Commercial

Airplane

Group

767

Service Bulletin

Number: 767-57-0068 Summary Date: September 16, 1999

ATA System: 5740 2781 2811

SUBJECT: WINGS - Leading Edge and Leading Edge Devices - Slat Track Housing Electrostatic Bond

Rework

CONCURRENT REQUIREMENTS

None

BACKGROUND

Accomplishment of this service bulletin will provide

an improved electrostatic bond path for the number

5 and 8 inboard slat track housing drain tube

assemblies.

A production change (PRRB12900-133) was

incorporated at Boeing to install a new slat track

housing drain tube assembly for the number 5 and 8

inboard slat track. The purpose of this change was

to prevent possible fuel leaks at these locations.

After production incorporation of the new drain tube

assemblies, Boeing determined that the installation

did not meet current required bonding specifications.

Incorporation of this service bulletin will ensure

proper bonding of the number 5 and 8 inboard slat

track drain tube assemblies.

ACTION (PRRB13024)

Open the main tank and dry bay access panels.

Remove the bonding jumper assembly from the

number 5 and 8 inboard slat track housing drain

tube installations. Remove and replace the

fasteners common to drain tube doubler assembly.

Install bonding jumper brackets to the rib stiffeners.

Install bonding jumpers between the drain tube

assemblies and the brackets installed on the rib

stiffeners. Close the main tank and dry bay access

panels.

EFFECTIVITY

All 767 airplanes line numbers 672 through 757.

COMPLIANCE

Boeing recommends this service bulletin be

completed within 5000 flight-cycles or 22 months,

whichever is earlier from the release date of this

service bulletin.

INDUSTRY SUPPORT INFORMATION

Boeing warranty remedies are available for

airplanes in warranty as of September 29, 1998.

Please refer to Paragraph 2.B., Industry Support

Information.

MANPOWER

Total Elapsed Time

Per Airplane Man-Hours (Hours)

25 7.5

MATERIAL INFORMATION

Boeing Supplied Kits/Parts

Refer to Paragraph 2.A., Material - Price and

Availability.

767-57-0068

Summary Page 1 of 2
BOEING SERVICE BULLETIN 767-57-0068

RIB NO. 9

WING LOWER

SKIN

HOUSING

SLAT TRACK

FRONT SPAR

A

SEE A

DOUBLER ASSEMBLY

TO THE DRAIN TUBE

THE FASTENERS COMMON

REMOVE AND REPLACE

REMOVE AND REPLACE EXISTING

BONDING JUMPER AND CLAMPS

INSTALL NEW BONDING

JUMPER AND BRACKET

FWD INBD

UP

S96564

September 16, 1999 767-57-0068

Summary Page 2 of 2
Commercial

Airplane

Group

767

Service Bulletin

Number: 767-57-0068

Date: September 16, 1999

ATA System: 5740 2781 2811

SUBJECT: WINGS - Leading Edge and Leading Edge Devices - Slat Track Housing Electrostatic Bond

Rework

1. PLANNING INFORMATION

A. Effectivity

1. Airplanes

Refer to Service Bulletin Index Document D624T001, Part 3 for Airplane Variable Number, Line

Number, and Serial Number data.

This service bulletin is for the airplanes shown below. An equivalent change is on subsequent

production airplanes. Refer to PRRB13024 for data about this change.

Airplane Models:

767-300 767-300F

IDENTIFICATION BY CUSTOMER, CUSTOMER CODE, GROUP AND VARIABLE NUMBER

AEROMEXICO (AMX)

VS211

AIR DO (HIA)

VS176

AIR MADAGASCAR (MAD)

VS316

AIR NEW ZEALAND (ANZ)

VN658

AIR 2000 (ATZ)

VS216

ALITALIA (ALI)

VS366-VS367 VS401

ALL NIPPON AIRWAYS (ANA)

VR401

AMERICAN AIRLINES (AAL)

VS196-VS203

ASIANA AIRLINES (AAR)

VR426

September 16, 1999 767-57-0068

Page 1 of 16
BOEING SERVICE BULLETIN 767-57-0068

BOEING (TBC)

VY999

BRITANNIA AIRWAYS (BRI)

VS051-VS054

BRITISH AIRWAYS (BAB)

VS246-VS248

CITY BIRD (CBD)

VS177

DELTA AIR LINES (DAL)

VN274-VN276 VR471-VR472 VS066-VS070 VS073-VS078 VS266-VS272

ETHIOPIAN AIRLINES (ETH)

VS306

JAPAN AIRLINES (JAL)

VK016 VK186 VR461

KLM - ROYAL DUTCH AIRLINES (KLM)

