081 or 767-54-0082. Continued inspections of the midspar fuse pins are required at reduced thresholds and repeat intervals in accordance with Paragraph 1.E., Compliance. No more work is necessary on airplanes that have been changed in accordance with either service bulletin 767- 54-0069, or the applicable 767 Strut Improvement Program (SIP) service bulletin 767-54-0080, 767-54-0081 or 767-54-0082. Accomplishment of either service bulletin 767-54-0069 or the applicable 767 SIP service bulletin 767-54-0080, 767-54-0081 or 767-54-0082 is terminating action for this service bulletin.

**REASON FOR REVISION** This revision is sent to reduce the midspar fuse pin inspection threshold and repeat intervals based on an operator report of a cracked midspar fuse pin, after the Revision 5 date of this service bulletin. These sections were changed: 1. Summary: Added statement of consequences of not accomplishing the service bulletin; added/changed references; added service history; changed Action paragraph; changed effectivity statement; added FAA AD statement; changed illustration. 2. Paragraph 1.A., Effectivity: Added Group/Configuration table 3. Paragraph 1.C., Reason: Added statement of consequences of not accomplishing the service bulletin; added/changed references; added service history; added Revision 6 changes information.Original Issue: April 14, 1994 Revision 6: November 05, 2009 767-54A0062 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 6 of 66 

### BOEING SERVICE BULLETIN 767-54A0062 **ALERT ALERT** 4. Paragraph 1.D., Description: Changed reference; added note; deleted Group descriptions; added Revision 6 change information. 5. Paragraph 1.E., Compliance: Added/deleted references; added/changed compliance table; added ferry flight information. 6. Paragraph 1.F., Approval: Added references. 7. Paragraph 1.G., Manpower: Changed task names 8. Paragraph 1.J.1., Existing Data: Added/changed/deleted references 9. Paragraph 1.K., Publications Affected: Added paragraph 10. Paragraph 2.C., Material - Price and Availability: Updated price and availability data 11. Paragraph 2.C.2., Parts and Materials Supplied by the Operator: Changed part number; deleted materials; revised notes. 12. Paragraph 3.A., General Instructions: Added instructions; added inspection information; revised referenced procedures information; added serviceable pin criteria. 13. Paragraph 3.B., Work Instructions: Changed instructions to CONDITION/Option format; added/changed/ deleted instructions; deleted torque stripe requirement. 14. Figure 1: Deleted figure 15. Figure 2: Changed title; changed illustration; changed step numbers; added/changed references. 16. Figure 3: Changed/added illustration; added/changed steps; added/changed/deleted references; added corrosion information. 17. Figure 4: Added/changed illustration; added/changed steps; changed reference; added option for Magnetic Particle Inspection; added corrosion information. 18. Figure 5: Changed illustration; changed/deleted steps; changed reference. 19. Figure 6: Completely revised figure 20. Figure 7: New Figure 21. Appendix A: New Appendix 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.Original Issue: April 14, 1994 Revision 6: November 05, 2009 767-54A0062 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 7 of 66 

### BOEING SERVICE BULLETIN 767-54A0062 **ALERT ALERT REVISION HISTORY**  Original Issue: April 14, 1994 Revision 1: May 11, 1994 Revision 2: December 21, 1994 Revision 3: June 15, 1995 Revision 4: May 7, 1998 Revision 5: November 11, 2002 Revision 6: November 5, 2009Original Issue: April 14, 1994 Revision 6: November 05, 2009 767-54A0062 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 8 of 66 

### BOEING SERVICE BULLETIN 767-54A0062 **ALERT ALERT**

BLANK PAGEOriginal Issue: April 14, 1994 Revision 6: November 05, 2009 767-54A0062 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 9 of 66 ALERT ALERT 

### Commercial **Airplanes** 

# 767

**ALERT ALERT**  

# Service Bulletin

**Number: 767-54A0062** 

### Summary Original Issue: April 14, 1994 Revision 6: November 05, 2009 ATA System: 5451 **SUBJECT:** NACELLES / PYLONS - Strut Attach Fuse Pins - Midspar Fuse Pin 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** This inspection/replacement program will permit early detection of cracks in the midspar fuse pin on the inboard and outboard sides of the number one and number two pylons. Midspar fuse pin cracks can result in the loss of structural integrity of the midspar fuse pins and cause an engine breakaway from the airplane. There have been eight reports involving a total of fourteen midspar fuse pins suspected of having longitudinal cracks. Of these fuse pins, seven pins were confirmed cracked. The cracked pins were from one operator on airplanes with 15,628 to 23,056 flight cycles. Both airplanes are equipped with CF6-80A engines. The first pins suspected of being cracked were found during midspar bushing migration rework. The cracks were found by a detailed visual inspection. The cracking was confirmed by magnetic particle inspection with the pins removed. The second cracked pin was found using eddy current inspection on the inner bore of the fuse pin with the engine installed. Subsequent inspections of at least sixty-nine additional fuse pins from the same engine type have revealed no cracks. These additional pins were on airplanes with as many as 23,007 flight cycles. These cracks are believed to be caused by stresses due to ovalization of the fuse pin. Because this strut has redundant load paths, one pin can fail without affecting flight safety. Boeing testing of similar fuse pins showed no significant reduction in shear strength with longitudinal cracks up to 1 inch. An all base message M-7240-94-0006 was sent to inform operators of the development of this service bulletin and of Delta Airlines involvement as the “Lead the Fleet” airline.Original Issue: April 14, 1994 Revision 6: November 05, 2009 767-54A0062 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 10 of 66 

### BOEING SERVICE BULLETIN 767-54A0062 **ALERT ALERT** Subsequent to the release of Revision 4 of this service bulletin one operator has reported a fractured midspar fuse pin. The fractured midspar fuse pin was found during routine maintenance on the outboard side of the number one pylon. Further inspection of the inboard side of the number one pylon, revealed the midspar fuse pin to have corrosion within the bore and on the pin surface. The 767-ER airplane was equipped with RB211 engines and had accumulated 9,456 flight cycles. Service bulletin 767-54-0069 to replace the midspar fuse pins and service bulletin 767-54-0082 to modify the nacelle strut and wing structure had not been incorporated on this airplane. Reduced thresholds for the inspections given in this service bulletin will provide early detection of cracks and ensure the structural integrity of the number one and two pylons. An all base message M-7200-02-01708 was sent to inform operators of the development of revision 5 of this service bulletin. After the Revision 5 date of this service bulletin, one operator of a 767-300 airplane with CF6-80C2 engines reported a fractured midspar fuse pin. The airplane had accumulated 16,054 flight cycles and neither service bulletin 767-54-0069 nor 767 Strut Improvement Program (SIP) service bulletin 767-54-0081 had been incorporated. The fractured midspar fuse pin was found during routine maintenance on the outboard side of the number one pylon, prior to the next scheduled midspar fuse pin inspection in accordance with Revision 5 of this service bulletin. Further inspection revealed a cracked midspar fuse pin on the inboard side of the number one pylon. Subsequent inspection of both midspar fuse pins revealed discrepant circumferential machining grooves on the fuse pin main bore surface, in addition to longitudinal cracks. Eddy Current Inspection (ECI) of the midspar fuse pins in accordance with the requirements of Revision 5 of this service bulletin will not reveal the presence of the discrepant machining grooves. The roughness of the discrepant machining grooves exceeded the maximum allowable roughness of the fuse pin main bore surface. Metallurgical analysis determined the fuse pin fracture or crack origins coincided with the discrepant machining groove locations, in all cases. Stresses due to pin ovalization contributed to the longitudinal cracking of the midspar fuse pins. Multi-Operator Message (MOM) 1-1171248586 was sent to inform operators of the development of Revision 6 of this service bulletin. Reduced inspection thresholds and repeat intervals in accordance with Revision 6 of this service bulletin will provide early detection of cracks due to discrepant circumferential machining grooves and will ensure the structural integrity of the number one and two pylons. Boeing Service Related Problems (SRP) 767-SRP-54-0093 and 767-SRP-54-0131 are related to this service bulletin.

**ACTION** Do either Part 1 - On Wing Midspar Fuse Pin Inspection or Part 2 - Off Wing Midspar Fuse Pin Inspection or Part 3 - Midspar Fuse Pin Replacement of each inboard and outboard midspar fuse pin on the number one and two pylons, for any crack and any corrosion. — If any crack is found on the midspar fuse pin, replace the fuse pin. — If any corrosion is only found on a non-critical midspar fuse pin surface, remove the corrosion and continue the fuse pin inspection or replace the fuse pin. — If any corrosion is found on any midspar fuse pin surface except a non-critical surface, either contact Boeing for repair instructions and do the repair or replace the fuse pin.Original Issue: April 14, 1994 Revision 6: November 05, 2009 767-54A0062 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 11 of 66 

### BOEING SERVICE BULLETIN 767-54A0062 **ALERT ALERT** — If no crack is found and no corrosion is found on the midspar fuse pin, install the fuse pin (if removed) or replace the fuse pin. Repeat either Part 1 - On Wing Midspar Fuse Pin Inspection or Part 2 - Off Wing Midspar Fuse Pin Inspection or Part 3 - Midspar Fuse Pin Replacement of each inboard and outboard midspar fuse pin on the number one and two pylons, in accordance with Paragraph 1.E., Compliance. Accomplishment of either service bulletin 767-54-0069 or the applicable 767 SIP service bulletin 767-54-0080, 767-54-0081 or 767-54-0082 is terminating action for this service bulletin.

**EFFECTIVITY** 767-200, 767-300 and 767-300F Airplanes. Refer to Paragraph 1.A.1., Airplanes, for the list of affected airplanes.

**COMPLIANCE** The Federal Aviation Administration (FAA) will possibly release an Airworthiness Directive related to Revision 6 of this service bulletin. The Airworthiness Directive will make the compliance tasks and times given in this service bulletin mandatory. FAA Airworthiness Directives (AD) 94-11-02 and 2003-03-02 are related to this service bulletin. See Service Bulletin Paragraph 1.E. for compliance information.

**INDUSTRY SUPPORT INFORMATION** This service bulletin was first released before October of 1994. Thus industry support for affected airplanes depends upon whether you ever filed a warranty claim with Boeing on this service bulletin.

**MANPOWER** See the table in the Manpower section.

**MATERIAL INFORMATION** Operator Supplied Parts/Materials. Refer to Paragraph 2.A., Material - Price and Availability.Original Issue: April 14, 1994 Revision 6: November 05, 2009 767-54A0062 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 12 of 66 

### BOEING SERVICE BULLETIN 767-54A0062 **ALERT ALERT**

PIN COTTER DETAIL I SEE

WING FITTING

WASHER MIDSPAR FITTING WASHER SELF-LOCKING NUT

(2 LOCATIONS)



### DETAIL I TYPICAL MIDSPAR FITTING

DO A DETAILED AND EDDY CURRENT (MAGNETIC PARTICLE OPTIONAL, OFF WING) INSPECTION OF THE MIDSPAR FUSE PIN FOR ANY CRACK AND ANY CORROSION. REPLACE FUSE PIN IF ANY CRACK OR ANY CORROSION IS FOUND, EXCEPT ON NON-CRITICAL SURFACES. REMOVE CORROSION ON NON-CRITICAL SURFACES OR REPLACE FUSE PIN. DO REPEAT INSPECTIONS. CASTELLATED NUT WASHER

BOLT WASHER END CAP

FWD UPE09896Original Issue: April 14, 1994 Revision 6: November 05, 2009 767-54A0062 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 13 of 66 ALERT ALERT 

### Commercial **Airplanes** 

# 767

**ALERT ALERT**  

# Service Bulletin

**Number: 767-54A0062** Original Issue: April 14, 1994 Revision 6: November 05, 2009 ATA System: 5451 **SUBJECT:** NACELLES / PYLONS - Strut Attach Fuse Pins - Midspar Fuse Pin 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.

