Commercial 

Airplanes 767

Service Bulletin

ALERT

Number: 767-53A0228

Original Issue: July 28, 2011

ATA System: 5350

SUBJECT: FUSELAGE - Fuselage Section 45 - Overwing Emergency Exit Hatch Openings - Lower

Main Sill - Inspection

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ECCN: 9E991

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Copyright © 2011 The Boeing Company

Unpublished Work - All Rights Reserved

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5.0
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BOEING SERVICE BULLETIN 767-53A0228

ALERT ALERT

BLANK PAGE
Table of Contents

Summary ...................................................... 5

1. PLANNING INFORMATION ........................................ 9

A. Effectivity ................................................ 9

1. Airplanes ............................................. 9

2. Spares Affected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

B. Concurrent Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

C. Reason . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

D. Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

E. Compliance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

F. Approval . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

G. Manpower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

H. Weight and Balance Changes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

I. Electrical Load Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

J. References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

1. Existing Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

2. Data supplied with this Service Bulletin . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

3. Installation Drawings Used in the Preparation of this Service Bulletin . . . . . . . . . . . . 27

K. Publications Affected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

L. Interchangeability and Intermixability of Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

2. MATERIAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

A. Material - Price and Availability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

B. Industry Support Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

C. Parts Necessary For Each Airplane . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

1. Kits/Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

2. Parts and Materials Supplied by the Operator . . . . . . . . . . . . . . . . . . . . . . . . 29

3. Parts Modified and Reidentified . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

4. Parts Removed and Not Replaced . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

D. Parts Necessary to Change Spares . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

E. Special Tooling - Price and Availability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

F. Special Tooling Necessary to do this Service Bulletin . . . . . . . . . . . . . . . . . . . . . . . 29

3. ACCOMPLISHMENT INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

A. GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

B. WORK INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

FIGURE 1: LEFT SIDE - OVERWING EMERGENCY EXIT HATCH OPENING - LOWER MAIN SILL - STA

883.5 - INSPECTIONS [Group 1; Group 4, Configuration 1] . . . . . . . . . . . . . . . . . 39

FIGURE 2: LEFT SIDE - FORWARD OVERWING EMERGENCY EXIT HATCH OPENING - LOWER MAIN

SILL - STA 883.5 - INSPECTIONS [Group 2; Group 4, Configuration 2] . . . . . . . . . . 41

FIGURE 3: LEFT SIDE - AFT OVERWING EMERGENCY EXIT HATCH OPENING - LOWER MAIN SILL

- STA 903.5 - INSPECTIONS [Group 2; Group 4, Configuration 2] . . . . . . . . . . . . . 43

FIGURE 4: LEFT SIDE - OVERWING EMERGENCY EXIT HATCH OPENING - LOWER MAIN SILL - STA

903.5 - INSPECTIONS [Group 3; Group 4, Configuration 3] . . . . . . . . . . . . . . . . . 45

FIGURE 5: RIGHT SIDE - OVERWING EMERGENCY EXIT HATCH OPENING - LOWER MAIN SILL - STA

883.5 - INSPECTIONS [Group 1; Group 4, Configuration 1] . . . . . . . . . . . . . . . . . 47

FIGURE 6: RIGHT SIDE - FORWARD OVERWING EMERGENCY EXIT HATCH OPENING - LOWER MAIN

SILL - STA 883.5 - INSPECTIONS [Group 2; Group 4, Configuration 2] . . . . . . . . . . 49

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BOEING SERVICE BULLETIN 767-53A0228

ALERT ALERT
FIGURE 7: RIGHT SIDE - AFT OVERWING EMERGENCY EXIT HATCH OPENING - LOWER MAIN SILL

- STA 903.5 - INSPECTIONS [Group 2; Group 4, Configuration 2] . . . . . . . . . . . . . 51

FIGURE 8: RIGHT SIDE - OVERWING EMERGENCY EXIT HATCH OPENING - LOWER MAIN SILL - STA

903.5 - INSPECTIONS [Group 3; Group 4, Configuration 3] . . . . . . . . . . . . . . . . . 53

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BOEING SERVICE BULLETIN 767-53A0228

ALERT ALERT
Commercial 

Airplanes 767

Service Bulletin

ALERT

Summary Number: 767-53A0228

Original Issue: July 28, 2011

ATA System: 5350

SUBJECT: FUSELAGE - Fuselage Section 45 - Overwing Emergency Exit Hatch Openings - Lower

Main Sill - Inspection

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

Cracking has been reported on the lower main sill inner chord of the overwing emergency exit hatch opening

at Body Station (STA) 884, Stringer 18R. The cause of the cracking is fatigue. If cracking exists in the lower

main sill of the overwing emergency exit hatch opening and is not repaired, it could result in reduced structural

integrity of the overwing emergency exit hatch opening and consequent rapid decompression of the airplane.

The problem was discovered on a regular maintenance visit on an airplane that had completed 42,079 flight

cycles.

This service bulletin gives instruction to find and repair cracking of the lower main sill inner chord and surrounding

structure.

Boeing Service Related Problem (SRP) 767-SRP-53-0358 is related to this service bulletin.

Boeing Fleet Team Digest (FTD) 767 FTD 53-10001 is related to this service bulletin.

ACTION

Disarm the off-wing escape system. Remove seats, overwing emergency exit hatches, sidewall panels and

sidewall insulation as necessary to get access to the lower main sills of the overwing emergency exit hatch

openings.

Group 1-2; Group 4, Configuration 1-2:

At STA 883.5, do a surface High Frequency Eddy Current (HFEC) and detailed inspections of the lower main

sill inner chord. Also, do a detailed inspection of the surrounding structure. If any crack, corrosion damage, or

other irregularity is found, do the applicable SRM repair or contact Boeing for repair instructions.

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Group 2-3; Group 4, Configuration 2-3:

At STA 903.5, do a detailed inspections of the lower main sill inner chord and surrounding structure. If any crack,

corrosion damage, or other irregularity is found, do the applicable SRM repair or contact Boeing for repair

instructions.

Install all removed sidewall insulation, sidewall panels, overwing emergency exit hatches and seats. Arm the

off-wing escape system. Put the airplane back to a serviceable condition.

Group 4, Configuration 4:

No work is necessary. This configuration is for airplanes not yet delivered that will have no overwing emergency

exit hatches.

EFFECTIVITY

767-200/-300 series airplanes with overwing emergency exit hatches. 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 this service

bulletin. The Airworthiness Directive will make the compliance tasks and times given in this service bulletin

mandatory.

Refer to Paragraph 1.E., Compliance.

INDUSTRY SUPPORT INFORMATION

Boeing warranty remedies are not available for the inspection and/or repair procedures given in this service

bulletin.

MANPOWER

WORK PACKAGE 1 - LEFT SIDE

Airplanes Total Task Hours Elapsed Hours

Group 1; Group 4, Configuration 1 9.00 5.00

Group 2; Group 4, Configuration 2 13.95 7.65

Group 3; Group 4, Configuration 3 8.35 4.35

WORK PACKAGE 2 - RIGHT SIDE

Airplanes Total Task Hours Elapsed Hours

Group 1; Group 4, Configuration 1 9.00 5.00

Group 2; Group 4, Configuration 2 13.95 7.65

Group 3; Group 4, Configuration 3 8.35 4.35

Refer to Paragraph 1.G., Manpower.