VS136

LAN PERU (LPU)

VN970

LANCHILE AIRLINES (LAN)

VR251 VS131-VS133

LAPA ARGENTINA (LAZ)

VS111

LAUDA AIR (LAL)

VS301

LTU (LTU)

VS061

QANTAS (QAN)

VS186-VS187

SHANGHAI AIRLINES (SHA)

VR421

SKYMARK AIRLINES (SKM)

VS261-VS262

TWA (TWA)

VS206-VS207

UNITED AIRLINES (UAL)

VS091-VS096

UPS (UPS)

VR201-VR207 VW719-VW721

September 16, 1999 767-57-0068

2
BOEING SERVICE BULLETIN 767-57-0068

IDENTIFICATION BY VARIABLE NUMBER

VK016 VK186 VN274-VN276 VN658 VN970 VR201-VR207

VR251 VR401 VR421 VR426 VR461 VR471-VR472

VS051-VS054 VS061 VS066-VS070 VS073-VS078 VS091-VS096 VS111

VS131-VS133 VS136 VS176-VS177 VS186-VS187 VS196-VS203 VS206-VS207

VS211 VS216 VS246-VS248 VS261-VS262 VS266-VS272 VS301

VS306 VS316 VS366-VS367 VS401 VW719-VW721 VY999

2. Spares Affected

None

September 16, 1999 767-57-0068

3
BOEING SERVICE BULLETIN 767-57-0068

B. Concurrent Requirements

None

C. Reason

Accomplishment of this service bulletin will provide an improved electrostatic bond path for the

number 5 and 8 inboard slat track housing drain tube assemblies.

A production change (PRRB12900-133) was incorporated at Boeing to install a new slat track

housing drain tube assembly for the number 5 and 8 inboard slat track. The purpose of this change

was to prevent possible fuel leaks at these locations. After production incorporation of the new drain

tube assemblies, Boeing determined that the installation did not meet current required bonding

specifications.

Incorporation of this service bulletin will ensure proper bonding of the number 5 and 8 inboard slat

track drain tube assemblies.

D. Description

Open the main tank and dry bay access panels. Remove the bonding jumper assembly from the

number 5 and 8 inboard slat track housing drain tube installations. Remove and replace the

fasteners common to drain tube doubler assembly. Install bonding jumper brackets to the rib

stiffeners. Install bonding jumpers between the drain tube assemblies and the brackets installed on

the rib stiffeners. Close the main tank and dry bay access panels.

An evaluation form is attached to this service bulletin. Please use this form to tell us what you think

of the quality of this service bulletin.

E. Compliance

Boeing recommends this service bulletin be completed within 5000 flight-cycles or 22 months,

whichever is earlier from the release date of 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 Federal Aviation Regulations (FAR) and

are FAA approved. This service bulletin and the FAA approval were based on the airplane in its

original Boeing delivery configuration or as modified by other FAA 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.

September 16, 1999 767-57-0068

4
BOEING SERVICE BULLETIN 767-57-0068

G. Manpower

The table below shows an estimate of the man-hours necessary to do this change for each airplane.

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.

Task Number of Persons Man-Hours Elapsed Time (Hours)

Open Main Tank and

Dry Bay Access Panels

4 13 3.25

Remove and Install

Bonding Assembly

2 2 1

Close Main Tank

Access Panels / Refuel

4 7 1.75

Perform Leak Check 2 2 1

Close Dry Bay Access

Panels

2 1 .5

TOTAL FOR EACH AIRPLANE 25 7.5

H. Weight and Balance Changes

Change in Weight Change in Moment

Airplane (Pounds) (Pound-Inches)

+ 0.4 lbs + 364.0 lb-in

I. Electrical Load Data

Not changed

September 16, 1999 767-57-0068

5
BOEING SERVICE BULLETIN 767-57-0068

J. References

1. Existing Data:

a. Engineering Change Memo PRRB13024

b. 767 Maintenance Manual (AMM) Subject 12-11-01, 28-11-00 and 28-26-00

c. Boeing Standard Wiring Practices Manual (BSWPM) 20-20-00

d. Boeing Standard Overhaul Practices Manual (BSOPM) 20-11-03, 20-41-02, 20-43-03, and

20-50-19

2. Data supplied with this service bulletin:

None

3. Installation Drawings Used in the Preparation of This Service Bulletin:

Drawing Number Title

112T2019 Drain Tube Installation

112T5090 Rib Installation

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.