**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.

**GROUP CONFIGURATION DESCRIPTION** 1 - 767-200 airplane line numbers 6 thru 347 with CF6-80A Engines and 311T3102-1 (311T3102-3 Optional) Midspar Fuse Pins 2 - 767-200 airplane line numbers 1 thru 254 with JT9D-7R4 Engines and 311T3102-1 (311T3102- 3 Optional) Midspar Fuse Pins 3 - 767-300 airplane line numbers 136 thru 427 with CF6-80A Engines and 311T3102-2 (311T3102-4 Optional) Midspar Fuse Pins 4 - 767-300 airplane line numbers 132 thru 329 with JT9D-7R4 Engines and 311T3102-2 (311T3102-4 Optional) Midspar Fuse PinsOriginal Issue: April 14, 1994 Revision 6: November 05, 2009 767-54A0062 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 14 of 66 

### BOEING SERVICE BULLETIN 767-54A0062 **ALERT ALERT**

Airplane models:

767-200 767-300 767-300F IDENTIFICATION BY CUSTOMER, CUSTOMER CODE, GROUP AND VARIABLE NUMBER AA 767 LLC (SVX) 2 VE067 ABX AIR (ABX) 1 VA301 VA304–VA305 VA309–VA312 VA314–VA315 VA509 VB101–VB123 VB125 2 VA803 VA807–VA809 VB302 AEROFLOT (ARO) 5 VL896–VL897 VN471–VN472 AEROMEXICO (AMX) 6 VF071 VF093 VF162 VN166 VN531 AEROSVIT (UKA) 6 VN154–VN155 VN157 AEROTURBINE (AUB) 1 VB051 VB054–VB055 VB321 5 VB331–VB332 AIR ALGERIE (ALG) 5 VK131–VK133 AIR CANADA (ACN) 2 VA701–VA709 VA711–VA719 VB001–VB002 VB201–VB202 5 VN051–VN054 VN056–VN062 VN546–VN547 VN751–VN752 VN811–VN812 6 VN541 VN931–VN936 AIR CHINA (BEJ) 6 VE085 VK161–VK164 5 - 767-200, 767-300 and 767-300F airplane line numbers 158 thru 636 with CF6-80C2 Engines and 311T2102-1 (311T2102-2 Optional) Midspar Fuse Pins 6 - 767-200 and 767-300 airplane line numbers 165 thru 635 with PW4000 Engines and 311T2102-1 (311T2102-2 Optional) Midspar Fuse Pins 7 - 767-300 airplane line numbers 265 thru 627 with RB211-524H Engines and 311T2102-1 (311T2102-2 Optional) Midspar Fuse Pins **GROUP CONFIGURATION DESCRIPTION**Original Issue: April 14, 1994 Revision 6: November 05, 2009 767-54A0062 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 15 of 66 

### BOEING SERVICE BULLETIN 767-54A0062 **ALERT ALERT** AIR ITALY (RIT) 5 VF001–VF002 VL913 AIR MADAGASCAR (MAD) 6 VN167 VN556 AIR NEW ZEALAND (ANZ) 5 VN653 VN655–VN656 AIR PACIFIC (APC) 5 VN676 AIR SEYCHELLES (ASY) 1 VE104 2 VB301 AIR TRANSPORT INTERNATIONAL (TIN) 1 VA313 VA511–VA512 AIR ZIMBABWE (ZMB) 6 VF061–VF062 ALITALIA COMPAGNIA AEREA ITALIANA SPA (ILQ) 5 VL701–VL702 VN426 VN732 VN813 ALL NIPPON AIRWAYS (ANA) 5 VK081–VK112 VN191–VN196 AMERICAN AIRLINES (AAL) 1 VA501–VA505 VA514–VA523 VA525 VA527–VA530 5 VN001–VN041 AMERIJET INTERNATIONAL (AMJ) 1 VA303 VA306 ARKEFLY (HXL) 6 VN156 VN164–VN165 ASIANA AIRLINES (AAR) 5 VK143–VK144 VW851 AUSTRIAN AIRLINES AG (AUL) 6 VN242–VN243 VN671 AVIANCA (AVI) 6 VE171 VF072 VF161 VN152 VN500 VN532 AWAS (AWW) 1 VB325 5 VN651 6 VE172 VF092Original Issue: April 14, 1994 Revision 6: November 05, 2009 767-54A0062 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 16 of 66 

### BOEING SERVICE BULLETIN 767-54A0062 **ALERT ALERT** BELLVIEW AIRLINES (BEB) 5 VE125–VE126 BLUE CITY HOLDING (BCY) 2 VE069 BLUE PANORAMA AIRLINES (BPA) 6 VN174 VN225 VN681 BOEING (TBC) 2 VA001 BOEING CAPITAL CORPORATION (ZMF) 1 VE117 BRISTOL AIR LIMITED (BMD) 2 VA804 BRITISH AIRWAYS (BAB) 7 VN111–VN114 VN118–VN122 VN124–VN127 VN133–VN137 BTM CAPITAL CORPORATION (BTO) 2 VE022–VE023 CARGOJET AIRWAYS LTD. (WNT) 1 VA510 VA513 CHILEAN AIR FORCE (CHF) 6 VN561 CHINA EASTERN AIRLINES (CEA) 7 VL871–VL873 COLOMBIAN AIR FORCE (CLB) 6 VE086 COMPANIA MEXICANA DE AVIACION S.A. DE C.V. (CMA) 5 VF041–VF042 VL001–VL002 CONDOR (CDF) 6 VN683–VN691 CSDS AVIATION (CSO) 1 VA506–VA507 DELTA AIR LINES (DAL) 1 VA302 3 VK036 VK039–VK054 5 VL753 VN301–VN306 6 VK055–VK056 VN251–VN268 DNIPROAVIA (DNE) 6 VN495Original Issue: April 14, 1994 Revision 6: November 05, 2009 767-54A0062 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 17 of 66 

### BOEING SERVICE BULLETIN 767-54A0062 **ALERT ALERT** EL AL ISRAEL AIRLINES (ELA) 2 VB283–VB284 6 VF101–VF102 VN537 VN682 VN972 ERITREAN AIR LINES (ERJ) 2 VE066 ETHIOPIAN AIRLINES (ETH) 5 VL898 6 VN388 EUROATLANTIC AIRWAYS (MAE) 5 VN055 6 VN151 VN551 VN562 EVERGREEN MAINTENANCE CENTER (EAC) 2 VE061 FIRST AIR (BRS) 1 VA508 FLYGLOBESPAN.COM (FGS) 5 VL891 VN654 GA TELESIS (GTG) 4 VK002–VK003 GABON AIRLINES (GBO) 2 VA017–VA018 GECAS (GEF) 5 VN731 GENERIC CUSTOMER/SUPPLIER (XXX) 2 VA005 VE002 VE041 VE063 5 VN310 VN314 6 VN221–VN222 GOL AIRLINES (GOT) 5 VF171 VN637 VN753 6 VN163 VN557 GUGGENHEIM AVIATION PARTNERS (GPR) 6 VN153 HAWAIIAN AIRLINES (HWI) 3 VK031–VK034 6 VN171–VN173 VN381 HEWA BORA AIRWAYS (EXD) 2 VE021Original Issue: April 14, 1994 Revision 6: November 05, 2009 767-54A0062 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 18 of 66 

### BOEING SERVICE BULLETIN 767-54A0062 **ALERT ALERT** HIS MAJESTY THE SULTAN'S FLIGHT (BWN) 5 VF180 ICELANDAIR (ICE) 6 VN158 VN211 ILFC (ILF) 5 VF051 INTEGRATED DEFENSE SYSTEMS (BAC) 2 VA806 ITOCHU CORPORATION (CIT) 5 VF181–VF183 JAL INTERNATIONAL (JAL) 2 VB371–VB373 4 VK001 VK004–VK011 VK021–VK022 5 VK012–VK015 JETAIRFLY (TLB) 5 VN234 JORDAN AVIATION (JOR) 1 VB327 VB329–VB330 KALAIR (BERMUDA) (KLB) 5 VN311 KAM AIR (KMC) 2 VA019 KENYA AIRWAYS (KEN) 5 VK141 VL003 VN421 LAN AIRLINES (LAN) 5 VL703 VN063–VN064 6 VN168 VN966–VN967 VN971 LOT POLISH AIRLINES (LOT) 5 VL893 VN233 VN291–VN292 VN652 MALEV HUNGARIAN AIRLINES LTD. (HGA) 5 VF172 MARTINAIR HOLLAND (MTH) 6 VN223–VN224 VN385 VN672 MID EAST JET (SKL) 5 VF251 NEOS (NEO) 5 VL892 VL894Original Issue: April 14, 1994 Revision 6: November 05, 2009 767-54A0062 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 19 of 66 

### BOEING SERVICE BULLETIN 767-54A0062 **ALERT ALERT** NORTH AMERICAN AIRLINES (NNA) 5 VL755 VL895 VL911 VN634 VN922 OMNI AIR INTERNATIONAL (OAE) 5 VN424 VN427 VN635 PACE AIRLINES (PIE) 1 VB053 PHOENIX AIRCRAFT LEASING, INC. (PLB) 2 VA810 PTC AEROSPACE (PTE) 2 VB282 QANTAS (QAN) 5 VN081–VN097 7 VN115–VN117 VN123 VN130–VN132 ROYAL AIR MAROC (RAM) 5 VN636 ROYAL BRUNEI AIRLINES (RBA) 6 VN372 VN382–VN384 VN386–VN387 RYAN INTERNATIONAL AIRLINES (RYN) 3 VK035 VK038 6 VL011 VN376 S7 AIRLINES (SBR) 5 VN638 SAFI AIRWAYS (FFI) 2 VE084 SALAMIS AVIATION (LMV) 2 VE068 SHANGHAI AIRLINES (SHA) 6 VK171 SKY HOLDING COMPANY (PSH) 6 VL931 SKY KING (SKN) 2 VE064 SKYSTAR (SYW) 2 VA008 VA011–VA012 VA020 SMARTLYNX AIRLINES (LCH) 6 VN536 VN542Original Issue: April 14, 1994 Revision 6: November 05, 2009 767-54A0062 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 20 of 66 

### BOEING SERVICE BULLETIN 767-54A0062 **ALERT ALERT** SOJITZ CORPORATION (SOJ) 5 VN231–VN232 STAR AIR (SBJ) 1 VA307–VA308 VB323 VB328 VE101–VE103 5 VB441–VB444 TAA (TNL) 2 VA002–VA004 VA007 VA014–VA015 TAM (TPR) 5 VN422–VN423 VN425 TAMPA CARGO (TMP) 5 VE121–VE124 TEEBAH AIRLINES (EBH) 2 VA710 THOMAS COOK AIRLINES UK (JMA) 5 VN951–VN952 THOMSON AIRWAYS (BRI) 5 VL751–VL752 VL754 VN791–VN792 VN921 TRANSAERO AIRLINES (TRX) 1 VE116 VE118 5 VE143 VN307–VN309 VN313 6 VN371 VN631–VN633 TRANSATLANTIC INTL AIRLINES (TIB) 2 VA016 TUIFLY NORDIC (TNS) 5 VL912 UNITED AIR LINES (UAL) 6 VN491–VN494 VN496–VN499 VN501–VN513 UPS (UPS) 5 VW701–VW713 US AIRWAYS (USA) 5 VE141–VE142 VE144–VE149 VE151–VE152 UT FINANCE CORPORATION (ZZJ) 2 VE001 UZBEKISTAN AIRWAYS (UZB) 6 VL806 VISION AIR (VEG) 2 VA006 VA009–VA010Original Issue: April 14, 1994 Revision 6: November 05, 2009 767-54A0062 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 21 of 66 

### BOEING SERVICE BULLETIN 767-54A0062 **ALERT ALERT** VIVA MACAU (VMC) 5 VK142 6 VF091 WELLS FARGO (FSB) 5 VL004–VL006 WEST DOVER LLC (WDR) 3 VK037 YONA (IOP) 5 VN312

IDENTIFICATION BY VARIABLE NUMBER **Variable Group** VA001–VA020 2 VA301–VA315 1 VA501–VA530 1 VA701–VA719 2 VA801–VA810 2 VB001–VB002 2 VB051–VB055 1 VB101–VB125 1 VB201–VB202 2 VB251–VB253 1 VB281–VB284 2 VB301–VB302 2 VB321–VB330 1 VB331–VB332 5 VB371–VB373 2 VB401 1 VB441–VB444 5 VE001–VE003 2 VE021–VE023 2 VE041–VE043 2 VE061–VE069 2 VE083–VE084 2 VE085–VE086 6 VE101–VE104 1 VE116–VE118 1 VE121–VE126 5 VE141–VE152 5Original Issue: April 14, 1994 Revision 6: November 05, 2009 767-54A0062 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 22 of 66 

### BOEING SERVICE BULLETIN 767-54A0062 **ALERT ALERT**

VE171–VE172 6 VF001–VF002 5 VF041–VF042 5 VF051 5 VF061–VF062 6 VF071–VF072 6 VF091–VF093 6 VF101–VF102 6 VF161–VF162 6 VF171–VF172 5 VF180–VF183 5 VF251 5 VK001–VK011 4 VK012–VK015 5 VK021–VK022 4 VK031–VK054 3 VK055–VK056 6 VK081–VK112 5 VK131–VK133 5 VK141–VK144 5 VK161–VK164 6 VK171 6 VL001–VL006 5 VL011 6 VL701–VL703 5 VL751–VL755 5 VL806 6 VL871–VL873 7 VL891–VL898 5 VL911–VL913 5 VL931 6 VN001–VN041 5 VN051–VN064 5 VN081–VN097 5 VN111–VN127 7 VN130–VN137 7 VN151–VN158 6 VN163–VN168 6 VN171–VN174 6 **Variable Group**Original Issue: April 14, 1994 Revision 6: November 05, 2009 767-54A0062 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 23 of 66 

### BOEING SERVICE BULLETIN 767-54A0062 **ALERT ALERT**

VN191–VN196 5 VN211–VN212 6 VN221–VN225 6 VN231–VN234 5 VN241–VN243 6 VN251–VN268 6 VN291–VN292 5 VN301–VN314 5 VN371–VN372 6 VN376 6 VN381–VN388 6 VN421–VN427 5 VN471–VN472 5 VN491–VN513 6 VN531–VN532 6 VN536–VN537 6 VN541–VN542 6 VN546–VN547 5 VN551 6 VN556–VN557 6 VN561–VN562 6 VN631–VN633 6 VN634–VN638 5 VN651–VN656 5 VN671–VN672 6 VN676 5 VN681–VN691 6 VN731–VN732 5 VN751–VN753 5 VN791–VN792 5 VN811–VN813 5 VN921–VN922 5 VN931–VN936 6 VN951–VN952 5 VN966–VN967 6 VN971–VN972 6 VW701–VW713 5 VW851 5 **Variable Group**Original Issue: April 14, 1994 Revision 6: November 05, 2009 767-54A0062 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 24 of 66 

### BOEING SERVICE BULLETIN 767-54A0062 **ALERT ALERT**

2. Spares Affected

None **B. Concurrent Requirements**

None.