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BOEING SERVICE BULLETIN 767-53A0228

ALERT ALERT
MATERIAL INFORMATION

None.

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ALERT ALERT
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BOEING SERVICE BULLETIN 767-53A0228

ALERT ALERT

BLANK PAGE
Commercial 

Airplanes 767

Service Bulletin

ALERT

Number: 767-53A0228

Original Issue: July 28, 2011

ATA System: 5350

SUBJECT: FUSELAGE - Fuselage Section 45 - Overwing Emergency Exit Hatch Openings - Lower

Main Sill - Inspection

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 D624T001 Part 3 for Airplane Variable Number, Line

Number, and Serial Number data.

This service bulletin is for the airplane(s) shown below.

NOTE: This service bulletin is for the airplanes identified below. The effectivity list shown below

is complete for airplanes through line number 1017. At least one airplane after line number

1017 is also affected by this service bulletin, and these airplanes are in Group(s) 2,4.

These airplanes will be added to the service bulletin's MyBoeingFleet.com (MBF) \"get

effectivity\" result when they are added to the MBF Fleet Profile Page.

GROUP CONFIGURATION DESCRIPTION

767-200 airplanes through line number 1020 with a single forward

overwing emergency exit hatch on each side of the airplane.

1 -

767-200/-300 airplanes through line number 1020 with two overwing

emergency exit hatches on each side of the airplane.

2 -

767-300 airplanes through line number 1020 with a single aft overwing

emergency exit hatch on each side of the airplane.

3 -

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GROUP CONFIGURATION DESCRIPTION

767 airplanes after line number 1020. These airplanes are not yet

delivered and their configuration is unknown.

4 -

Airplanes with a single forward overwing emergency exit hatch on

each side of the airplane.

1

Airplanes with two overwing emergency exit hatches on each side

of the airplane.

2

Airplanes with a single aft overwing emergency exit hatch on each

side of the airplane.

3

4 Airplanes with no overwing emergency exit hatches.

Airplane Models:

767-200, 767-300

Variable Number Group

VA001 - VA020 1

VA301 - VA315 1

VA501 - VA530 1

VA701 - VA719 1

VA801 - VA810 1

VB001 - VB002 1

VB051 - VB055 1

VB101 - VB125 1

VB201 - VB202 1

VB251 - VB253 1

VB281 - VB284 1

VB301 - VB302 2

VB321 - VB332 2

VB371 - VB373 1

VB401 1

VB441 - VB444 1

VE001 - VE003 1

VE021 - VE023 1

VE041 - VE043 1

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BOEING SERVICE BULLETIN 767-53A0228

ALERT ALERT
Variable Number Group

VE061 - VE069 1

VE083 - VE086 1

VE101 - VE104 1

VE116 - VE118 1

VE121 - VE126 1

VE141 - VE152 1

VE171 - VE172 1

VF001 - VF002 1

VF041 - VF042 1

VF051 1

VF061 - VF062 1

VF071 - VF072 1

VF091 - VF093 1

VF101 - VF102 2

VF161 - VF162 1

VF171 - VF172 1

VF180 - VF184 1

VF251 1

VK001 - VK016 2

VK021 - VK022 2

VK031 - VK056 2

VK081 - VK113 2

VK141 - VK148 2

VK161 - VK164 3

VK171 2

VK181 2

VK186 2

VL001 - VL006 3

VL011 3

VL701 - VL703 2

VL751 - VL755 3

VL931 - VL932 2

VL941 2

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BOEING SERVICE BULLETIN 767-53A0228

ALERT ALERT
Variable Number Group

VN001 - VN041 2

VN051 - VN064 2

VN081 - VN099 2

VN151 - VN158 2

VN163 - VN168 2

VN171 - VN174 3

VN191 - VN198 2

VN211 - VN212 3

VN221 - VN225 2

VN231 - VN234 3

VN241 - VN243 3

VN251 - VN276 2

VN291 - VN293 2

VN301 - VN314 3

VN422 - VN427 2

VN436 2

VN491 - VN513 2

VN634 - VN636 3

VN651 - VN658 2

VN671 - VN672 2

VN676 2

VN681 - VN691 2

VN731 - VN732 2

VN751 - VN753 2

VN791 - VN792 3

VN811 - VN813 2

VN931 - VN936 2

VN966 - VN972 2

VR051 - VR060 1

VR081 1

VR084 1

VR086 - VR089 1

VR106 - VR109 1

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BOEING SERVICE BULLETIN 767-53A0228

ALERT ALERT
Variable Number Group

VR401 2

VR421 - VR423 2

VR426 2

VR441 2

VR461 2

VR471 - VR472 2

VS061 3

VS066 - VS070 2

VS073 - VS078 2

VS091 - VS104 2

VS111 - VS113 2

VS131 - VS133 2

VS176 - VS177 2

VS186 - VS187 2

VS196 - VS203 2

VS206 - VS208 2

VS231 2

VS266 - VS274 2

VS291 - VS293 2

VS301 - VS303 2

VS366 - VS367 2

VS381 - VS382 2

VS391 - VS392 2

VS401 2

VS466 - VS472 2

VS486 2

VS496 - VS497 3

VS506 - VS507 3

VS526 2

VS546 - VS549 2

VS701 - VS736 2

VS751 - VS759 2

VS821 - VS825 2

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BOEING SERVICE BULLETIN 767-53A0228

ALERT ALERT
Variable Number Group

VS841 - VS844 2

VS861 2

VS896 2

VS901 - VS912 2

VS921 - VS928 2

VS931 - VS933 2

VS951 - VS954 2

VS961 - VS967 2

VS971 - VS975 2

VV001 1

2. Spares Affected

None.

B. Concurrent Requirements

None.

C. Reason

Cracking has been reported on the lower main sill inner chord of the lower main sill of the overwing

emergency exit hatch opening at Body Station (STA) 884, Stringer 18R. The cause of the cracking is

fatigue. If cracking exists in the lower main sill of the overwing emergency exit hatch opening and is

not repaired, it could result in reduced structural integrity of the overwing emergency exit hatch opening

and consequent rapid decompression of the airplane.

The problem was discovered on a regular maintenance visit on an airplane that had completed 42,079

flight cycles.

This service bulletin gives instruction to find and repair cracking of the lower main sill inner chord and

surrounding structure.

Boeing Service Related Problem (SRP) 767-SRP-53-0358 is related to this service bulletin.

Boeing Fleet Team Digest (FTD) 767 FTD 53-10001 is related to this service bulletin.

D. Description

Disarm the off-wing escape system. Remove seats, overwing emergency exit hatches, sidewall panels

and sidewall insulation as necessary to get access to the lower main sills of the overwing emergency

exit hatch openings.

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BOEING SERVICE BULLETIN 767-53A0228

ALERT ALERT
Group 1-2; Group 4, Configuration 1-2:

At STA 883.5, do a surface High Frequency Eddy Current (HFEC) and detailed inspections of the lower

main sill inner chord. Also, do a detailed inspection of the surrounding structure. If any crack, corrosion

damage, or other irregularity is found, do the applicable SRM repair or contact Boeing for repair

instructions.