K. Publications Changed

Publication Chapter-Section

767 Illustrated Parts Catalog 57-40

767 Maintenance Manual 12-21, 28-11

L. Interchangeability and Intermixability of Parts

None

September 16, 1999 767-57-0068

6
BOEING SERVICE BULLETIN 767-57-0068

2. MATERIAL INFORMATION

A. Material - Price and Availability

Boeing can supply the kits shown in Paragraph 2.C., Parts Necessary For Each Airplane, as shown

below. If there is a limit in the quantity (QTY) of kits, a supply sequence is given by Spares.

Unit Price thru

Kit Number Name Date QTY Jan 31/00

015T1623-1 Top Kit Nov 9/99 87 $ 322.00

The kits are subject to the terms and conditions of the Boeing standard purchase order

acknowledgment. After the Unit Price date, new price data is applicable. Prices are in United States

dollars. Terms: Net 30 days.

Send purchase orders and letters about the supply data to the Director of Spares and refer to this

service bulletin number.

B. Industry Support Information

Boeing warranty remedies are available for 767 airplanes in warranty as of September 29, 1998. For

man-hour reimbursement for airplanes in warranty as of that date, send a warranty claim to Boeing

Product Assurance Contracts. The kits for airplanes in warranty as of that date will be supplied at no

charge. Send a purchase order for the kits to Boeing Spares. Please refer to this service bulletin

number and reference the airplane variable number in your purchase order.

C. Parts Necessary For Each Airplane

1. Kits:

To get the kits shown below, refer to Paragraph 2.A., Material - Price and Availability.

NOTE: One top kit and the items shown in Paragraph 2.C.2., Parts and Materials Supplied by the

Operator, are necessary for each airplane.

015T1623 TOP KIT - SLAT TRACK HOUSING ELECTROSTATIC

BONDING

-2 -1

Quantity Part Number Name

. - 015T1623-1 Top Kit

- 2 015T1623-2 Sub Kit

1 . 287T0020-325 Bracket

12 . BACB30FP6A4 Bolt

12 . BACC30M6 Collar

1 . BACJ40AC44-6 Jumper

1 . BACJ40AC44-8 Jumper

2 . BACN10YR3CD Nut

1 . BACN10YR3CM Nut

4 . BACR15FT6AD6 Rivet

1 . BACS12GU3K8 Screw

1 . BACS12GU3K9 Screw

September 16, 1999 767-57-0068

7
BOEING SERVICE BULLETIN 767-57-0068

(Continued)

015T1623 TOP KIT - SLAT TRACK HOUSING ELECTROSTATIC

BONDING

-2 -1

Quantity Part Number Name

4 . NAS1149C0316R Washer

2 . NAS1149C0363R Washer

5 . NAS1149D0316H Washer

2 . NAS1149D0363H Washer

1 . AN735C8 Clamp,

1 . AN735DC8 Clamp,

(a) The kit has more parts than are necessary for installation. Discard

parts that are not used or keep the parts for spares.

(c) If grip length shown is not available at Boeing, fasteners supplied in

kits may be one grip length longer than indicated.

2. Parts and Materials Supplied by the Operator:

QTY Part Number {Specification} Name

8 ounces BMS 10-20 Type II (a) Primer

8 ounces BMS 5-45 Class C (a) Sealant

(a) See the Qualified Products List at the end of the Boeing Material

Specification (BMS) for supplier data.

D. Parts Necessary to Change Spares

None

E. Existing Parts Accountability

None

F. Special Tooling - Price and Availability

None

G. Special Tooling Necessary to do this Service Bulletin

No special tools or equipment are necessary to do the change in this service bulletin. But,

maintenance and overhaul tools in the manuals given in Paragraph 1.J., References, can be

necessary. Examine operator tool supply to make sure all necessary tools are available.

September 16, 1999 767-57-0068

8
BOEING SERVICE BULLETIN 767-57-0068

3. ACCOMPLISHMENT INSTRUCTIONS

GENERAL NOTES

1. The paragraphs identified with a letter give the general work instructions and the necessary tests.

The instructions identified with numbers on the figures give the recommended sequence of steps.

2. 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.

3. Alternative fasteners are given in 767 Structural Repair Manual, Chapter 51.

4. Obey all of the warnings and cautions given in the specified manual sections.

5. As an alternative to the Boeing specified manuals, operators equivalent procedures can be used.

WORK INSTRUCTIONS

A. Defuel the main tanks as specified in 767 AMM 28-26-00.

B. Open the main tank and dry bay access panels listed below as specified in 767 AMM 28-11-00, to

access the number 5 and 8 inboard slat track housing drain tube assembly.