**C. Reason** This inspection/replacement program will permit early detection of cracks in the midspar fuse pin on the inboard and outboard sides of the number one and number two pylons. Midspar fuse pin cracks can result in the loss of structural integrity of the midspar fuse pins and cause an engine breakaway from the airplane. There have been eight reports involving a total of fourteen midspar fuse pins suspected of having longitudinal cracks. Of these fuse pins, seven pins were confirmed cracked. The cracked pins were from one operator on airplanes with 15,628 to 23,056 flight cycles. Both airplanes are equipped with CF6-80A engines. The first pins suspected of being cracked were found during a midspar bushing migration rework. The cracks were found by a detailed visual inspection. The cracking was confirmed by magnetic particle inspection with the pins removed. The second cracked pin was found using eddy current inspectionon the inner bore of the fuse pin with the engine installed. Subsequent inspections of at least sixtynine additional fuse pins from the same engine type have revealed no cracks. These additional pins were on airplanes with as many as 23,007 flight cycles. These cracks are believed to be caused by stresses due to ovalization of the fuse pin. Because this strut has redundant load paths, one pin can fail without affecting flight safety. Boeing testing of similar fuse pins showed no significant reduction in shear strength with longitudinal cracks up to 1 inch. An all base message M-7240-94-0006 was sent to inform operators of the development of this service bulletin and of Delta Airlines involvement as the “Lead the Fleet” airline. Subsequent to the release of Revision 4 of this service bulletin one operator has reported a fractured midspar fuse pin. The fractured midspar fuse pin was found during routine maintenance on the outboard side of the number one pylon. Further inspection of the inboard side of the number one pylon, revealed the midspar fuse pin to have corrosion within the bore and on the pin surface. The 767-ER airplane was equipped with RB211 engines and had accumulated 9,456 flight cycles. Service bulletin 767-54-0069 to replace the midspar fuse pins and service bulletin 767-54-0082 to modify the nacelle strut and wing structure had not been incorporated on this airplane. Reduced thresholds for the inspections given in this service bulletin will provide early detection of cracks and ensure the structural integrity of the number one and two pylons. An all base message M-7200-02-01708 was sent to inform operators of the development of Revision 5 of this service bulletin.Original Issue: April 14, 1994 Revision 6: November 05, 2009 767-54A0062 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 25 of 66 

### BOEING SERVICE BULLETIN 767-54A0062 **ALERT ALERT**

After the Revision 5 date of this service bulletin, one operator of a 767-300 airplane with CF6-80C2 engines reported a fractured midspar fuse pin. The airplane had accumulated 16,054 flight cycles and neither service bulletin 767-54-0069 nor 767 Strut Improvement Program (SIP) service bulletin 767- 54-0081 had been incorporated. The fractured midspar fuse pin was found during routine maintenance on the outboard side of the number one pylon, prior to the next scheduled midspar fuse pin inspection in accordance with Revision 5 of this service bulletin. Further inspection revealed a cracked midspar fuse pin on the inboard side of the number one pylon. Subsequent inspection of both midspar fuse pins revealed discrepant circumferential machining grooves on the fuse pin main bore surface, in addition to longitudinal cracks. Eddy Current Inspection of the midspar fuse pins in accordance with the requirements of Revision 5 of this service bulletin will not reveal the presence of the discrepant machining grooves. The roughness of the discrepant machining grooves exceeded the maximum allowable roughness of the fuse pin main bore surface. Metallurgical analysis determined the fuse pin fracture or crack origins coincided with the discrepant machining groove locations, in all cases. Stresses due to pin ovalization contributed to the longitudinal cracking of the midspar fuse pins. Multi-Operator Message (MOM) 1-1171248586 was sent to inform operators of the development of Revision 6 of this service bulletin. Reduced inspection thresholds and repeat intervals in accordance with Revision 6 of this service bulletin will provide early detection of cracks due to discrepant circumferential machining grooves and will ensure the structural integrity of the number one and two pylons. Boeing Service Related Problems (SRP) 767-SRP-54-0093 and 767-SRP-54-0131 are related to this service bulletin. Revision 1 is sent to do the following: Revise the compliance and repeat inspection thresholds in Figure 1. Add BMS 10-11 primer to the operator supplied parts list. Change the VN546-VN547 airplanes from Group 6 to Group 5. Modify the action and description to direct operators to contact Boeing for a possible ferry flight to repair facility if cracks are found. Change 767 Maintenance Manual 54-51-02 Temporary Revision dates to reflect a change in tooling requirements. Clarify the removal of cadmium plating in Figure 4. Revision 2 is sent to do the following: — Clarify the fuse pin plating removal. — Call out BMS 5-95 as a superseding sealant to BMS 5-79. — Add VE118 to Group 1 airplanes. — Clarify aft fairing door access panel numbers. — Add corrosion inspection text to Figure 3 and 4. — Add “Remove and Retain” text to Figure 3. — Remove torque values and add 767 AMM reference to Figure 3. — Add statements to Figure 1 addressing corrosion inspection. Revision 3 is sent to do the following:Original Issue: April 14, 1994 Revision 6: November 05, 2009 767-54A0062 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 26 of 66 

### BOEING SERVICE BULLETIN 767-54A0062 **ALERT ALERT**

Change the text in Figure 1 to read: “On Group 5, 6 and 7 airplanes with 311T2102-1 fuse pins, when the fuse pins reach or exceed 15,000 flight-cycles within 90 days of the release date of revision 1 of this service bulletin.” The word “within” was omitted. Change the text in Figure 1 to read: “Replace or reinspect fuse pin within 15,000 flight-cycles.” The text “15,000” was inadvertently replaced with 10,000 during the last revision. Revision 4 is sent to do the following: Limit the effectivity to 767 airplanes line position 1 through 636. Airplanes line position 637 and on have received a new fuse pin configuration in production that do not require inspections as specified in this service bulletin. Add new replacement fuse pin part numbers. Add Alternate Method of Compliance for installation of the new fuse pin part numbers. Add reference to service bulletin 767-54-0069 as terminating action for the repeat inspections. Add requirement to install a torque stripe on midspar fuse pin primary nut. Revision 5 is sent to do the following: Reduce the compliance recommendation statements given in “Figure 1 - Inspection Threshold and Repeat Inspection Interval Logic Diagram”. Add reference to service bulletins 767-54-0080, 767-54-0081 and 767-54-0082 as terminating action to the repeat inspections. Add clarification to the finish and corrosion preventive compound requirements during the installation of the midspar fuse pins within Figures 3, 5 and 6. Revision 6 is sent to reduce inspection thresholds and repeat intervals to provide early detection of cracks due to discrepant circumferential machining grooves and to ensure the structural integrity of the number one and two pylons. Refer to the Reason For Revision paragraph of the Revision Transmittal Sheet for a detailed list of changes in this revision. Boeing Service Related Problems (SRP) 767-SRP-54-0093 and 767-SRP-54-0131 are related to this service bulletin. **D. Description** Do either Part 1 - On Wing Midspar Fuse Pin Inspection or Part 2 - Off Wing Midspar Fuse Pin Inspection or Part 3 - Midspar Fuse Pin Replacement of each inboard and outboard midspar fuse pin on the number one and two pylons, for any crack and any corrosion. — If any crack is found on the midspar fuse pin, replace the fuse pin. — If any corrosion is only found on a non-critical midspar fuse pin surface, remove the corrosion and continue the fuse pin inspection or replace the fuse pin. — If any corrosion is found on any midspar fuse pin surface except a non-critical surface, either contact Boeing for repair instructions and do the repair or replace the fuse pin. — If no crack is found and no corrosion is found on the midspar fuse pin, install the fuse pin (if removed) or replace the fuse pin.Original Issue: April 14, 1994 Revision 6: November 05, 2009 767-54A0062 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 27 of 66 

### BOEING SERVICE BULLETIN 767-54A0062 **ALERT ALERT**

Repeat either Part 1 - On Wing Midspar Fuse Pin Inspection or Part 2 - Off Wing Midspar Fuse Pin Inspection or Part 3 - Midspar Fuse Pin Replacement of each inboard and outboard midspar fuse pin on the number one and two pylons, in accordance with Paragraph 1.E., Compliance. Accomplishment of either service bulletin 767-54-0069 or the applicable 767 SIP service bulletin 767- 54-0080, 767-54-0081 or 767-54-0082 is terminating action for this service bulletin. Revision 1: No more work is necessary on airplanes changed by the original issue of this service bulletin. Revision 2: No more work is necessary on airplanes changed by the original issue or Revision 1 of this service bulletin. Revision 3: No more work is necessary on airplanes changed by the original issue, Revision 1 or Revision 2 of this service bulletin. Revision 4: No more work is necessary on airplanes changed by the original issue, Revision 1, Revision 2, or Revision 3 of this service bulletin.

Revision 5: More work is necessary on airplanes that have not completed the midspar fuse pin inspections or replacement requirements given in this service bulletin within the last 5 years or 5000 flight cycles. Accomplish the midspar fuse pin inspection and replacement requirements given in this service bulletin within 30 days from the release date of revision 5 of this service bulletin. Airplanes that have accomplished the midspar fuse pin inspections or replacement requirements given in this service bulletin within the last 5 years or 5000 flight cycles, repeat the inspection and replacement requirements as given in Figure 1 - Inspection Threshold and Repeat Inspection Interval Logic Diagram”, until terminating action is completed.

Revision 6: More work is necessary on airplanes that have not been changed in accordance with either service bulletin 767-54-0069, or the applicable 767 SIP service bulletin 767-54-0080, 767-54-0081 or 767-54- 0082. Continued inspections of the midspar fuse pins are required at reduced thresholds and repeat intervals in accordance with Paragraph 1.E., Compliance. No more work is necessary on airplanes that have been changed in accordance with either service bulletin 767-54-0069, or the applicable 767 Strut Improvement Program (SIP) service bulletin 767-54- 0080, 767-54-0081 or 767-54-0082. Accomplishment of either service bulletin 767-54-0069 or the applicable 767 SIP service bulletin 767-54-0080, 767-54-0081 or 767-54-0082 is terminating action for this service bulletin. These service bulletins have similar access requirements as this service bulletin but are not required by this service bulletin: — 767-54-0059 "Nacelle Pylon - Wing to Strut Attach Fittings - Mid Spar Bushing - Inspection and Replacement" — 767-54-0061 "Nacelle Pylon - Wing to Strut Attach Fittings - Lower Spar Bushing - Inspection and Replacement" — 767-54-0095 "Nacelle Pylon - Wing to Strut Attach Fittings - Upper Spar Bushing - Inspection and Replacement" (Replaced 767-54-0060) The changes in this service bulletin will not change the Engine Indication and Crew Alerting System (EICAS).Original Issue: April 14, 1994 Revision 6: November 05, 2009 767-54A0062 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 28 of 66 

### BOEING SERVICE BULLETIN 767-54A0062 **ALERT ALERT E. Compliance**  The Federal Aviation Administration (FAA) will possibly release an Airworthiness Directive related to Revision 6 of this service bulletin. The Airworthiness Directive will make the compliance tasks and times given in this service bulletin mandatory. Accomplish the actions in Table 1 below in accordance with Paragraph 3., Accomplishment Instructions. Evaluate and accomplish the actions in Table 1 below independently for each midspar fuse pin. Table 1: Midspar Fuse Pin Inspection

**Condition Action (a) Compliance Time**  **(Whichever Occurs Later) Repeat Interval**  **(Not to Exceed)** ALL AIRPLANES Do Part 1 - On Wing Midspar Fuse Pin Inspection for any crack and any corrosion

-ORDo Part 2 - Off Wing Midspar Fuse Pin Inspection for any crack and any corrosion

-ORDo Part 3 - Midspar Fuse Pin Replacement 1) Before 5,000 Total Flight Cycles on the midspar fuse pin or 5 Years since the midspar fuse pin was installed as new, whichever occurs first