Group 2-3; Group 4, Configuration 2-3:

At STA 903.5, do a detailed inspections of the lower main sill inner chord and surrounding structure.

If any crack, corrosion damage, or other irregularity is found, do the applicable SRM repair or contact

Boeing for repair instructions.

Install all removed sidewall insulation, sidewall panels, overwing emergency exit hatches and seats.

Arm the off-wing escape system. Put the airplane back to a serviceable condition.

Group 4, Configuration 4:

No work is necessary. This configuration is for airplanes not yet delivered that will have no overwing

emergency exit hatches.

NOTE: If the damaged area is more than the specified limits, write to Boeing for repair instructions.

Give the size and location of the damage. When possible, send sketches and photographs.

If the damage includes corrosion, send data on the length, width, and largest depth of clean

up.

Send to:

BOEING COMMERCIAL AIRPLANES GROUP

ATTENTION: MANAGER, AIRLINE SUPPORT

The work in this service bulletin is done in the maintenance zone(s) given below.

Group 1:

Affected Maintenance Zones

Model Zone

767-200 241, 242

Group 2,4:

Affected Maintenance Zones

Model Zone

767-200, 767-300 241, 242

Group 3:

Affected Maintenance Zones

Model Zone

767-300 241, 242

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BOEING SERVICE BULLETIN 767-53A0228

ALERT ALERT
E. Compliance

The Federal Aviation Administration (FAA) will possibly release an Airworthiness Directive related to

this service bulletin. The Airworthiness Directive will make the compliance tasks and times given in this

service bulletin mandatory.

Group 1; Group 4, Configuration 1:

Table 1: Overwing Emergency Exit Hatch Opening - Lower Main Sill - Inspection and Repair - WORK

PACKAGE 1 - LEFT SIDE

Repeat Interval

(Not to Exceed)

Compliance Time

(Whichever Occurs Later)

Condition Action

Within 3,000 -

flight cycles after

the original issue

date of this service bulletin

Before

37,500 total

flight cycles

Do a HFEC inspection of the lower

main sill inner chord around STA

883.5 in accordance with Paragraph 3.B., Work Instructions

WORK PACKAGE 1, Step 2.b.,

and

All airplanes

Do detailed inspections of the

lower main sill inner chord and

surrounding structure around STA

883.5 in accordance with Paragraph 3.B., Work Instructions

WORK PACKAGE 1, Step 2.b.

3,750 flight cycles

(a)

Within 3,750 flight cycles after

the initial detailed inspection

Repeat the detailed inspections of

the lower main sill inner chord and

surrounding structure around STA

883.5 in accordance with Paragraph 3.B., Work Instructions

WORK PACKAGE 1, Step 2.b.,

and

No crack, corrosion

damage, or other irregularity is found

7,500 flight cycles

(a)

Within 7,500 flight cycles after

the initial HFEC inspection

Repeat the HFEC inspection of the

lower main sill inner chord around

STA 883.5 in accordance with

Paragraph 3.B., Work Instructions

WORK PACKAGE 1, Step 2.b.

Repair in accordance with Para- Before further flight (a)

graph 3.B., Work Instructions

WORK PACKAGE 1, Step 2.b.(1)

Any crack is found in

the lower main sill inner

chord

Contact Boeing for instructions and Before further flight

do the work instructed by Boeing

Any corrosion damage

or other irregularity is

found in the lower main

sill inner chord

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BOEING SERVICE BULLETIN 767-53A0228

ALERT ALERT
Group 1; Group 4, Configuration 1:

Table 1: Overwing Emergency Exit Hatch Opening - Lower Main Sill - Inspection and Repair - WORK

PACKAGE 1 - LEFT SIDE

Repeat Interval

(Not to Exceed)

Compliance Time

(Whichever Occurs Later)

Condition Action

Contact Boeing for instructions and Before further flight -

do the work instructed by Boeing

Any crack, corrosion

damage, or other irregularity is found in the

structure other than the

lower main sill inner

chord

(a) Accomplishment of the repair in accordance with Paragraph 3.B., Work Instructions WORK PACKAGE

1, Step 2.b.(1) terminates the inspections in this service bulletin at this location.

Group 1; Group 4, Configuration 1:

Table 2: Overwing Emergency Exit Hatch Opening - Lower Main Sill - Inspection and Repair - WORK

PACKAGE 2 - RIGHT SIDE

Repeat Interval

(Not to Exceed)

Compliance Time

(Whichever Occurs Later)

Condition Action

Within 3,000 -

flight cycles after

the original issue

date of this service bulletin

Before

37,500 total

flight cycles

Do a HFEC inspection of the lower

main sill inner chord around STA

883.5 in accordance with Paragraph 3.B., Work Instructions

WORK PACKAGE 2, Step 2.b.,

and

All airplanes

Do detailed inspections of the

lower main sill inner chord and

surrounding structure around STA

883.5 in accordance with Paragraph 3.B., Work Instructions

WORK PACKAGE 2, Step 2.b.

3,750 flight cycles

(a)

Within 3,750 flight cycles after

the initial detailed inspection

Repeat the detailed inspections of

the lower main sill inner chord and

surrounding structure around STA

883.5 in accordance with Paragraph 3.B., Work Instructions

WORK PACKAGE 2, Step 2.b.,

and

No crack, corrosion

damage, or other irregularity is found

7,500 flight cycles

(a)

Within 7,500 flight cycles after

the initial HFEC inspection

Repeat the HFEC inspection of the

lower main sill inner chord around

STA 883.5 in accordance with

Paragraph 3.B., Work Instructions

WORK PACKAGE 2, Step 2.b.

Repair in accordance with Para- Before further flight (a)

graph 3.B., Work Instructions

WORK PACKAGE 2, Step 2.b.(1)

Any crack is found in

the lower main sill inner

chord

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BOEING SERVICE BULLETIN 767-53A0228

ALERT ALERT
Group 1; Group 4, Configuration 1:

Table 2: Overwing Emergency Exit Hatch Opening - Lower Main Sill - Inspection and Repair - WORK

PACKAGE 2 - RIGHT SIDE

Repeat Interval

(Not to Exceed)

Compliance Time

(Whichever Occurs Later)

Condition Action

Contact Boeing for instructions and Before further flight

do the work instructed by Boeing

Any corrosion damage

or other irregularity is

found in the lower main

sill inner chord

Contact Boeing for instructions and Before further flight -

do the work instructed by Boeing

Any crack, corrosion

damage, or other irregularity is found in the

structure other than the

lower main sill inner

chord

(a) Accomplishment of the repair in accordance with Paragraph 3.B., Work Instructions WORK PACKAGE

2, Step 2.b.(1) terminates the inspections in this service bulletin at this location.

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BOEING SERVICE BULLETIN 767-53A0228

ALERT ALERT
Group 2; Group 4, Configuration 2:

Table 3: Overwing Emergency Exit Hatch Openings - Lower Main Sill - Inspection and Repair - WORK

PACKAGE 1 - LEFT SIDE

Repeat Interval

(Not to Exceed)

Compliance Time

(Whichever Occurs Later)

Condition Action

Within 3,000

flight cycles after

the original issue

date of this service bulletin

Before

37,500 total

flight cycles

Do a HFEC inspection of the lower

main sill inner chord around STA

883.5 in accordance with Paragraph 3.B., Work Instructions

WORK PACKAGE 1, Step 3.b.,

and

All airplanes

Do detailed inspections of the

lower main sill inner chord and

surrounding structure around STA

883.5 in accordance with Paragraph 3.B., Work Instructions

WORK PACKAGE 1, Step 3.b.