Panel Number Location

533AB Left Wing Dry Bay

633AB Right Wing Dry Bay

532FB Left Wing Main Tank

632FB Right Wing Main Tank

C. Replace the bonding jumper assembly for the number 5 and 8 inboard slat track housing drain

tube installation as shown in Figure 1.

D. Close the main tank access panels listed below as specified in 767 AMM 28-11-00.

Panel Number Location

532FB Left Wing Main Tank

632FB Right Wing Main Tank

September 16, 1999 767-57-0068

9
BOEING SERVICE BULLETIN 767-57-0068

E. Refuel the main tanks as specified in 767 AMM 12-11-01.

NOTE: A minimum of 4400 gallons of fuel is required in each wing tank to adequately check for

fuel leaks of the slat track drain tube assembly.

F. Perform a visual inspection of the number 5 and 8 inboard slat track housing drain tube opening,

located in the dry bay to make sure there are no fuel leaks.

G. Close the dry bay access panels listed below as specified in 767 AMM 28-11-00.

Panel Number Location

533AB Left Wing Dry Bay

633AB Right Wing Dry Bay

H. Put the airplane back to a serviceable condition.

September 16, 1999 767-57-0068

10
BOEING SERVICE BULLETIN 767-57-0068

FIGURE TABLE OF CONTENTS

Title Page

FIGURE 1. INBOARD SLAT TRACK DRAIN TUBE ELECTROSTATIC BOND

REWORK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

September 16, 1999 767-57-0068

11
BOEING SERVICE BULLETIN 767-57-0068

RIB NO. 9

WING LOWER

SKIN

HOUSING

SLAT TRACK

FRONT SPAR

SEE D

SEE B

A

SEE A

FWD INBD

UP

S96566

FIGURE 1. INBOARD SLAT TRACK DRAIN TUBE ELECTROSTATIC BOND REWORK

September 16, 1999 SHEET 1 OF 5 767-57-0068

12
BOEING SERVICE BULLETIN 767-57-0068

D

C 1 2 3 4

7

5

A-A

HOSE

FLEX

B

DRAIN

TUBE

SEE C

FWD

UP

C

E

.90

+/-0.10

(12 LOCATIONS)

JUMPER (b)

BONDING

ASSEMBLY

DOUBLER BRACKET

(4 LOCATIONS)

FWD

A

A

FWD INBD

UP

+/-0.10

4.20

S96671

FIGURE 1. INBOARD SLAT TRACK DRAIN TUBE ELECTROSTATIC BOND REWORK

September 16, 1999 SHEET 2 OF 5 767-57-0068

13
BOEING SERVICE BULLETIN 767-57-0068

WASHER B

WASHER C

WASHER E

WASHER F

CLAMP A

JUMPER A

WASHER D

CLAMP B

BONDING JUMPER B

WASHER A WASHER D

JUMPER A

WASHER A

SCREW

NUT

BONDING

A

SCREW

B

BONDING 6 7 NUT

BONDING

D

ASSEMBLY

COUPLING

BONDING

6 7

S96762

FIGURE 1. INBOARD SLAT TRACK DRAIN TUBE ELECTROSTATIC BOND REWORK

September 16, 1999 SHEET 3 OF 5 767-57-0068

14
BOEING SERVICE BULLETIN 767-57-0068

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

The QTY numbers shown below are the numbers of parts necessary for one side of the airplane.

STEP TASK NAME PART NUMBER QTY NOTES

1 Remove /

Discard

Fasteners --- 12 from the doubler assembly by alternating

fastener removal, removing and installing

only 6 fasteners at a time. Alternating the

fastener removal and installation will

maintain the doubler assembly fuel seal

and prevent the potential of misalignment

during the drill and ream procedures.

2 Drill /

Ream

Holes 12 in the doubler assembly as indicated.

3 Install Fasteners --- 12 in the doubler assembly as indicated.

4 Apply Fillet Seal BMS 5-45 - to both ends of the (12) fasteners installed

in the doubler assembly. Refer to BSOPM Class B 20-50-19.

5 Install Bracket 287T0020-325 1 to the rib 9 stiffener as indicated. Refer to

BSOPM 20-11-03 and BSWPM 20-20-00

Fasteners for bonding requirements. --- 4

6 Remove /

Discard

Bonding Clamp AN735D8 2

Bonding Jumper BACJ40A20-6 1

Fasteners --- 2

7 Install Bonding

Clamp

"A" AN735DC8 1 Designated (electrostatic) bond path.

Prepare fay surface bond and install parts

per BSWPM 20-20-00, except fillet seal

bonding clamps with BMS 5-45, Class B.