-OR2) Within 2,000 Flight Cycles or 2 Years after the midspar fuse pin was last inspected in accordance with this service bulletin, whichever occurs first. Within 30 days after the Revision 6 date of this service bulletin Within 2,000 Flight Cycles or 2 Years, whichever occurs first

CONDITION 1: Any Crack Is Found by Detailed Inspection Do Part 3 - Midspar Fuse Pin Replacement in accordance with CONDITION 1 BEFORE FURTHER FLIGHT (b) - -

CONDITION 2: No Crack Is Found AND Any Corrosion Is Only FoundOn A NonCritical Surface (c) Do Part 3 - Midspar Fuse Pin Replacement in accordance with CONDITION 2, Option 1

-ORDo the Midspar Fuse Pin Rework in accordance with CONDITION 2, Option 2 BEFORE FURTHER FLIGHT (b) - -Original Issue: April 14, 1994 Revision 6: November 05, 2009 767-54A0062 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 29 of 66 

### BOEING SERVICE BULLETIN 767-54A0062 **ALERT ALERT**

CONDITION 2.1: Any Corrosion Found Is Removed Do Part 3 - Midspar Fuse Pin Replacement in accordance with CONDITION 2.1, Option 1

-ORDo an Eddy Current Inspection (ECI) of the Midspar Fuse Pin for any crack in accordance with CONDITION 2.1, Option 2

-ORDo Part 4 - Magnetic Particle Inspection of the Midspar Fuse Pin for any crack in accordance with CONDITION 2.1, Option 3 BEFORE FURTHER FLIGHT (b) - -

CONDITION 2.1.1: Any Crack Is Found By ECI Do Part 3 - Midspar Fuse Pin Replacement in accordance with CONDITION 2.1.1, Option 1

-ORDo Part 4 - Magnetic Particle Inspection of the Midspar Fuse Pin for any crack in accordance with CONDITION 2.1.1, Option 2 BEFORE FURTHER FLIGHT (b) - - Table 1: Midspar Fuse Pin Inspection

**Condition Action (a) Compliance Time**  **(Whichever Occurs Later) Repeat Interval**  **(Not to Exceed)**Original Issue: April 14, 1994 Revision 6: November 05, 2009 767-54A0062 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 30 of 66 

### BOEING SERVICE BULLETIN 767-54A0062 **ALERT ALERT**

CONDITION 2.1.2: No Crack Is Found By ECI Do Part 3 - Midspar Fuse Pin Replacement in accordance with CONDITION 2.1.2, Option 1

-ORDo Part 5 - Fuse Pin Secondary Retention Hardware Installation in accordance with Part 1, CONDITION 2.1.2, Option 2

-ORInstall the Midspar Fuse Pin (if removed) in accordance with Part 2, CONDITION 2.1.2, Option 2 BEFORE FURTHER FLIGHT - -

CONDITION 2.1.3: Any Crack Is Found By MPI Do Part 3 - Midspar Fuse Pin Replacement in accordance with CONDITION 2.1.3 BEFORE FURTHER FLIGHT (b) - -

CONDITION 2.1.4: No Crack Is Found By MPI Do Part 3 - Midspar Fuse Pin Replacement in accordance with CONDITION 2.1.4, Option 1

-ORInstall the Midspar Fuse Pin in accordance with CONDITION 2.1.4, Option 2 BEFORE FURTHER FLIGHT - -

CONDITION 2.1.5: No Crack Is Found By MPI Do Part 3 - Midspar Fuse Pin Replacement in accordance with CONDITION 2.1.3

-ORDo a Midspar Fuse Pin Repair in accordance with CONDITION 2.1.5, Option 2 BEFORE FURTHER FLIGHT (b) - -

CONDITION 2.2: Any Corrosion Found Is Not Removed Do Part 3 - Midspar Fuse Pin Replacement in accordance with CONDITION 2.2 BEFORE FURTHER FLIGHT (b) - - Table 1: Midspar Fuse Pin Inspection

**Condition Action (a) Compliance Time**  **(Whichever Occurs Later) Repeat Interval**  **(Not to Exceed)**Original Issue: April 14, 1994 Revision 6: November 05, 2009 767-54A0062 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 31 of 66 

### BOEING SERVICE BULLETIN 767-54A0062 **ALERT ALERT**

CONDITION 3: No Crack Is Found AND Any Corrosion Is Found On Any Surface Other Than A Non-Critical Surface (c) Do Part 3 - Midspar Fuse Pin Replacement in accordance with CONDITION 3, Option 1

-ORDo a Midspar Fuse Pin Repair in accordance with CONDITION 3, Option 2 BEFORE FURTHER FLIGHT (b) - -

CONDITION 3.1: Any Crack Is Found By ECI Do Part 3 - Midspar Fuse Pin Replacement in accordance with CONDITION 3.1, Option 1

-ORDo a Magnetic Particle Inspection (MPI) of the Midspar Fuse Pin for any crack in accordance with CONDITION 3.1 Option 2 BEFORE FURTHER FLIGHT (b) - -

CONDITION 3.2: No Crack Is Found By ECI Do Part 3 - Midspar Fuse Pin Replacement in accordance with CONDITION 3.2, Option 1

-ORDo a Midspar Fuse Pin Repair in accordance with CONDITION 3.2, Option 2 BEFORE FURTHER FLIGHT (b) - -

CONDITION 4: No Crack Is Found AND No Corrosion Is Found By Detailed Inspection Do Part 3 - Midspar Fuse Pin Replacement in accordance with CONDITION 4, Option 1

-ORDo an Eddy Current Inspection (ECI) of the Midspar Fuse Pin for any crack in accordance with CONDITION 4, Option 2 BEFORE FURTHER FLIGHT - - Table 1: Midspar Fuse Pin Inspection

**Condition Action (a) Compliance Time**  **(Whichever Occurs Later) Repeat Interval**  **(Not to Exceed)**Original Issue: April 14, 1994 Revision 6: November 05, 2009 767-54A0062 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 32 of 66 

### BOEING SERVICE BULLETIN 767-54A0062 **ALERT ALERT**

Federal Aviation Administration (FAA) Airworthiness Directives (AD) 94-11-02 and 2003-03-02 are related to this service bulletin. **F. Approval** This service bulletin was examined by the Federal Aviation Administration (FAA). The changes specified in this service bulletin comply with the applicable regulations and are FAA approved, as well as European Aviation Safety Agency (EASA)/Joint Aviation Authorities (JAA) approved for all EASA/ JAA approved airplanes listed in the service bulletin effectivity. This service bulletin and its approval were based on the airplane in its original Boeing delivery configuration or as modified by other approved Boeing changes. If an airplane has a non-Boeing modification or repair that affects a component or system also affected by this service bulletin, the operator is responsible for obtaining appropriate regulatory agency approval before incorporating this service bulletin. The FAA has examined the inspection, and/or replacement procedures specified in Revision 3 to Service Bulletin 767-54A0062 “Nacelles/Pylon - Strut Attach fuse Pins - Midspar Fuse Pin Inspection and Replacement”. The FAA has approved the inspection, and/or replacement as an alternative to those specified in Airworthiness Directives (AD) 94-11-02, Amendment 39-8918. The FAA has examined the configuration changes, inspection, and/or repair procedures specified in Revision 4 to this service bulletin. The FAA has approved the configuration changes, inspection, and/ or repair procedures as an alternative to those specified in Airworthiness Directives (AD) 94-11-02, Amendment 39-8918. The FAA has examined the configuration changes, inspection, and/or repair procedures specified in Revision 5 to this service bulletin. The FAA has approved the configuration changes, inspection, and/ or repair procedures as an alternative to those specified in Airworthiness Directives (AD) 94-11-02, Amendment 39-8918. (a) Accomplishment of service bulletin 767-54-0069, or the applicable 767 Strut Improvement Program (SIP) service bulletin 767-54-0080, 767-54-0081 or 767-54-0082 is terminating action for this service bulletin. (b) A non-revenue ferry flight to a repair facility may be allowed. Non-revenue ferry flights for airplanes with one or less midspar fuse pin with either CONDITION 1, 2, 2.1, 2.1.1, 2.1.3, 2.2, 3, 3.1 or 3.2 per wing, will be considered on a case-by-case basis. An airplane with more than one midspar fuse pin with either CONDITION 1, 2, 2.1, 2.1.1, 2.1.3, 2.2, 3, 3.1 or 3.2 found on one wing, will not be considered for ferry flights. Ferry flight approval will be contingent on Eddy Current Inspection of both midspar fuse pins on each wing, and verification that only one midspar fuse pin per wing has either CONDITION 1, 2, 2.1, 2.1.1, 2.1.3, 2.2, 3, 3.1 or 3.2. A Detailed Inspection of the other strut-to-wing load paths, including the Upper Link, Upper Link Fuse Pin, Diagonal Brace and Lower Diagonal Brace Fuse Pin is required. Contact Boeing with inspection results and for further instructions. (c) Refer to Paragraph 3.A.,General Information, for more information on non-critical midspar fuse pin surfaces. Table 1: Midspar Fuse Pin Inspection

**Condition Action (a) Compliance Time**  **(Whichever Occurs Later) Repeat Interval**  **(Not to Exceed)**Original Issue: April 14, 1994 Revision 6: November 05, 2009 767-54A0062 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 33 of 66 

### BOEING SERVICE BULLETIN 767-54A0062 **ALERT ALERT**

This service bulletin has been approved by the FAA. In addition, the Manager of the Seattle Aircraft Certification Office approves the accomplishment of the inspections, replacements, and repairs specified in Section 1.E, Compliance, of SB 767-54A0062, Revision 6 as an AMOC to the applicable inspections, replacements, and repairs required by paragraphs (h), (i), and (j) of AD 2003-03-02. All provisions of AD 2003-03-02 that are not specifically referenced in the preceding sentence remain fully applicable and must be complied with. **G. Manpower** The data below shows an estimate of the man-hours necessary to do this inspection/replacement for each airplane and/or strut whichever is applicable. This estimate is for direct labor only, done by an experienced crew. Adjust the estimate with operator man-hour data if necessary. The estimate does not include lost time. These are some examples of lost time: — Time to adjust to the workplace — Time to schedule the work — Time to examine the work — Time to cure the materials — Time to make the parts — Time to find the tools.

**FUSE PIN INSPECTION - ENGINE NOT REMOVED** Task Number of Persons Man-Hours Elapsed Time (Hours) Open Access 2 2 1 Inspection 1 2 2 Close Access 2 2 1 TOTAL FOR EACH STRUT 6 4

FUSE PIN INSPECTION - ON BENCH Task Number of Persons Man-Hours Elapsed Time (Hours) Inspection 1 2 2 TOTAL PER AIRPLANE 2 2

FUSE PIN REPLACEMENT - ENGINE NOT REMOVED Task Number of Persons Man-Hours Elapsed Time (Hours) Open Access 5 15 3 Removal of components from aft fairing hydraulic bay 1 88

-EDP supply shut off valve. -Hydraulic reservoir -Alternating current pump. Replace fuse pins 1 1 1Original Issue: April 14, 1994 Revision 6: November 05, 2009 767-54A0062 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 34 of 66 

### BOEING SERVICE BULLETIN 767-54A0062 **ALERT ALERT**

**H. Weight and Balance Changes**

None

**I. Electrical Load Data** Not changed

**J. References** 1. Existing Data: a. Service Related Problem (SRP) 767-SRP-54-0093, 767-SRP-54-0131. b. 767 Airplane Maintenance Manual (AMM) 6-43-00, 27-81-00, 29-11-00, 29-11-06, 29-11-20, 54-51-04, 54-52-00, 54-52-01, 54-53-00, and 78-31-00. c. Boeing Multi-Operator Message (MOM) 1-1171248586 d. 767 Nondestructive Test (NDT) Manual D634T301, Part 6, Subject 54-51-01 e. Boeing Service Bulletin 767-54-0059, “Nacelles/Pylons - Wing to Strut Attach Fittings - Midspar Bushing Inspection and Replacement”. f. Boeing Service Bulletin 767-54-0095, “Nacelles/Pylons - Wing to Strut Attach Fittings - Forward Upper Spar Bushing Inspection and Replacement”. Install components from aft fairing hydraulic bay 1 10 10

Close Access 5 15 3 TOTAL PER STRUT 49 25

FUSE PIN REPLACEMENT - ENGINE REMOVED Task Number of Persons Man-Hours Elapsed Time (Hours) Remove engine 5 20 4 Removal of components from aft fairing hydraulic bay 1 88

-EDP supply shut off valve. -Hydraulic reservoir -Alternating current pump. Replace fuse pin 1 1 1 Install components from aft fairing hydraulic bay 1 10 10

Install engine 5 30 6 TOTAL PER STRUT 69 29Original Issue: April 14, 1994 Revision 6: November 05, 2009 767-54A0062 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 35 of 66 