3,750 flight cycles

(a)

Within 3,750 flight cycles after

the initial detailed inspection

Repeat the detailed inspections of

the lower main sill inner chord and

surrounding structure around STA

883.5 in accordance with Paragraph 3.B., Work Instructions

WORK PACKAGE 1, Step 3.b.,

and

No crack, corrosion

damage, or other irregularity is found

7,500 flight cycles

(a)

Within 7,500 flight cycles after

the initial HFEC inspection

Repeat the HFEC inspection of the

lower main sill inner chord around

STA 883.5 in accordance with

Paragraph 3.B., Work Instructions

WORK PACKAGE 1, Step 3.b.

Repair in accordance with Para- Before further flight (a)

graph 3.B., Work Instructions

WORK PACKAGE 1, Step 3.b.(1)

Any crack is found in

the lower main sill inner

chord

Contact Boeing for instructions and Before further flight

do the work instructed by Boeing

Any corrosion damage

or other irregularity is

found in the lower main

sill inner chord

Contact Boeing for instructions and Before further flight -

do the work instructed by Boeing

Any crack, corrosion

damage, or other irregularity is found in the

structure other than the

lower main sill inner

chord

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BOEING SERVICE BULLETIN 767-53A0228

ALERT ALERT
Group 2; Group 4, Configuration 2:

Table 3: Overwing Emergency Exit Hatch Openings - Lower Main Sill - Inspection and Repair - WORK

PACKAGE 1 - LEFT SIDE

Repeat Interval

(Not to Exceed)

Compliance Time

(Whichever Occurs Later)

Condition Action

Within 3,000 -

flight cycles after

the original issue

date of this service bulletin

Before

37,500 total

flight cycles

Do detailed inspections of the

lower main sill inner chord and

surrounding structure around STA

903.5 in accordance with Paragraph 3.B., Work Instructions

WORK PACKAGE 1, Step 3.c.

All airplanes

3,750 flight cycles

(b)

Within 3,750 flight cycles after

the initial detailed inspection

Repeat the detailed inspections of

the lower main sill inner chord and

surrounding structure around STA

903.5 in accordance with Paragraph 3.B., Work Instructions

WORK PACKAGE 1, Step 3.c.

No crack, corrosion

damage, or other irregularity is found

Repair in accordance with Para- Before further flight (b)

graph 3.B., Work Instructions

WORK PACKAGE 1, Step 3.c.(1)

Any crack is found in

the lower main sill inner

chord

Contact Boeing for instructions and Before further flight

do the work instructed by Boeing

Any corrosion damage

or other irregularity is

found in the lower main

sill inner chord

Contact Boeing for instructions and Before further flight -

do the work instructed by Boeing

Any crack, corrosion

damage, or other irregularity is found in the

structure other than the

lower main sill inner

chord

(a) Accomplishment of the repair in accordance with Paragraph 3.B., Work Instructions WORK PACKAGE

1, Step 3.b.(1) terminates the inspections in this service bulletin at this location.

(b) Accomplishment of the repair in accordance with Paragraph 3.B., Work Instructions WORK PACKAGE

1, Step 3.c.(1) terminates the inspections in this service bulletin at this location.

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BOEING SERVICE BULLETIN 767-53A0228

ALERT ALERT
Group 2; Group 4, Configuration 2:

Table 4: Overwing Emergency Exit Hatch Openings - Lower Main Sill - Inspection and Repair - WORK

PACKAGE 2 - RIGHT SIDE

Repeat Interval

(Not to Exceed)

Compliance Time

(Whichever Occurs Later)

Condition Action

Within 3,000 -

flight cycles after

the original issue

date of this service bulletin

Before

37,500 total

flight cycles

Do a HFEC inspection of the lower

main sill inner chord around STA

883.5 in accordance with Paragraph 3.B., Work Instructions

WORK PACKAGE 2, Step 3.b.,

and

All airplanes

Do detailed inspections of the

lower main sill inner chord and

surrounding structure around STA

883.5 in accordance with Paragraph 3.B., Work Instructions

WORK PACKAGE 2, Step 3.b.

3,750 flight cycles

(a)

Within 3,750 flight cycles after

the initial detailed inspection

Repeat the detailed inspections of

the lower main sill inner chord and

surrounding structure around STA

883.5 in accordance with Paragraph 3.B., Work Instructions

WORK PACKAGE 2, Step 3.b.,

and

No crack, corrosion

damage, or other irregularity is found

7,500 flight cycles

(a)

Within 7,500 flight cycles after

the initial HFEC inspection

Repeat the HFEC inspection of the

lower main sill inner chord around

STA 883.5 in accordance with

Paragraph 3.B., Work Instructions

WORK PACKAGE 2, Step 3.b.

Repair in accordance with Para- Before further flight (a)

graph 3.B., Work Instructions

WORK PACKAGE 2, Step 3.b.(1)

Any crack is found in

the lower main sill inner

chord

Contact Boeing for instructions and Before further flight

do the work instructed by Boeing

Any corrosion damage

or other irregularity is

found in the lower main

sill inner chord

Contact Boeing for instructions and Before further flight -

do the work instructed by Boeing

Any crack, corrosion

damage, or other irregularity is found in the

structure other than the

lower main sill inner

chord

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BOEING SERVICE BULLETIN 767-53A0228

ALERT ALERT
Group 2; Group 4, Configuration 2:

Table 4: Overwing Emergency Exit Hatch Openings - Lower Main Sill - Inspection and Repair - WORK

PACKAGE 2 - RIGHT SIDE

Repeat Interval

(Not to Exceed)

Compliance Time

(Whichever Occurs Later)

Condition Action

Within 3,000 -

flight cycles after

the original issue

date of this service bulletin

Before

37,500 total

flight cycles

Do detailed inspections of the

lower main sill inner chord and

surrounding structure around STA

903.5 in accordance with Paragraph 3.B., Work Instructions

WORK PACKAGE 2, Step 3.c.

All airplanes

3,750 flight cycles

(b)

Within 3,750 flight cycles after

the initial detailed inspection

Repeat the detailed inspections of

the lower main sill inner chord and

surrounding structure around STA

903.5 in accordance with Paragraph 3.B., Work Instructions

WORK PACKAGE 2, Step 3.c.

No crack, corrosion

damage, or other irregularity is found

Repair in accordance with Para- Before further flight (b)

graph 3.B., Work Instructions

WORK PACKAGE 2, Step 3.c.(1)

Any crack is found in

the lower main sill inner

chord

Contact Boeing for instructions and Before further flight

do the work instructed by Boeing

Any corrosion damage

or other irregularity is

found in the lower main

sill inner chord

Contact Boeing for instructions and Before further flight -

do the work instructed by Boeing

Any crack, corrosion

damage, or other irregularity is found in the

structure other than the

lower main sill inner

chord

(a) Accomplishment of the repair in accordance with Paragraph 3.B., Work Instructions WORK PACKAGE

2, Step 3.b.(1) terminates the inspections in this service bulletin at this location.