Refer to BSOPM 20-50-19. Ensure entire

bond surface is free of finish. Use cleaning

procedure 1, 2 or 3 as applicable if finish is

present or cleaning procedure 5 if surface

is bare. Refer to BSWPM 20-20-00. Apply

alodine 600 and BMS 10-20, Type II to any

bare metal areas remaining after the

bonding clamps and fillet seal is installed.

Refer to BSOPM 20-43-03 and 20-41-02.

Reference Note (a) for bonding jumper "A"

and "B" installation sequence. Verify

resistance does not exceed .010 OHMS.

Measure the resistance from the rib 9

stiffener at least .25 inches away from the

bonding bracket to the slat track drain can

at least .25 inches away from the bonding

jumper attachment. Refer to BSWPM

20-20-00 and BSOPM 20-11-03.

Bonding

Clamp

"B" AN735C8 1

Bonding

Jumper

"A" BACJ40AC44-6 1

Bonding

Jumper

"B" BACJ40AC44-8 1

Fasteners --- 3

(a) Install bonding jumper "A" with the terminal end marked by a red band to bonding clamp "B" and

connect the terminal end marked with a blue band to bonding clamp "A". Install bonding jumper

"B" with the terminal end marked by a red band to the bracket installed on the rib 9 stiffener and

connect the terminal end marked with a blue band to bonding clamp "A".

FIGURE 1. INBOARD SLAT TRACK DRAIN TUBE ELECTROSTATIC BOND REWORK

September 16, 1999 SHEET 4 OF 5 767-57-0068

15
BOEING SERVICE BULLETIN 767-57-0068

The codes shown below agree with the letter shown in the upper left corner of the fastener symbols in the

figure. A number in the lower right corner gives the grip length of the fastener.

COUNTERSINK

(OPTIONAL) EXAMPLE OF FASTENER CODE

LENGTH/GRIP

FASTENER

7

6F

(OPTIONAL)

DIAMETER

FASTENER

(OPTIONAL)

F = FAR SIDE

N = NEAR SIDE

LETTER CODE HEAD LOCATION

D

C

B53324

CODE NAME PART NUMBER HOLE DIA NOTES

A Screw BACS12GU3K8 ---

Washer "A" NAS1149D0316H

Washer "B" NAS1149D0363H

Washer "C" NAS1149D0316H Use two washers if and as required to

prevent crushing of drain tube.

Nut BACN10YR3CD

B Screw BACS12GU3K9 ---

Washer "D" NAS1149C0316R

Washer "E" NAS1149C0363R

Washer "F" NAS1149C0316R Use two washers if and as required to

prevent crushing of drain tube.

Nut BACN10YR3CM

C Bolt BACB30FP6A4 0.1991 - 0.2011

Collar BACC30M6

D Rivet BACR15FT6AD6 0.191 - 0.202

E Washer NAS1149D0316H ---

Nut BACN10YR3CD

FIGURE 1. INBOARD SLAT TRACK DRAIN TUBE ELECTROSTATIC BOND REWORK

September 16, 1999 SHEET 5 OF 5 767-57-0068

16
Commercial

Airplane

Group

767

Service Bulletin

Number: 767-57-0068 Evaluation Form Date: September 16, 1999

ATA System: 5740 2781 2811

Prepared By: Robert Mehring

SUBJECT: WINGS - Leading Edge and Leading Edge Devices - Slat Track Housing Electrostatic Bond

Rework

Use this evaluation form to tell us what you think of the quality of this service bulletin. We will use the data

that you give us to improve the quality of our service bulletins.

NOTE: Please do not use this evaluation form to tell us to make changes to your manuals. To make these

changes, please use a Publication Change Request (PCR) form.

Please give us this data:

(If necessary, please use the other side. Thank you for the time you used to give us your comments.)

OPERATOR: TODAY'S DATE:

PREPARED BY: TITLE:

ORGANIZATION: TELEX CODE:

TELEPHONE NUMBER: BASE:

Please rate the quality of this service bulletin: (good) 4321 (poor)

Please rate the quality of the illustrations: (good) 4321 (poor)

Will you do the change given by this service bulletin? Yes No If not, please explain:

Is this service bulletin easy to understand? Yes No If not, please explain:

Is this service bulletin easy to use? Yes No If not, please explain:

Are the Planning Information, Material Information, and

Accomplishment Instructions accurate? Yes No If not, please explain:

Is the Manpower estimate accurate? Yes No If not, please explain:

Give the completed evaluation form to your Boeing Field Service Representative or send the evaluation form

directly to this address:

Manager

Service Bulletin Engineering

Boeing Commercial Airplane Group

P.O. Box 3707, Mail Stop 2H-37

Seattle, WA 98124-2207