### BOEING SERVICE BULLETIN 767-54A0062 **ALERT ALERT**

**NOTE:** Service bulletin 767-54-0060 was replaced by 767-54-0095. g. Boeing Service Bulletin 767-54-0061, “Nacelles/Pylons - Wing to Strut Attach Fittings - Lower Spar Bushing Inspection and Replacement”. h. Boeing Service Bulletin 767-54-0069, “Nacelles/Pylons - Midspar Fitting - Underwing Side Load Fitting - Fuse Pin Replacement and Wing Rework”. i. Boeing Service Bulletin 767-54-0080, “NACELLES/PYLONS - Pratt and Whitney Powered Airplanes - Nacelle Strut and Wing Structure Modification”. j. Boeing Service Bulletin 767-54-0081, “NACELLES/PYLONS - General Electric Powered Airplanes - Nacelle Strut and Wing Structure Modification”. k. Boeing Service Bulletin 767-54-0082, “NACELLES/PYLONS - Rolls Royce Powered Airplanes - Nacelle Strut and Wing Structure Modification”. l. Boeing Standard Overhaul Practices Manual (BSOPM) 20-10-01, 20-10-03, 20-20-01, 20- 30-02, 20-30-03 and 20-50-10. m. Boeing All Base Message M-7240-94-0006, M-7200-02-01708 n. FAA Airworthiness Directive (AD) 94-11-02, 2003-03-02 o. Boeing Parts Standards Document D-590 p. Boeing Drawing 012W6100 q. 767 Component Maintenance Manual (CMM) 54-50-21. 2. Data supplied with this Service Bulletin:

None 3. Installation Drawings Used in the Preparation of this Service Bulletin:

These drawings were used to prepare this service bulletin. These drawings are not necessary to make the specified changes, and are not supplied with this service bulletin. These drawings may not be applicable to all airplane configurations or operators. **Drawing Number Title** 311T5700 STRUT TO WING INSTL 310T3030 ENGINE TO STRUT MOUNT INSTL 310T1030 ENGINE STRUT MOUNT INSTL - CF6-80 ENGINE 310T2030 STRUT TO WING INSTL - CF6-80C ENGINE 310T4040 STRUT TO WING INSTLOriginal Issue: April 14, 1994 Revision 6: November 05, 2009 767-54A0062 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 36 of 66 

### BOEING SERVICE BULLETIN 767-54A0062 **ALERT ALERT**

**K. Publications Affected**

1. Publications

2. Damage Tolerance Based Structural Inspections: Boeing has evaluated the repairs and/or changes in this service bulletin for effects on Fatigue Critical Structure (FCS) and for changes to Damage Tolerance Inspections (DTI) required in the Maintenance Program. This service bulletin affects FCS and new DTI requirements for the structure affected are contained in Paragraph 1.E., Compliance, of this service bulletin. **L. Interchangeability and Intermixability of Parts** Refer to Paragraph 2.C., Parts Necessary For Each Airplane, for interchangeability and intermixability information. **Publication Chapter-Section** 767 Airplane Maintenance Manual 54-51Original Issue: April 14, 1994 Revision 6: November 05, 2009 767-54A0062 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 37 of 66 

### BOEING SERVICE BULLETIN 767-54A0062 **ALERT ALERT**

**2. MATERIAL INFORMATION A. Material - Price and Availability**  Boeing can supply the parts shown in Paragraph 2.C., Parts Necessary For Each Airplane, as shown below. If there is a limit to the quantity (QTY) of available parts, a supply sequence is given by Spares. More parts become available as shown in the Reorder Lead Time (ROLT). ROLT is calculated from the date Boeing gets the purchase order.

The parts are subject to the terms and conditions of the Boeing standard purchase order acknowledgment. After the Unit Price date, new price and ROLT data is applicable. Prices are in United States dollars. Terms: Net 30 days. Reference this service bulletin and submit your purchase order by one of the methods that follow: 1. Order on-line via ATA Spec 2000 or Boeing Part Page 2. Fax to (206) 662-7145 3. Spares Customer Support - MC 36-65 Boeing Spares Department P.O. Box 3707 Seattle, Washington 98124-2207 USA **B. Industry Support Information** This service bulletin was first released before October of 1994. Thus industry support for affected airplanes depends upon whether you ever filled a warranty claim with Boeing on this service bulletin. **C. Parts Necessary For Each Airplane**

1. Kits/Parts:

None. **Part Number Name ROLT (weeks)**  **Unit Price Thru Dec 31/09**  311T3102-1 Fuse Pin (a) No Longer Available 311T3102-2 Fuse Pin (b) No Longer Available 311T2102-1 Fuse Pin (c) No Longer Available 311T3102-3 Fuse Pin (a) 35 $4,596.00 311T3102-4 Fuse Pin (b) 35 $4,596.00 311T2102-2 Fuse Pin (c) 46 $1,635.00 (a) The 311T3102-1 fuse pin is no longer available. The 311T3102-3 fuse pin replaces the 311T3102-1 fuse pin. (b) The 311T3102-2 fuse pin is no longer available. The 311T3102-4 fuse pin replaces the 311T3102-2 fuse pin. (c) The 311T2102-1 fuse pin is no longer available. The 311T2102-2 fuse pin replaces the 311T2102-1 fuse pin.Original Issue: April 14, 1994 Revision 6: November 05, 2009 767-54A0062 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 38 of 66 

### BOEING SERVICE BULLETIN 767-54A0062 **ALERT ALERT**

2. Parts and Materials Supplied by the Operator: To get the parts shown below, refer to Paragraph 2.A., Material - Price and Availability.Original Issue: April 14, 1994 Revision 6: November 05, 2009 767-54A0062 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 39 of 66 

### BOEING SERVICE BULLETIN 767-54A0062 **ALERT ALERT**

**NOTE:** Quantities shown are necessary for each airplane.

**NOTE:** Parts in the table below are listed for replacement if not serviceable. Quantities shown are necessary for each airplane. Not all operator supplied parts are used on all airplane groups. Parts can be salvaged from existing installation if in serviceable condition. **Airplane Group 7654321**  **Quantity New Part Number Notes Existing Part Number Name** . . . . . 4 4 311T3102-1 (a) 311T3102-1 Fuse Pin . . . 4 4 . . 311T3102-2 (b) 311T3102-2 Fuse Pin 4 4 4 . . . . 311T2102-1 (c) 311T2102-1 Fuse Pin . . . . . 4 4 311T3102-3 (a)(d) 311T3102-1 Fuse Pin . . . 4 4 . . 311T3102-4 (b)(d) 311T3102-2 Fuse Pin 4 4 4 . . . . 311T2102-2 (c)(d) 311T2102-1 Fuse Pin (a) The 311T3102-1 fuse pin is no longer available. The 311T3102-3 fuse pin replaces the 311T3102-1 fuse pin. (b) The 311T3102-2 fuse pin is no longer available. The 311T3102-4 fuse pin replaces the 311T3102-2 fuse pin. (c) The 311T2102-1 fuse pin is no longer available. The 311T2102-2 fuse pin replaces the 311T2102-1 fuse pin. (d) Discard the existing part if cracked. Keep if not cracked and confirmed by magnetic particle inspection. If kept part is installed reinspections of the part is required in this bulletin as specified in Paragraph 1.E., Compliance. (e) This is the part number for the new equivalent or replacement part.

Airplane Group 7654321 Quantity Part Number Name . . . 4 4 4 4 BACB30LT6D83 (j) Bolt . . 4 . . . . BACB30LT6D86 (j) Bolt . 4 . . . . . BACB30LT6D87 (j) Bolt 4 . . . . . . BACB30LT6D88 (j) Bolt 4 4 4 4 4 4 4 MS24665-304 (h)(j) Cotter Pin 4 4 4 4 4 4 4 BACN10JD6AU (j) Nut 4 4 4 4 4 4 4 NAS1805-16 (j) Nut 4 4 . . . 4 4 311N5066-2 (b) (j) Washer . . . 4 4 4 4 311T3097-3 (b) (j) Washer 4 4 4 4 4 4 4 311T3097-4 (b) (j) Washer . . . 4 4 4 4 311T3097-5 (b) (j) Washer 4 4 4 4 4 4 4 AN960C616L (j) Washer 4 4 4 4 4 4 4 AN970-6 (j) Washer 4 4 . . . . . BACW10BN6SP (j) WasherOriginal Issue: April 14, 1994 Revision 6: November 05, 2009 767-54A0062 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 40 of 66 

### BOEING SERVICE BULLETIN 767-54A0062 **ALERT ALERT**

3. Parts Modified and Reidentified:

None. 4. Parts Removed and Not Replaced:

None. **D. Parts Necessary to Change Spares**

None **E. Special Tooling - Price and Availability** The operator can supply the tools shown in Paragraph 2.F., Special Tooling Necessary to do this Service Bulletin. Tool price and supply data are not given. **F. Special Tooling Necessary to do this Service Bulletin** No special tools or equipment are necessary to do the change in this service bulletin. But, new maintenance tools listed below and in the manuals given in Paragraph 1.J., References, will be necessary. Examine operator tool supply to make sure all necessary tools are available. . . . . . 4 4 311T3103-2 (d) End Retaining cap . . . 4 4 . . 311T3103-3 (e) End Retaining cap 4 4 4 . . . . 311T2103-1 (f) End Retaining cap (c) (c) (c) (c) (c) (c) (c) BMS 10-11, Type I Primer (a) This note is not used. (b) Not all washer part numbers are used. (c) One pint required. (d) End cap 311T3103-2 is used with 311T3102-1 (311T3102-3 optional) fuse pin. (e) End cap 311T3103-3 is used with 311T3102-2 (311T3102-4 optional) fuse pin. (f) End cap 311T2103-1 is used with 311T2102-1 (311T2102-2 optional) fuse pin. (g) This note is not used. (h) Refer to the applicable Qualified Products List (QPL) of the military specification listed for the approved material part number vendor. (j) Refer to 767 Structural Repair Manual Chapter 51, Boeing document D-590 and Boeing drawing 012W6100 for alternative fasteners.

**Tool Kit Number Name** A54011 (a) Mid Spar Fuse Pin Removal / Installation Tool Kit (a) Tool kit is used to perform inspection and removal/installation of fuse pin.Original Issue: April 14, 1994 Revision 6: November 05, 2009 767-54A0062 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 41 of 66 

### BOEING SERVICE BULLETIN 767-54A0062 **ALERT ALERT 3. ACCOMPLISHMENT INSTRUCTIONS** 

**A. GENERAL INFORMATION**

**CAUTION:** KEEP THE WORK AREA, WIRES AND ELECTRICAL BUNDLES CLEAN OF METAL PARTICLES OR CONTAMINATION WHEN YOU USE TOOLS. UNWANTED MATERIAL, METAL PARTICLES OR CONTAMINATION CAUGHT IN WIRE BUNDLES CAN CAUSE DAMAGE TO THE BUNDLES. DAMAGED WIRE BUNDLES CAN CAUSE SPARKS OR OTHER ELECTRICAL DAMAGE.

**NOTE:** 1. The instructions identified in Paragraph 3.B., Work Instructions, and the Figures give the recommended sequence of steps. The sequence of steps to do this service bulletin can be changed. 2. Manual titles are referred to by acronyms. Refer to Paragraph 1.J., References, for definition of the acronyms. 3. Obey all of the warnings and cautions given in the specified manual sections. 4. Unless shown differently, these dimensions and tolerances are used: — Linear dimensions are in inches — Tolerance on linear dimensions, other than rivet and bolt edge margins, is plus or minus 0.03 inch. — Tolerance on rivet and bolt edge margin is plus or minus 0.05 inch — Angular tolerance is plus or minus 2 degrees — Hole dimensions for standard solid rivets are given in 767 Structural Repair Manual, Chapter 51. — Torque limits to tighten nuts and bolts are given in 767 Structural Repair Manual, Chapter 51. 5. For approved fastener and process material substitutions, refer to 767 Structural Repair Manual, Chapter 51, Alternate fasteners are given in 767 Structural Repair Manual Chapter 51 and Boeing Drawing 012W6100. 6. If the length of fasteners specified in this service bulletin do not meet the installation standards, fasteners of the same specification, or an approved substitute, one grip length longer or shorter may be used. 7. A Detailed Inspection is defined as: An intensive examination of a specific item, installation, or assembly to detect damage, failure, or irregularity. Available lighting is normally supplemented with a direct source of good lighting at an intensity deemed appropriate. Inspection aids such as mirrors magnifying lenses, etc. may be necessary. Surface cleaning and elaborate procedures may be required. 8. These work instructions refer to procedures included on other Boeing documents. When the words "refer to" are used and the operator has an accepted alternative procedure, the accepted alternative procedure can be used. When the words "in accordance with" are included in the instruction, the procedure in the Boeing document must be used. 9. A serviceable midspar fuse pin meets the following criteria: — Has prior service historyOriginal Issue: April 14, 1994 Revision 6: November 05, 2009 767-54A0062 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 42 of 66 

### BOEING SERVICE BULLETIN 767-54A0062 **ALERT ALERT**

AND — No crack or corrosion can be found by Detailed Inspection in accordance with paragraph 3.B., Work Instructions, AND EITHER — No crack can be found by Eddy Current Inspection (ECI) in accordance with Paragraph 3.B., Work Instructions, OR — Any crack found by ECI cannot also be found by Magnetic Particle Inspection (MPI) in accordance with Paragraph 3.B., Work Instructions, OR — No crack can be found by MPI in accordance with Paragraph 3.B., Work Instructions. 10. The midspar fuse pins have multiple non-critical surfaces. The non-critical fuse pin surfaces are shown in Figure 3, Figure 4 and Appendix A.