(b) Accomplishment of the repair in accordance with Paragraph 3.B., Work Instructions WORK PACKAGE

2, Step 3.c.(1) terminates the inspections in this service bulletin at this location.

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BOEING SERVICE BULLETIN 767-53A0228

ALERT ALERT
Group 3; Group 4, Configuration 3:

Table 5: Overwing Emergency Exit Hatch Opening - Lower Main Sill - Inspection and Repair - WORK

PACKAGE 1 - LEFT SIDE

Repeat Interval

(Not to Exceed)

Compliance Time

(Whichever Occurs Later)

Condition Action

Within 3,000 -

flight cycles after

the original issue

date of this service bulletin

Before

37,500 total

flight cycles

Do detailed inspections of the

lower main sill inner chord and

surrounding structure around STA

903.5 in accordance with Paragraph 3.B., Work Instructions

WORK PACKAGE 1, Step 4.b.

All airplanes

3,750 flight cycles

(a)

Within 3,750 flight cycles after

the initial detailed inspection

Repeat the detailed inspections of

the lower main sill inner chord and

surrounding structure around STA

903.5 in accordance with Paragraph 3.B., Work Instructions

WORK PACKAGE 1, Step 4.b.

No crack, corrosion

damage, or other irregularity is found

Repair in accordance with Para- Before further flight (a)

graph 3.B., Work Instructions

WORK PACKAGE 1, Step 4.b.(1)

Any crack is found in

the lower main sill inner

chord

Contact Boeing for instructions and Before further flight

do the work instructed by Boeing

Any corrosion damage

or other irregularity is

found in the lower main

sill inner chord

Contact Boeing for instructions and Before further flight -

do the work instructed by Boeing

Any crack, corrosion

damage, or other irregularity is found in the

structure other than the

lower main sill inner

chord

(a) Accomplishment of the repair in accordance with Paragraph 3.B., Work Instructions WORK PACKAGE

1, Step 4.b.(1) terminates the inspections in this service bulletin at this location.

Group 3; Group 4, Configuration 3:

Table 6: Overwing Emergency Exit Hatch Opening - Lower Main Sill - Inspection and Repair - WORK

PACKAGE 2 - RIGHT SIDE

Repeat Interval

(Not to Exceed)

Compliance Time

(Whichever Occurs Later)

Condition Action

Within 3,000 -

flight cycles after

the original issue

date of this service bulletin

Before

37,500 total

flight cycles

Do detailed inspections of the

lower main sill inner chord and

surrounding structure around STA

903.5 in accordance with Paragraph 3.B., Work Instructions

WORK PACKAGE 2, Step 4.b.

All airplanes

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BOEING SERVICE BULLETIN 767-53A0228

ALERT ALERT
Group 3; Group 4, Configuration 3:

Table 6: Overwing Emergency Exit Hatch Opening - Lower Main Sill - Inspection and Repair - WORK

PACKAGE 2 - RIGHT SIDE

Repeat Interval

(Not to Exceed)

Compliance Time

(Whichever Occurs Later)

Condition Action

3,750 flight cycles

(a)

Within 3,750 flight cycles after

the initial detailed inspection

Repeat the detailed inspections of

the lower main sill inner chord and

surrounding structure around STA

903.5 in accordance with Paragraph 3.B., Work Instructions

WORK PACKAGE 2, Step 4.b.

No crack, corrosion

damage, or other irregularity is found

Repair in accordance with Para- Before further flight (a)

graph 3.B., Work Instructions

WORK PACKAGE 2, Step 4.b.(1)

Any crack is found in

the lower main sill inner

chord

Contact Boeing for instructions and Before further flight

do the work instructed by Boeing

Any corrosion damage

or other irregularity is

found in the lower main

sill inner chord

Contact Boeing for instructions and Before further flight -

do the work instructed by Boeing

Any crack, corrosion

damage, or other irregularity is found in the

structure other than the

lower main sill inner

chord

(a) Accomplishment of the repair in accordance with Paragraph 3.B., Work Instructions WORK PACKAGE

2, Step 4.b.(1) terminates the inspections in this service bulletin at this location.

Group 4, Configuration 4:

No work is necessary.

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.

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BOEING SERVICE BULLETIN 767-53A0228

ALERT ALERT
G. Manpower

The table below shows an estimate of the task hours necessary to do this service bulletin for each

airplane. This estimate is for direct labor only, done by an experienced crew. Adjust the estimate with

operator task 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 inspect the work

• Time to cure the materials

• Time to make the parts

• Time to find the tools.

Group 1; Group 4, Configuration 1:

WORK PACKAGE 1 - LEFT SIDE

Task Number of Persons Task Hours Elapsed Hours

Open Access 2 4.00 2.00

FIGURE 1 1 1.00 1.00

Close Access 2 4.00 2.00

TOTAL FOR EACH AIRPLANE 9.00 5.00

Group 1; Group 4, Configuration 1:

WORK PACKAGE 2 - RIGHT SIDE

Task Number of Persons Task Hours Elapsed Hours

Open Access 2 4.00 2.00

FIGURE 5 1 1.00 1.00

Close Access 2 4.00 2.00

TOTAL FOR EACH AIRPLANE 9.00 5.00

Group 2; Group 4, Configuration 2:

WORK PACKAGE 1 - LEFT SIDE

Task Number of Persons Task Hours Elapsed Hours

Open Access 2 6.30 3.15

FIGURE 2 1 1.00 1.00

FIGURE 3 1 0.35 0.35

Close Access 2 6.30 3.15

TOTAL FOR EACH AIRPLANE 13.95 7.65

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BOEING SERVICE BULLETIN 767-53A0228

ALERT ALERT
Group 2; Group 4, Configuration 2:

WORK PACKAGE 2 - RIGHT SIDE

Task Number of Persons Task Hours Elapsed Hours

Open Access 2 6.30 3.15

FIGURE 6 1 1.00 1.00

FIGURE 7 1 0.35 0.35

Close Access 2 6.30 3.15

TOTAL FOR EACH AIRPLANE 13.95 7.65

Group 3; Group 4, Configuration 3:

WORK PACKAGE 1 - LEFT SIDE

Task Number of Persons Task Hours Elapsed Hours

Open Access 2 4.00 2.00

FIGURE 4 1 0.35 0.35

Close Access 2 4.00 2.00

TOTAL FOR EACH AIRPLANE 8.35 4.35

Group 3; Group 4, Configuration 3:

WORK PACKAGE 2 - RIGHT SIDE

Task Number of Persons Task Hours Elapsed Hours

Open Access 2 4.00 2.00

FIGURE 8 1 0.35 0.35

Close Access 2 4.00 2.00

TOTAL FOR EACH AIRPLANE 8.35 4.35

H. Weight and Balance Changes

None.

I. Electrical Load Data

Not changed.