**B. WORK INSTRUCTIONS** 1. Do either Part 1 - On Wing Midspar Fuse Pin Inspection or Part 2 - Off Wing Midspar Fuse Pin Inspection or Part 3 - Midspar Fuse Pin Replacement of the inboard and outboard midspar fuse pins, on the number one and two pylons. **Part 1 - On Wing Midspar Fuse Pin Inspection** 1. Retract the leading edge slats if they are extended and install the leading edge slat drive unit locks. Refer to 767 AMM 27-81-00 and 767 AMM 78-31-00 as accepted procedures. 2. Remove aft fairing access doors and midspar fuse pin access doors in accordance with Figure 2. 3. Do a Detailed Inspection of the midspar fuse pin for any crack and any corrosion in accordance with Figure 3. a. CONDITION 1: Any Crack Is Found By Detailed Inspection, Do Part 3 - Midspar Fuse Pin Replacement b. CONDITION 2: No Crack Is Found AND Any Corrosion Is Only Found On A Non-Critical Surface (1) Option 1: Do Part 3 - Midspar Fuse Pin Replacement (2) Option 2: Midspar Fuse Pin Rework (a) Remove any light corrosion in accordance with Figure 3; remove any heavy corrosion in accordance with Appendix A. (b) CONDITION 2.1: Any Corrosion Found Is Removed 1) Option 1: Do Part 3 - Midspar Fuse Pin Replacement 2) Option 2: Do an Eddy Current Inspection (ECI) of the midspar fuse pin for any crack in accordance with Figure 3. {a} CONDITION 2.1.1: Any Crack Is Found By ECIOriginal Issue: April 14, 1994 Revision 6: November 05, 2009 767-54A0062 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 43 of 66 

### BOEING SERVICE BULLETIN 767-54A0062 **ALERT ALERT** 1} Option 1: Do Part 3 - Midspar Fuse Pin Replacement 2} Option 2: Do Part 4 - Magnetic Particle Inspection of the Midspar Fuse Pin for Any Crack {b} CONDITION 2.1.2: No Crack Is Found By ECI 1} Option 1: Do Part 3 - Midspar Fuse Pin Replacement 2} Option 2: Do Part 5 - Fuse Pin Secondary Retention Hardware Installation 3) Option 3: Do Part 4 - Magnetic Particle Inspection of the Midspar Fuse Pin for Any Crack (c) CONDITION 2.2: Any Corrosion Found Is Not Removed, Do Part 3 - Midspar Fuse Pin Replacement c. CONDITION 3: No Crack Is Found AND Any Corrosion Is Found On Any Surface Other Than A Non-Critical Surface (1) Option 1: Do Part 3 - Midspar Fuse Pin Replacement (2) Option 2: Midspar Fuse Pin Repair (a) Remove the midspar fuse pin. Refer to 767 AMM 54-51-04 as an accepted procedure. (b) Do an Eddy Current Inspection (ECI) of the midspar fuse pin for any crack in accordance with Figure 4. 1) CONDITION 3.1: Any Crack Is Found By ECI {a} Option 1: Do Part 3 - Midspar Fuse Pin Replacement {b} Option 2: Do Part 6 - Magnetic Particle Inspection of the Midspar Fuse Pin for Any Crack Prior to Repair 2) CONDITION 3.2: No Crack Is Found By ECI {a} Option 1: Do Part 3 - Midspar Fuse Pin Replacement {b} Option 2: Midspar Fuse Pin Repair 1} Contact Boeing for Repair Instructions and Do the Repair. 2} Install the repaired midspar fuse pin. Refer to 767 AMM 54-51-04 as an accepted procedure. d. CONDITION 4: No Crack Is Found AND No Corrosion Is Found By Detailed Inspection (1) Option 1: Do Part 3 - Midspar Fuse Pin ReplacementOriginal Issue: April 14, 1994 Revision 6: November 05, 2009 767-54A0062 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 44 of 66 

### BOEING SERVICE BULLETIN 767-54A0062 **ALERT ALERT** (2) Option 2: Do an Eddy Current Inspection (ECI) of the midspar fuse pin for any crack in accordance with Figure 3. (a) CONDITION 2.1.1: Any Crack Is Found By ECI 1) Option 1: Do Part 3 - Midspar Fuse Pin Replacement 2) Option 2: Do Part 4 - Magnetic Particle Inspection of the Midspar Fuse Pin for Any Crack (b) CONDITION 2.1.2: No Crack Is Found By ECI 1) Option 1: Do Part 3 - Midspar Fuse Pin Replacement 2) Option 2: Do Part 5 - Fuse Pin Secondary Retention Hardware Installation 4. Install aft fairing access doors and midspar fuse pin access doors in accordance with Figure 2. 5. Remove the leading edge slat drive unit locks, if installed. Refer to 767 AMM 27-81-00 as an accepted procedure. 6. Return airplane to a serviceable condition. 7. Repeat either Part 1 - On Wing Midspar Fuse Pin Inspection or Part 2 - Off Wing Midspar Fuse Pin Inspection or Part 3 - Midspar Fuse Pin Replacement in accordance with Paragraph 1.E., Compliance. **Part 2 - Off Wing Midspar Fuse Pin Inspection** 1. Retract the leading edge slats if they are extended and install the leading edge slat drive unit locks. Refer to 767 AMM 27-81-00 and 767 AMM 78-31-00 as accepted procedures. 2. Remove aft fairing access doors and midspar fuse pin access doors in accordance with Figure 2. 3. Remove the midspar fuse pin. Refer to 767 AMM 54-51-04 as an accepted procedure. 4. Do a Detailed Inspection of the midspar fuse pin for any crack and any corrosion in accordance with Figure 4. a. CONDITION 1: Any Crack Is Found By Detailed Inspection, Do Part 3 - Midspar Fuse Pin Replacement b. CONDITION 2: No Crack Is Found AND Any Corrosion Is Only Found On A Non-Critical Surface (1) Option 1: Do Part 3 - Midspar Fuse Pin Replacement (2) Option 2: Midspar Fuse Pin Rework (a) Remove any light corrosion in accordance with Figure 3; remove any heavy corrosion in accordance with Appendix A. (b) CONDITION 2.1: Any Corrosion Found Is RemovedOriginal Issue: April 14, 1994 Revision 6: November 05, 2009 767-54A0062 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 45 of 66 

### BOEING SERVICE BULLETIN 767-54A0062 **ALERT ALERT** 1) Option 1: Do Part 3 - Midspar Fuse Pin Replacement 2) Option 2: Do an Eddy Current Inspection (ECI) of the midspar fuse pin for any crack in accordance with Figure 4. {a} CONDITION 2.1.1: Any Crack Is Found By ECI 1} Option 1: Do Part 3 - Midspar Fuse Pin Replacement 2} Option 2: Do Part 4 - Magnetic Particle Inspection of the Midspar Fuse Pin for Any Crack {b} CONDITION 2.1.2: No Crack Is Found By ECI 1} Option 1: Do Part 3 - Midspar Fuse Pin Replacement 2} Option 2: Install the midspar fuse pin. Refer to 767 AMM 54-51-04 as an accepted procedure. 3) Option 3: Do Part 4 - Magnetic Particle Inspection of the Midspar Fuse Pin for Any Crack (c) CONDITION 2.2: Any Corrosion Found Is Not Removed, Do Part 3 - Midspar Fuse Pin Replacement c. CONDITION 3: No Crack Is Found AND Any Corrosion Is Found On Any Surface Other Than A Non-Critical Surface (1) Option 1: Do Part 3 - Midspar Fuse Pin Replacement (2) Option 2: Midspar Fuse Pin Repair (a) Do an Eddy Current Inspection (ECI) of the midspar fuse pin for any crack in accordance with Figure 4. 1) CONDITION 3.1: Any Crack Is Found By ECI {a} Option 1: Do Part 3 - Midspar Fuse Pin Replacement {b} Option 2: Do Part 6 - Magnetic Particle Inspection of the Midspar Fuse Pin for Any Crack Prior to Repair 2) CONDITION 3.2: No Crack Is Found By ECI {a} Option 1: Do Part 3 - Midspar Fuse Pin Replacement {b} Option 2: Midspar Fuse Pin Repair 1} Contact Boeing for Repair Instructions and Do the Repair. 2} Install the repaired midspar fuse pin. Refer to 767 AMM 54-51-04 as an accepted procedure.Original Issue: April 14, 1994 Revision 6: November 05, 2009 767-54A0062 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 46 of 66 

### BOEING SERVICE BULLETIN 767-54A0062 **ALERT ALERT** d. CONDITION 4: No Crack Is Found AND No Corrosion Is Found By Detailed Inspection (1) Option 1: Do Part 3 - Midspar Fuse Pin Replacement (2) Option 2: Do an Eddy Current Inspection (ECI) of the midspar fuse pin for any crack in accordance with Figure 3. (a) CONDITION 2.1.1: Any Crack Is Found By ECI 1) Option 1: Do Part 3 - Midspar Fuse Pin Replacement 2) Option 2: Do Part 4 - Magnetic Particle Inspection of the Midspar Fuse Pin for Any Crack (b) CONDITION 2.1.2: No Crack Is Found By ECI 1) Option 1: Do Part 3 - Midspar Fuse Pin Replacement 2) Option 2: Install the midspar fuse pin. Refer to 767 AMM 54-51-04 as an accepted procedure. 5. Install aft fairing access doors and midspar fuse pin access doors in accordance with Figure 2. 6. Remove the leading edge slat drive unit locks, if installed. Refer to 767 AMM 27-81-00 as an accepted procedure. 7. Return airplane to a serviceable condition. 8. Repeat either Part 1 - On Wing Midspar Fuse Pin Inspection or Part 2 - Off Wing Midspar Fuse Pin Inspection or Part 3 - Midspar Fuse Pin Replacement in accordance with Paragraph 1.E., Compliance. **Part 3 - Midspar Fuse Pin Replacement** 1. Replace the midspar fuse pin in accordance with Figure 5. **Part 4 - Magnetic Particle Inspection of the Midspar Fuse Pin for Any Crack** 1. Remove the midspar fuse pin, if required. Refer to 767 AMM 54-51-04 as an accepted procedure. 2. Do a Magnetic Particle Inspection (MPI) of the midspar fuse pin for any crack in accordance with Figure 6. a. CONDITION 2.1.3: Any Crack is Found by MPI, Do Part 3 - Midspar Fuse Pin Replacement b. CONDITION 2.1.4: No Crack is Found by MPI (1) Option 1: Do Part 3 - Midspar Fuse Pin Replacement (2) Option 2: Midspar Fuse Pin Installation (a) If the midspar fuse pin finish was previously removed, restore the fuse pin finish in accordance with Figure 7.Original Issue: April 14, 1994 Revision 6: November 05, 2009 767-54A0062 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 47 of 66 

### BOEING SERVICE BULLETIN 767-54A0062 **ALERT ALERT** (b) Install the midspar fuse pin. Refer to 767 AMM 54-51-04 as an accepted procedure. **Part 5 - Fuse Pin Secondary Retention Hardware Installation** 1. If the midspar fuse pin finish was previously removed, restore the fuse pin finish in accordance with Figure 7. 2. Install the fuse pin secondary retention hardware in accordance with Figure 3. **Part 6 - Magnetic Particle Inspection of the Midspar Fuse Pin for Any Crack Prior to Repair** 1. Remove the midspar fuse pin, if required. Refer to 767 AMM 54-51-04 as an accepted procedure. 2. Do a Magnetic Particle Inspection (MPI) of the midspar fuse pin for any crack in accordance with Figure 6. a. CONDITION 2.1.3: Any Crack is Found by MPI, Do Part 3 - Midspar Fuse Pin Replacement b. CONDITION 2.1.5: No Crack is Found by MPI (1) Option 1: Do Part 3 - Midspar Fuse Pin Replacement (2) Option 2: Midspar Fuse Pin Repair (a) Contact Boeing for Repair Instructions and Do the Repair. (b) Install the midspar fuse pin. Refer to 767 AMM 54-51-04 as an accepted procedure.**FIGURE 1: DELETED - REFER TO PARAGRAPH 1.E. - COMPLIANCE** Original Issue: April 14, 1994 Revision 6: November 05, 2009 767-54A0062 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 48 of 66 

### BOEING SERVICE BULLETIN 767-54A0062 **ALERT ALERT FIGURE 1: DELETED - REFER TO PARAGRAPH 1.E. - COMPLIANCE** 

This Figure has been deleted. See Paragraph 1.E., Compliance, for inspection and maintenance alternatives. THIS FIGURE DOES NOT HAVE AN ILLUSTRATIONV75032

**(SHEET 1 OF 1) FIGURE 2: MIDSPAR FUSE PIN ACCESS**  Original Issue: April 14, 1994 Revision 6: November 05, 2009 767-54A0062 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 49 of 66 

### BOEING SERVICE BULLETIN 767-54A0062 **ALERT ALERT FIGURE 2: MIDSPAR FUSE PIN ACCESS** 

JT9D-7R4 ENGINES PW4000 ENGINES

RB511-524 ENGINES CF6-80A ENGINES CF6-80C2 ENGINES

FWD UP 1 1

4 2

3 1E09773

**(SHEET 1 OF 2) FIGURE 2: MIDSPAR FUSE PIN ACCESS**  Original Issue: April 14, 1994 Revision 6: November 05, 2009 767-54A0062 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 50 of 66 

### BOEING SERVICE BULLETIN 767-54A0062 **ALERT ALERT** The step numbers shown below agree with the numbers shown in the circle symbols in the figure.