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BOEING SERVICE BULLETIN 767-53A0228

ALERT ALERT
J. References

1. Existing Data

a. Boeing Service Letter 767-SL-51-036

b. Boeing Service Related Problem (SRP) 767-SRP-53-0358

c. 767 Aircraft Maintenance Manual (AMM) 25-21-01, 25-21-05, 25-25-01, 25-65-00, 52-21-01

d. 767 Fleet Team Digest (FTD) 53-10001

e. 767 Non-Destructive Testing (NDT) Manual Part 6, 51-00-01, Part 6, 51-00-19

f. 767-200 Structural Repair Manual (SRM) 53-50-07

g. 767-300 Structural Repair Manual (SRM) 53-50-07

h. 767-300BCF Structural Repair Manual (SRM) 53-50-07

2. Data supplied with this Service Bulletin

None.

3. Installation Drawings Used in the Preparation of this Service Bulletin

This drawing was used to prepare this service bulletin. This drawing is not necessary to make the

specified changes, and is not supplied with this service bulletin. This drawing may not be applicable

to all airplane configurations or operators.

Drawing Number Title

145T8310 SILL INSTL - LOWER EMERGENCY EXIT

K. Publications Affected

1. Publications:

None.

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. DTI requirements for the structure affected

are contained in Paragraph 1.E., Compliance of this service bulletin.

L. Interchangeability and Intermixability of Parts

Accomplishment of this service bulletin does not affect interchangeability or intermixability of parts.

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ALERT ALERT
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BOEING SERVICE BULLETIN 767-53A0228

ALERT ALERT

BLANK PAGE
2. MATERIAL INFORMATION

A. Material - Price and Availability

None.

B. Industry Support Information

Boeing warranty remedies are not available for the inspection and/or repair procedures given in this

service bulletin.

C. Parts Necessary For Each Airplane

1. Kits/Parts

None.

2. Parts and Materials Supplied by the Operator

None.

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

None.

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, 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.

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ALERT ALERT
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BOEING SERVICE BULLETIN 767-53A0228

ALERT ALERT

BLANK PAGE
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 Figure(s)

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. The work instructions are divided into work packages. Task Hours and Elapsed Hours

for each package are given in Paragraph 1.G., Manpower. You can do each work

package independently.

5. 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

6. Use the approved fastener and process material substitutions in accordance with

SRM Chapter 51. Alternate fasteners are listed in SRM Chapter 51 and Boeing

Drawing 012W6100.

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 in 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. Boeing Service Letter 767-SL-51-036, Damage Reporting and Repair Plan/Design

Guidelines, is an acceptable procedure to request information from Boeing for

additional structural repair instructions. The Service Letter describes what information

must be provided to Boeing before a structural repair can be provided.

10. If it is necessary to remove more parts for access, you can remove those parts. If

you can get access without removing identified parts, it is not necessary to remove

all of the identified parts. Jacking and shoring limitations must be observed.

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BOEING SERVICE BULLETIN 767-53A0228

ALERT ALERT
B. WORK INSTRUCTIONS

Group 1-3; Group 4, Configuration 1-3:

WORK PACKAGE 1 - LEFT SIDE

1. Disarm the off-wing escape system. Refer to 767 AMM 25-65-00 as an accepted procedure.

2. Group 1; Group 4, Configuration 1:

a. Do the following steps as necessary to get access to the lower main sill of the overwing

emergency exit hatch opening around the frame at Body Station (STA) 883.5 (immediately

aft of the overwing emergency exit hatch):

(1) Remove seats within 6 inches forward and aft of the frame. Refer to 767 AMM 25-25-01

as an accepted procedure.

(2) Remove the overwing emergency exit hatch. Refer to 767 AMM 52-21-01 as an accepted

procedure.

(3) Remove sidewall panels within 6 inches forward and aft of the frame. Refer to 767 AMM

25-21-01 as an accepted procedure.

(4) Remove or fold back sidewall insulation within 6 inches forward and aft of the frame and

4 inches above and below the lower main sill. Refer to 767 AMM 25-21-05 as an accepted

procedure.

b. Do High Frequency Eddy Current (HFEC) and detailed inspections of the lower main sill

around STA 883.5 in accordance with FIGURE 1.

(1) If any crack is found in the lower main sill inner chord, repair in accordance with 767-200

SRM 53-50-07 REPAIR 1.

(2) If any corrosion damage or other irregularity is found in the lower main sill inner chord,

contact Boeing for repair instructions and do the work instructed by Boeing.

(3) If any crack, corrosion damage, or other irregularity is found in structure other than the

lower main sill inner chord, contact Boeing for repair instructions and do the work instructed

by Boeing.

c. Do the following to close access to the lower main sill of the overwing emergency exit hatch

opening around the frame at STA 883.5:

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BOEING SERVICE BULLETIN 767-53A0228

ALERT ALERT
(1) Install removed sidewall insulation. Refer to 767 AMM 25-21-05 as an accepted procedure.

(2) Install removed sidewall panels. Refer to 767 AMM 25-21-01 as an accepted procedure.

(3) Install removed overwing emergency exit hatch. Refer to 767 AMM 52-21-01 as an

accepted procedure.

(4) Install removed seats. Refer to 767 AMM 25-25-01 as an accepted procedure.

3. Group 2; Group 4, Configuration 2:

a. Do the following steps as necessary to get access to the lower main sill of the overwing

emergency exit hatch openings around the frames at STA 883.5 (immediately aft of the forward

overwing emergency exit hatch) and STA 903.5 (immediately forward of the aft overwing

emergency exit hatch):

(1) Remove seats within 6 inches forward and aft of the frames. Refer to 767 AMM 25-25-01

as an accepted procedure.

(2) Remove the overwing emergency exit hatches. Refer to 767 AMM 52-21-01 as an accepted

procedure.

(3) Remove sidewall panels within 6 inches forward and aft of the frames. Refer to 767 AMM

25-21-01 as an accepted procedure.

(4) Remove or fold back sidewall insulation within 6 inches forward and aft of the frames and

4 inches above and below the lower main sill. Refer to 767 AMM 25-21-05 as an accepted

procedure.

b. Do HFEC and detailed inspections of the lower main sill around STA 883.5 in accordance

with FIGURE 2.

(1) If any crack is found in the lower main sill inner chord, repair in accordance with 767-200

SRM 53-50-07 REPAIR 2, 767-300 SRM 53-50-07 REPAIR 2 or 767-300BCF SRM

53-50-07 REPAIR 2.

(2) If any corrosion damage or other irregularity is found in the lower main sill inner chord,

contact Boeing for repair instructions and do the work instructed by Boeing.

(3) If any crack, corrosion damage, or other irregularity is found in structure other than the

lower main sill inner chord, contact Boeing for repair instructions and do the work instructed

by Boeing.

c. Do detailed inspections of the lower main sill around STA 903.5 in accordance with FIGURE

3.

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BOEING SERVICE BULLETIN 767-53A0228

ALERT ALERT
(1) If any crack is found in the lower main sill inner chord, repair in accordance with 767-200

SRM 53-50-07 REPAIR 2, 767-300 SRM 53-50-07 REPAIR 2 or 767-300BCF SRM

53-50-07 REPAIR 2.

(2) If any corrosion damage or other irregularity is found in the lower main sill inner chord,

contact Boeing for repair instructions and do the work instructed by Boeing.

(3) If any crack, corrosion damage, or other irregularity is found in structure other than the

lower main sill inner chord, contact Boeing for repair instructions and do the work instructed

by Boeing.

d. Do the following to close access to the lower main sill of the overwing emergency exit hatch

openings around the frames at STA 883.5 and STA 903.5:

(1) Install removed sidewall insulation. Refer to 767 AMM 25-21-05 as an accepted procedure.