**STEP TASK NAME IDENTIFICATION QTY NOTES** 1 Remove/ Install Group 1 thru Group 6 airplanes only Strut No. 1 - Aft fairing and fuse pin access doors 437BL 1 Refer to 767 AMM 06-43-00, 767 AMM 54-52-00, 767 AMM 54-52-01, and 767 AMM 54-53-00 as accepted procedures. 437ELX 1 436AL 1 437BR 1 437ERX 1 436AR 1 Strut No. 2 - Aft fairing and fuse pin access doors 447BL 1 447ELX 1 446AL 1 447BR 1 447ERX 1 446AR 1 Group 7 airplanes only Strut No. 1 - Aft fairing and fuse pin access doors 433DL 1 Refer to 767 AMM 06-43-00, 767 AMM 54-52-00, 767 AMM 54-52-01, and 767 AMM 54-53-00 as accepted procedures. 434AL 1 433LR 1 434AR 1 Strut No. 2 - Aft fairing and fuse pin access doors 443FL 1 444AL 1 443LR 1 444AR 1 Optional Additional Access 2 Remove/ Install Hydraulic line clamps - 2 Additional access can be gained to the left side fuse pins by removing the clamp blocks that support the hydraulic tubes on the left side of the struts. The hydraulic lines may need to be pushed upward after the clamp blocks are removed, to gainbetter access to the fuse pin secondary retention device nut and the cotter pin. 3 Remove/ Install EDP Supply Shut Off Valve - 1 Refer to 767 AMM 29-11-00 and 767 AMM 29-11-06 as accepted procedures. 4 Remove/ Install Hydraulic Reservoir - 1 Refer to 767 AMM 29-11-00 and 767 AMM 29-11-20 as accepted procedures.

**(SHEET 2 OF 2) FIGURE 3: ON WING MIDSPAR FUSE PIN INSPECTION**  Original Issue: April 14, 1994 Revision 6: November 05, 2009 767-54A0062 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 51 of 66 

### BOEING SERVICE BULLETIN 767-54A0062 **ALERT ALERT FIGURE 3: ON WING MIDSPAR FUSE PIN INSPECTION** 

A A PIN

NUT DETAIL I SEE

BOLT WING FITTING

WASHER FUSE PIN MIDSPAR FITTING WASHER SELF-LOCKING NUT CASTELLATED COTTER

END CAP WASHER WASHER

TYPICAL MIDSPAR FITTING 

### DETAIL I

(2 LOCATIONS) FWD UP

3 6 1 1 6 1 6

1 6 1 6 1 6

2 4 5E09779

**(SHEET 1 OF 4) FIGURE 3: ON WING MIDSPAR FUSE PIN INSPECTION**  Original Issue: April 14, 1994 Revision 6: November 05, 2009 767-54A0062 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 52 of 66 

### BOEING SERVICE BULLETIN 767-54A0062 **ALERT ALERT**

NOTE: 1. This figure shows an expanded view of the midspar fuse pin installation. However, the fuse pin cleaning and inspections in this figure only require removal of the secondary retention hardware (cotter pin, castellated nut, washer, end cap, washer and bolt). EDDY CURRENT INSPECTION AREA - FUSE PIN MAIN BORE SURFACE 

### A-A MIDSPAR FITTING LONGITUDINAL CRACK (EXAMPLE) WING ATTACH FITTING

FUSE PIN CROSS SECTION



### ON WING MIDSPAR FUSE PIN INSPECTION AREAS NON-CRITICAL FUSE PIN HEAD BEARING SURFACE

FUSE PIN MINOR BORE NON-CRITICAL FUSE PIN SHANK ENDFACE SURFACE

DETAILED INSPECTION AREA COVERS VISIBLE SURFACES EXCEPT THE MINOR BORE. NON-CRITICAL FUSE PIN END SURFACE

NON-CRITICAL CHAMFER SURFACE

NON-CRITICAL FUSE PIN HEAD EXTERIOR SURFACES NON-CRITICAL FUSE PIN HEAD EXTERIOR SURFACES1852624

**(SHEET 2 OF 4) FIGURE 3: ON WING MIDSPAR FUSE PIN INSPECTION**  Original Issue: April 14, 1994 Revision 6: November 05, 2009 767-54A0062 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 53 of 66 

### BOEING SERVICE BULLETIN 767-54A0062 **ALERT ALERT** 2. The step numbers shown below agree with the numbers shown in the circle symbols in the figure.

**STEP TASK NAME PART NUMBER QTY NOTES** Secondary Retention Hardware Removal 1 Remove Cotter pin - 2 If cotter pin cannot be removed normally, place wrench from the A54011 tool kit on nut and torque the secondary retention through bolt until the cotter pin shears off. Clean remaining pieces of cotter pin from bolt and nut. Remove/ Keep Castellated Nut - 2 Refer to 767 AMM 54-51-04 as an accepted procedure. Washer - 2 End cap - 2 Washer - 2 Bolt - 2 2 Clean Fuse Pin 311T3102-1 (311T3102-3 optional) OR 311T3102-2 (311T3102-4 optional) OR 311T2102-1 (311T2102-2 optional) 2 Remove any grease or corrosion inhibitors from fuse pin bore. Dothis carefully so that the paint (primer) and cadmium plate are not damaged. Refer to BSOPM 20-30- 03 as an accepted procedure. Use caution when cleaning the fuse pin. Nicks or scratches can cause false crack indications during Eddy Current Inspection. Detailed Inspection 3 Inspect Fuse Pin 311T3102-1 (311T3102-3 optional) OR 311T3102-2 (311T3102-4 optional) OR 311T2102-1 (311T2102-2 optional) 2 Do a Detailed Inspection of the fuse pin inner and outer surfaces for any crack and any corrosion. Light corrosion is characterized by discoloration or pitting that can be removed by hand sanding with a fine abrasive material. Heavy corrosion is corrosion that cannot be removed by hand sanding with a fine abrasive material.

**(SHEET 3 OF 4) FIGURE 3: ON WING MIDSPAR FUSE PIN INSPECTION**  Original Issue: April 14, 1994 Revision 6: November 05, 2009 767-54A0062 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 54 of 66 

### BOEING SERVICE BULLETIN 767-54A0062 **ALERT ALERT**

4 Clean (a) Fuse Pin 311T3102-1 (311T3102-3 optional) OR 311T3102-2 (311T3102-4 optional) OR 311T2102-1 (311T2102-2 optional) 2 Hand sand with a fine abrasive material to remove any light corrosion from the non-critical surfaces, if required. Refer to Table 2 below for a list of recommended light corrosion removal abrasives. Use caution when cleaning the fuse pin. Nicks or scratches can cause false crack indications during Eddy Current Inspection. Remove any heavy corrosion from the non-critical surfaces, in accordance with Appendix A, if required. Eddy Current Inspection [ECI] (a) 5 Inspect Fuse Pin 311T3102-1 (311T3102-3 optional) OR 311T3102-2 (311T3102-4 optional) OR 311T2102-1 (311T2102-2 optional) 2 Do an ECI of the fuse pin bore for any crack in accordance with 767 NDT D634T301, Part 6, Subject 54-51-01.

Secondary Retention Hardware Installation (a)(b) 6 Install (Kept) End cap - 2 Refer to 767 AMM 54-51-04 as an accepted procedure. Bolt - 2 Washer - 2 Washer - 2 Castellated Nut - 2 Install (New) Cotter pin - 2 (a) Not required if any crack is found by Detailed Inspection. (b) Not required if any crack is found by ECI.

**Table 2: RECOMMENDED LIGHT CORROSION REMOVAL ABRASIVES Backing Material Abrasive Material Recommended Grit Size**  Abrasive Paper or Cloth Aluminum Oxide 150 or finer Silicon Carbide 180 or finer Fabric or Pad - Fine to Ultrafine **STEP TASK NAME PART NUMBER QTY NOTES**

**(SHEET 4 OF 4) FIGURE 4: OFF WING MIDSPAR FUSE PIN INSPECTION**  Original Issue: April 14, 1994 Revision 6: November 05, 2009 767-54A0062 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 55 of 66 

### BOEING SERVICE BULLETIN 767-54A0062 **ALERT ALERT FIGURE 4: OFF WING MIDSPAR FUSE PIN INSPECTION** 

A A

EDDY CURRENT/MAGNETIC PARTICLE INSPECTION AREA - FUSE PIN MAIN BORE SURFACE 

### A-A LONGITUDINAL CRACK (EXAMPLE) FUSE PIN CROSS SECTION



### OFF WING MIDSPAR FUSE PIN INSPECTION AREAS NON-CRITICAL FUSE PIN SHANK ENDFACE SURFACE NON-CRITICAL FUSE PIN HEAD BEARING SURFACE

FUSE PIN MINOR BORE

DETAILED INSPECTION AREA COVERS ALL INSIDE AND OUTSIDE FUSE PIN SURFACES EXCEPT THE MINOR BORE. NON-CRITICAL FUSE PIN END SURFACE

NON-CRITICAL CHAMFER SURFACE NON-CRITICAL FUSE PIN HEAD EXTERIOR SURFACES NON-CRITICAL FUSE PIN HEAD EXTERIOR SURFACES 2 3 4 1E10317

**(SHEET 1 OF 3) FIGURE 4: OFF WING MIDSPAR FUSE PIN INSPECTION**  Original Issue: April 14, 1994 Revision 6: November 05, 2009 767-54A0062 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 56 of 66 

### BOEING SERVICE BULLETIN 767-54A0062 **ALERT ALERT** The step numbers shown below agree with the numbers shown in the circle symbols in the figure.

**STEP TASK NAME PART NUMBER QTY NOTES** 1 Clean Fuse Pin 311T3102-1 (311T3102-3 optional) OR 311T3102-2 (311T3102-4 optional) OR 311T2102-1 (311T2102-2 optional) 2 Remove any grease or corrosion inhibitors from fuse pin bore. Dothis carefully so that the paint (primer) and cadmium plate are not damaged. Refer to BSOPM 20-30- 03 as an accepted procedure. Use caution when cleaning the fuse pin. Nicks or scratches can cause false crack indications during Eddy Current Inspection. Detailed Inspection 2 Inspect Fuse Pin 311T3102-1 (311T3102-3 optional) OR 311T3102-2 (311T3102-4 optional) OR 311T2102-1 (311T2102-2 optional) 2 Do a Detailed Inspection of the fuse pin inner and outer surfaces for any crack and any corrosion. Light corrosion is characterized by discoloration or pitting that can be removed by hand sanding with a fine abrasive material. Heavy corrosion is corrosion that cannot be removed by hand sanding with a fine abrasive material. 3 Clean Fuse Pin (a) 311T3102-1 (311T3102-3 optional) OR 311T3102-2 (311T3102-4 optional) OR 311T2102-1 (311T2102-2 optional) 2 Hand sand with a fine abrasive material to remove any light corrosion from the non-critical surfaces, if required. Refer to Table 3 below for a list of recommended light corrosion removal abrasives. Use caution when cleaning the fuse pin. Nicks or scratches can cause false crack indications during Eddy Current Inspection. Remove any heavy corrosion from the non-critical surfaces, in accordance with Appendix A, if required. Eddy Current Inspection (ECI) (a)(b)

**(SHEET 2 OF 3) FIGURE 4: OFF WING MIDSPAR FUSE PIN INSPECTION**  Original Issue: April 14, 1994 Revision 6: November 05, 2009 767-54A0062 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 57 of 66 

### BOEING SERVICE BULLETIN 767-54A0062 **ALERT ALERT**

4 Inspect Fuse Pin 311T3102-1 (311T3102-3 optional) OR 311T3102-2 (311T3102-4 optional) OR 311T2102-1 (311T2102-2 optional) 2 Do an ECI of the fuse pin for any crack in accordance with 767 NDT D634T301, Part 6, Subject 54-51- 01. Optional to do a Magnetic Particle Inspection [MPI] of the fuse pin for any crack, in accordance with Figure 6. (a) Not required if any crack is found by detailed inspection. (b) MPI in accordance with Figure 6 is optional to the ECI, for fuse pin that is Off Wing.