(2) Install removed sidewall panels. Refer to 767 AMM 25-21-01 as an accepted procedure.

(3) Install removed overwing emergency exit hatch. Refer to 767 AMM 52-21-01 as an

accepted procedure.

(4) Install removed seats. Refer to 767 AMM 25-25-01 as an accepted procedure.

4. Group 3; Group 4, Configuration 3:

a. Do the following steps as necessary to get access to the lower main sill of the overwing

emergency exit hatch opening around the frame at STA 903.5 (immediately forward of the

overwing emergency exit hatch):

(1) Remove seats within 6 inches forward and aft of the frame. Refer to 767 AMM 25-25-01

as an accepted procedure.

(2) Remove the overwing emergency exit hatch. Refer to 767 AMM 52-21-01 as an accepted

procedure.

(3) Remove sidewall panels within 6 inches forward and aft of the frame. Refer to 767 AMM

25-21-01 as an accepted procedure.

(4) Remove or fold back sidewall insulation within 6 inches forward and aft of the frame and

4 inches above and below the lower main sill. Refer to 767 AMM 25-21-05 as an accepted

procedure.

b. Do detailed inspections of the lower main sill around STA 903.5 in accordance with FIGURE

4.

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34 of 54

BOEING SERVICE BULLETIN 767-53A0228

ALERT ALERT
(1) If any crack is found in the lower main sill inner chord, repair in accordance with 767-300

SRM 53-50-07 REPAIR 3 or 767-300BCF SRM 53-50-07 REPAIR 3.

(2) If any corrosion damage or other irregularity is found in the lower main sill inner chord,

contact Boeing for repair instructions and do the work instructed by Boeing.

(3) If any crack, corrosion damage, or other irregularity is found in structure other than the

lower main sill inner chord, contact Boeing for repair instructions and do the work instructed

by Boeing.

c. Do the following to close access to the lower main sill of the overwing emergency exit hatch

opening around the frame at STA 903.5:

(1) Install removed sidewall insulation. Refer to 767 AMM 25-21-05 as an accepted procedure.

(2) Install removed sidewall panels. Refer to 767 AMM 25-21-01 as an accepted procedure.

(3) Install removed overwing emergency exit hatch. Refer to 767 AMM 52-21-01 as an

accepted procedure.

(4) Install removed seats. Refer to 767 AMM 25-25-01 as an accepted procedure.

5. Arm the off-wing escape system. Refer to 767 AMM 25-65-00 as an accepted procedure.

6. Put the airplane back to a serviceable condition.

Group 1-3; Group 4, Configuration 1-3:

WORK PACKAGE 2 - RIGHT SIDE

1. Disarm the off-wing escape system. Refer to 767 AMM 25-65-00 as an accepted procedure.

2. Group 1; Group 4, Configuration 1:

a. Do the following steps as necessary to get access to the lower main sill of the overwing

emergency exit hatch opening around the frame at STA 883.5 (immediately aft of the overwing

emergency exit hatch):

(1) Remove seats within 6 inches forward and aft of the frame. Refer to 767 AMM 25-25-01

as an accepted procedure.

(2) Remove the overwing emergency exit hatch. Refer to 767 AMM 52-21-01 as an accepted

procedure.

(3) Remove sidewall panels within 6 inches forward and aft of the frame. Refer to 767 AMM

25-21-01 as an accepted procedure.

(4) Remove or fold back sidewall insulation within 6 inches forward and aft of the frame and

4 inches above and below the lower main sill. Refer to 767 AMM 25-21-05 as an accepted

procedure.

b. Do High Frequency Eddy Current (HFEC) and detailed inspections of the lower main sill

around STA 883.5 in accordance with FIGURE 5.

BOEING PROPRIETARY -

Copyright © Unpublished Work - See page 1 for details.

Original Issue: July 28, 2011

767-53A0228

35 of 54

BOEING SERVICE BULLETIN 767-53A0228

ALERT ALERT
(1) If any crack is found in the lower main sill inner chord, repair in accordance with 767-200

SRM 53-50-07 REPAIR 1.

(2) If any corrosion damage or other irregularity is found in the lower main sill inner chord,

contact Boeing for repair instructions and do the work instructed by Boeing.

(3) If any crack, corrosion damage, or other irregularity is found in structure other than the

lower main sill inner chord, contact Boeing for repair instructions and do the work instructed

by Boeing.

c. Do the following to close access to the lower main sill of the overwing emergency exit hatch

opening around the frame at STA 883.5:

(1) Install removed sidewall insulation. Refer to 767 AMM 25-21-05 as an accepted procedure.

(2) Install removed sidewall panels. Refer to 767 AMM 25-21-01 as an accepted procedure.

(3) Install removed overwing emergency exit hatch. Refer to 767 AMM 52-21-01 as an

accepted procedure.

(4) Install removed seats. Refer to 767 AMM 25-25-01 as an accepted procedure.

3. Group 2; Group 4, Configuration 2:

a. Do the following steps as necessary to get access to the lower main sill of the overwing

emergency exit hatch openings around the frames at STA 883.5 (immediately aft of the forward

overwing emergency exit hatch) and STA 903.5 (immediately forward of the aft overwing

emergency exit hatch):

(1) Remove seats within 6 inches forward and aft of the frames. Refer to 767 AMM 25-25-01

as an accepted procedure.

(2) Remove the overwing emergency exit hatch. Refer to 767 AMM 52-21-01 as an accepted

procedure.

(3) Remove sidewall panels within 6 inches forward and aft of the frames. Refer to 767 AMM

25-21-01 as an accepted procedure.

(4) Remove or fold back sidewall insulation within 6 inches forward and aft of the frames and

4 inches above and below the lower main sill. Refer to 767 AMM 25-21-05 as an accepted

procedure.

b. Do HFEC and detailed inspections of the lower main sill around STA 883.5 in accordance

with FIGURE 6.

BOEING PROPRIETARY -

Copyright © Unpublished Work - See page 1 for details.

Original Issue: July 28, 2011

767-53A0228

36 of 54

BOEING SERVICE BULLETIN 767-53A0228

ALERT ALERT
(1) If any crack is found in the lower main sill inner chord, repair in accordance with 767-200

SRM 53-50-07 REPAIR 2, 767-300 SRM 53-50-07 REPAIR 2 or 767-300BCF SRM

53-50-07 REPAIR 2.

(2) If any corrosion damage or other irregularity is found in the lower main sill inner chord,

contact Boeing for repair instructions and do the work instructed by Boeing.

(3) If any crack, corrosion damage, or other irregularity is found in structure other than the

lower main sill inner chord, contact Boeing for repair instructions and do the work instructed

by Boeing.

c. Do detailed inspections of the lower main sill around STA 903.5 in accordance with FIGURE

7.

(1) If any crack is found in the lower main sill inner chord, repair in accordance with 767-200

SRM 53-50-07 REPAIR 2, 767-300 SRM 53-50-07 REPAIR 2 or 767-300BCF SRM

53-50-07 REPAIR 2.

(2) If any corrosion damage or other irregularity is found in the lower main sill inner chord,

contact Boeing for repair instructions and do the work instructed by Boeing.