**Table 3: RECOMMENDED LIGHT CORROSION REMOVAL ABRASIVES Backing Material Abrasive Material Recommended Grit Size**  Abrasive Paper or Cloth Aluminum Oxide 150 or finer Silicon Carbide 180 or finer Fabric or Pad - Fine to Ultrafine **STEP TASK NAME PART NUMBER QTY NOTES**

**(SHEET 3 OF 3) FIGURE 5: MIDSPAR FUSE PIN REPLACEMENT**  Original Issue: April 14, 1994 Revision 6: November 05, 2009 767-54A0062 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 58 of 66 

### BOEING SERVICE BULLETIN 767-54A0062 **ALERT ALERT FIGURE 5: MIDSPAR FUSE PIN REPLACEMENT** 

PIN

1 2 2 1 2 1

2 1 2 1

4 1 2 1 2 1 2 1 2 1 DETAIL I SEE

(2 LOCATIONS)



### DETAIL I TYPICAL MIDSPAR FITTING WASHER END CAP

COTTER

NUT CASTELLATED

FITTING MIDSPAR

FUSE PIN FITTING WING DETAIL I SEE

BOLT WASHER SELF-LOCKING NUT

WASHER WASHER

FWD UPE10319

**(SHEET 1 OF 2) FIGURE 5: MIDSPAR FUSE PIN REPLACEMENT**  Original Issue: April 14, 1994 Revision 6: November 05, 2009 767-54A0062 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 59 of 66 

### BOEING SERVICE BULLETIN 767-54A0062 **ALERT ALERT** The step numbers shown below agree with the numbers shown in the circle symbols in the figure.

**STEP TASK NAME**  **IDENTIFICA TION**  **QTY NOTES**  1 Remove Fuse Pin - 1 and secondary retention hardware, if required. Refer to 767 AMM 54-51-04 as an accepted procedure. 2 InstallNew, Repaired, orServiceable Fuse Pin Group 1 and 2 Airplanes: 311T3102-1 (311T3102-3 optional) 1 and secondary retention hardware. Refer to 767 AMM 54-51-04 as an accepted procedure.

Group 3 and 4 Airplanes: 311T3102-2 (311T3102-4 optional) Group 5, 6 and 7 Airplanes: 311T2102-1 (311T2102-2 optional)

**(SHEET 2 OF 2) FIGURE 6: OFF WING MIDSPAR FUSE PIN MAGNETIC PARTICLE INSPECTION**  Original Issue: April 14, 1994 Revision 6: November 05, 2009 767-54A0062 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 60 of 66 

### BOEING SERVICE BULLETIN 767-54A0062 **ALERT ALERT FIGURE 6: OFF WING MIDSPAR FUSE PIN MAGNETIC PARTICLE INSPECTION** 

The step numbers shown below agree with the numbers shown in the circle symbols in the figure.

**STEP TASK NAME PART NUMBER QTY NOTES** 1 Clean Fuse Pin 311T3102-1 (311T3102-3 optional) OR 311T3102-2 (311T3102-4 optional) OR 311T2102-1 (311T2102-2 optional) 2 Remove primer and cadmium plate from fuse pin, if necessary. Refer to BSOPM 20-30-02 as an accepted procedure.

2 Inspect Fuse Pin 311T3102-1 (311T3102-3 optional) OR 311T3102-2 (311T3102-4 optional) OR 311T2102-1 (311T2102-2 optional) 2 Do a Magnetic Particle Inspection of the fuse pin for any crack. Refer to BSOPM 20-20-01 as an accepted procedure. 1 2E10564

**(SHEET 1 OF 1) FIGURE 7: MIDSPAR FUSE PIN FINISH RESTORATION**  Original Issue: April 14, 1994 Revision 6: November 05, 2009 767-54A0062 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 61 of 66 

### BOEING SERVICE BULLETIN 767-54A0062 **ALERT ALERT FIGURE 7: MIDSPAR FUSE PIN FINISH RESTORATION** 

The step numbers shown below agree with the numbers shown in the circle symbols in the figure.

**STEP TASK NAME PART NUMBER QTY NOTES** 1 Apply Cadmium Plate 311T3102-1 (311T3102-3 optional) OR 311T3102-2 (311T3102-4 optional) - to any area of the fuse pin where the existing cadmium plate was removed. Refer to 767 CMM 54- 50-21 Repair 7-1 as an accepted procedure. (a) 311T2102-1 (311T2102-2 optional) to any area of the fuse pin where the existing cadmium plate was removed. Refer to 767 CMM 54- 50-21 Repair 22-1 as an accepted procedure. (a) 2 Apply Primer BMS 10-11, Type 1 - Apply two coats to any area of the fuse pin where the existing primer was removed. (b) (a) This step is not required if the cadmium plate was not removed from the fuse pin. (b) This step is not required if the primer was not removed from the fuse pin. 1 21844041

**(SHEET 1 OF 1) APPENDIX A: APPROVED REPAIRS**  Original Issue: April 14, 1994 Revision 6: November 05, 2009 767-54A0062 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 62 of 66 

### BOEING SERVICE BULLETIN 767-54A0062 **ALERT ALERT APPENDIX A: APPROVED REPAIRS**  Heavy corrosion is corrosion that cannot be removed by hand sanding with one of the abrasives listed in Table 4 below. The following repairs are approved for removal of heavy corrosion from the non-critical midspar fuse pin surfaces.

1. MIDSPAR FUSE PIN 311T2102-1, -2 HEAVY CORROSION REPAIR **Table 4: RECOMMENDED LIGHT CORROSION REMOVAL ABRASIVES Backing Material Abrasive Material Recommended Grit Size**  Abrasive Paper or Cloth Aluminum Oxide 150 or finer Silicon Carbide 180 or finer Fabric or Pad - Fine to Ultrafine**APPENDIX A: APPROVED REPAIRS** Original Issue: April 14, 1994 Revision 6: November 05, 2009 767-54A0062 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 63 of 66 

### BOEING SERVICE BULLETIN 767-54A0062 **ALERT ALERT**

This repair is for Midspar Fuse Pin 311T2102-1 or -2 with heavy corrosion on a non-critical fuse pin surface. A 0.005 -B-

-AA A



### A-A 32

32 32 32

31° 29° 0.260 0.240

0.881 0.871 DIA.

0.080 0.020 R (BOTH ENDS) 0.120 0.060 X 15° CHAMFER 0.08 0.02 R 0.250 0.230 3.655 3.640 0.135 0.115

32 5.070 5.050

CHAMFER 45° TO DEPTH OF THREAD (NON-CRITICAL SURFACE) NON-CRITICAL FUSE PIN HEAD EXTERIOR SURFACES

NON-CRITICAL FUSE PIN HEAD EXTERIOR SURFACES 46° 44° 1.210 1.190 DIA.

NON-CRITICAL FUSE PIN HEAD BEARING SURFACE NON-CRITICAL FUSE PIN SHANK ENDFACE SURFACE NON-CRITICAL FUSE PIN END SURFACE

2.59 2.53 DIA. 2.19 2.13 DIA. ADD HEAT TREAT, BATCH NUMBER AND RC MARKINGS IN THIS AREA (IF REQUIRED) 1/8 HIGH LETTERS PART MARK 1/8 HIGH LETTERS IN THIS AREA (IF REQUIRED) 0.040 0.020 CHAMFER X 45°

SEE A



### A1852641**APPENDIX A: APPROVED REPAIRS** Original Issue: April 14, 1994 Revision 6: November 05, 2009 767-54A0062 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 64 of 66 

### BOEING SERVICE BULLETIN 767-54A0062 **ALERT ALERT**

**NOTE:** The fuse pin Part Number, Heat Treat, Batch Number and Rc markings are located on a noncritical surface of the fuse pin head, as indicated above. Heavy corrosion repair on this surface may cause these markings to become unreadable. Make sure not to lose these markings during fuse pin repair. — Machine the fuse pin as required to ensure complete removal of corrosion. The maximum allowable material removal depth for this repair is either 0.025 inch or the minimum applicable dimension shown in the figure above, whichever is less. Refer to Boeing Standard Overhaul Practices Manual (BSOPM) 20-10-02 as an accepted procedure. The fuse pin material is either 4330M or 4340 steel, 33 Rc max. NOTE: If removal of the maximum allowable material does not completely remove corrosion, the fuse pin is not serviceable. — Do a Detailed Inspection of the reworked surfaces, to make sure corrosion is completely removed. — Do a Magnetic Particle Inspection of the reworked surfaces for any crack. Refer to BSOPM 20-20-01 as an accepted procedure. If any crack is found, the fuse pin is not serviceable. — Shotpeen the reworked surfaces: Shot Size 230-400, Intensity 0.016A, Coverage 1.0. Refer to BSOPM 20-10-03 as an accepted procedure. — Vibroscribe or steel stamp the fuse pin Part Number in the indicated area, if required. — Part Mark the fuse pin Heat Treat, Batch Number and Rc info in the area shown, if required. Refer to BSOPM 20-50-10 as an accepted procedure. — Refinish the reworked surfaces. Refer to 767 Component Maintenance Manual (CMM) 54-50-21, Repair 22-1 as an accepted procedure.

2. MIDSPAR FUSE PIN 311T3102-1, -2, -3, -4 HEAVY CORROSION REPAIR**APPENDIX A: APPROVED REPAIRS** Original Issue: April 14, 1994 Revision 6: November 05, 2009 767-54A0062 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 65 of 66 

### BOEING SERVICE BULLETIN 767-54A0062 **ALERT ALERT**

This repair is for Midspar Fuse Pin 311T3102-1, -2, -3 or -4 with heavy corrosion on a non-critical fuse pin surface. A 0.005 -B-

-AA A



### A-A -CC .005

32

32 32 32

31° 29° 0.260 0.240

0.881 0.871 DIA.

0.080 0.020 R (BOTH ENDS) 0.120 0.060 X 15° CHAMFER 0.04 0.02 R 0.322 0.302 3.438 3.423 0.135 0.115

32 4.770 4.750

CHAMFER 45° TO DEPTH OF THREAD (NON-CRITICAL SURFACE) NON-CRITICAL FUSE PIN HEAD EXTERIOR SURFACES

NON-CRITICAL FUSE PIN HEAD EXTERIOR SURFACES 1.210 1.234 DIA.

NON-CRITICAL FUSE PIN HEAD BEARING SURFACE NON-CRITICAL FUSE PIN SHANK ENDFACE SURFACE NON-CRITICAL FUSE PIN END SURFACE

2.59 2.53 DIA. 2.19 2.13 DIA. ADD HEAT TREAT, BATCH NUMBER AND RC MARKINGS IN THIS AREA (IF REQUIRED) 1/8 HIGH LETTERS PART MARK 1/8 HIGH LETTERS IN THIS AREA (IF REQUIRED) 0.020 0.000 CHAMFER X 45°

0.040 0.020 CHAMFER X 45° 0.3756 0.3750 DIA. 0.040 0.020 CHAMFER X 45° 0.08 0.02 R

SEE A



### A1852648**APPENDIX A: APPROVED REPAIRS** Original Issue: April 14, 1994 Revision 6: November 05, 2009 767-54A0062 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 66 of 66 

### BOEING SERVICE BULLETIN 767-54A0062 **ALERT ALERT**

**NOTE:** The fuse pin Part Number, Heat Treat, Batch Number and Rc markings are located on a noncritical surface of the fuse pin head, as indicated above. Heavy corrosion repair on this surface may cause these markings to become unreadable. Make sure not to lose these markings during fuse pin repair. — Machine the fuse pin as required to ensure complete removal of corrosion. The maximum allowable material removal depth for this repair is either 0.025 inch or the minimum applicable dimension shown in the figure above, whichever is less. Refer to BSOPM 20-10-02 as an accepted procedure. The fuse pin material is either 4330M or 4340 steel, 33 Rc max. NOTE: If removal of the maximum allowable material does not completely remove corrosion, the fuse pin is not serviceable. — Do a Detailed Inspection of the reworked surfaces, to make sure corrosion is completely removed. — Do a Magnetic Particle Inspection of the reworked surfaces for any crack. Refer to BSOPM 20-20-01 as an accepted procedure. If any crack is found, the fuse pin is not serviceable. — Shotpeen the reworked surfaces: Shot Size 230-400, Intensity 0.016A, Coverage 1.0. Refer to BSOPM 20-10-03 as an accepted procedure. — Vibroscribe or steel stamp the fuse pin Part Number in the indicated area, if required. — Part Mark the fuse pin Heat Treat, Batch Number and Rc info in the area shown, if required. Refer to BSOPM 20-50-10 as an accepted procedure. — Refinish the reworked surfaces. Refer to CMM 54-50-21, Repair 7-1 as an accepted procedure.