(3) If any crack, corrosion damage, or other irregularity is found in structure other than the

lower main sill inner chord, contact Boeing for repair instructions and do the work instructed

by Boeing.

d. Do the following to close access to the lower main sill of the overwing emergency exit hatch

openings around the frames at STA 883.5 and STA 903.5:

(1) Install removed sidewall insulation. Refer to 767 AMM 25-21-05 as an accepted procedure.

(2) Install removed sidewall panels. Refer to 767 AMM 25-21-01 as an accepted procedure.

(3) Install removed overwing emergency exit hatch. Refer to 767 AMM 52-21-01 as an

accepted procedure.

(4) Install removed seats. Refer to 767 AMM 25-25-01 as an accepted procedure.

4. Group 3; Group 4, Configuration 3:

a. Do the following steps as necessary to get access to the lower main sill of the overwing

emergency exit hatch opening around the frame at STA 903.5 (immediately forward of the

overwing emergency exit hatch):

BOEING PROPRIETARY -

Copyright © Unpublished Work - See page 1 for details.

Original Issue: July 28, 2011

767-53A0228

37 of 54

BOEING SERVICE BULLETIN 767-53A0228

ALERT ALERT
(1) Remove seats within 6 inches forward and aft of the frame. Refer to 767 AMM 25-25-01

as an accepted procedure.

(2) Remove the overwing emergency exit hatch. Refer to 767 AMM 52-21-01 as an accepted

procedure.

(3) Remove sidewall panels within 6 inches forward and aft of the frame. Refer to 767 AMM

25-21-01 as an accepted procedure.

(4) Remove or fold back sidewall insulation within 6 inches forward and aft of the frame and

4 inches above and below the lower main sill. Refer to 767 AMM 25-21-05 as an accepted

procedure.

b. Do detailed inspections of the lower main sill around STA 903.5 in accordance with FIGURE

8.

(1) If any crack is found in the lower main sill inner chord, repair in accordance with 767-300

SRM 53-50-07 REPAIR 3 or 767-300BCF SRM 53-50-07 REPAIR 3.

(2) If any corrosion damage or other irregularity is found in the lower main sill inner chord,

contact Boeing for repair instructions and do the work instructed by Boeing.

(3) If any crack, corrosion damage, or other irregularity is found in structure other than the

lower main sill inner chord, contact Boeing for repair instructions and do the work instructed

by Boeing.

c. Do the following to close access to the lower main sill of the overwing emergency exit hatch

opening around the frame at STA 903.5:

(1) Install removed sidewall insulation. Refer to 767 AMM 25-21-05 as an accepted procedure.

(2) Install removed sidewall panels. Refer to 767 AMM 25-21-01 as an accepted procedure.

(3) Install removed overwing emergency exit hatch. Refer to 767 AMM 52-21-01 as an

accepted procedure.

(4) Install removed seats. Refer to 767 AMM 25-25-01 as an accepted procedure.

5. Arm the off-wing escape system. Refer to 767 AMM 25-65-00 as an accepted procedure.

6. Put the airplane back to a serviceable condition.

Group 4, Configuration 4:

AIRPLANES WITH NO OVERWING EMERGENCY EXIT HATCHES

1. No work is necessary.

BOEING PROPRIETARY -

Copyright © Unpublished Work - See page 1 for details.

Original Issue: July 28, 2011

767-53A0228

38 of 54

BOEING SERVICE BULLETIN 767-53A0228

ALERT ALERT
This Figure applies only to: Group 1; Group 4, Configuration 1.

FIGURE 1: LEFT SIDE - OVERWING EMERGENCY EXIT HATCH OPENING - LOWER MAIN SILL - STA

883.5 - INSPECTIONS

(SHEET 1 OF 2)

BOEING PROPRIETARY -

Copyright © Unpublished Work - See page 1 for details.

Original Issue: July 28, 2011

767-53A0228

39 of 54

BOEING SERVICE BULLETIN 767-53A0228

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

STEP TASK NAME IDENTIFICATION QTY MORE DATA

LOWER MAIN SILL IN- - - (b)

NER CHORD

1 Inspect

LOWER MAIN SILL IN- - - (a)

NER CHORD

2 Inspect

3 Inspect STRUCTURE - - (c)

(a) Do a surface HFEC inspection of the upper surface of the lower main sill inner chord for cracks in accordance with 767 NDT Part 6, 51-00-01 or 767 NDT Part 6, 51-00-19.

(b) Do a detailed inspection of the upper surface of the lower main sill inner chord for cracks, corrosion

damage, or other irregularity. Use 5-10x magnification.

(c) Do a detailed inspection of all visible surfaces of the structure within 2 inches in all directions around the

lower main sill inspection area shown in step 1. This inspection is to detect cracks, corrosion damage, or

other irregularity.

FIGURE 1: LEFT SIDE - OVERWING EMERGENCY EXIT HATCH OPENING - LOWER MAIN SILL - STA

883.5 - INSPECTIONS

(SHEET 2 OF 2)

BOEING PROPRIETARY -

Copyright © Unpublished Work - See page 1 for details.

Original Issue: July 28, 2011

767-53A0228

40 of 54

BOEING SERVICE BULLETIN 767-53A0228

ALERT ALERT
This Figure applies only to: Group 2; Group 4, Configuration 2.

FIGURE 2: LEFT SIDE - FORWARD OVERWING EMERGENCY EXIT HATCH OPENING - LOWER MAIN

SILL - STA 883.5 - INSPECTIONS

(SHEET 1 OF 2)

BOEING PROPRIETARY -

Copyright © Unpublished Work - See page 1 for details.

Original Issue: July 28, 2011

767-53A0228

41 of 54

BOEING SERVICE BULLETIN 767-53A0228

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

STEP TASK NAME IDENTIFICATION QTY MORE DATA

LOWER MAIN SILL IN- - - (b)

NER CHORD

1 Inspect

LOWER MAIN SILL IN- - - (a)

NER CHORD

2 Inspect

3 Inspect STRUCTURE - - (c)

(a) Do a surface HFEC inspection of the upper surface of the lower main sill inner chord for cracks in accordance with 767 NDT Part 6, 51-00-01 or 767 NDT Part 6, 51-00-19.

(b) Do a detailed inspection of the upper surface of the lower main sill inner chord for cracks, corrosion

damage, or other irregularity. Use 5-10x magnification.

(c) Do a detailed inspection of all visible surfaces of the structure within 2 inches in all directions around the

lower main sill inspection area shown in step 1. This inspection is to detect cracks, corrosion damage, or

other irregularity.

FIGURE 2: LEFT SIDE - FORWARD OVERWING EMERGENCY EXIT HATCH OPENING - LOWER MAIN

SILL - STA 883.5 - INSPECTIONS

(SHEET 2 OF 2)

BOEING PROPRIETARY -

Copyright © Unpublished Work - See page 1 for details.

Original Issue: July 28, 2011

767-53A0228

42 of 54

BOEING SERVICE BULLETIN 767-53A0228

ALERT ALERT
This Figure applies only to: Group 2; Group 4, Configuration 2.

FIGURE 3: LEFT SIDE - AFT OVERWING EMERGENCY EXIT HATCH OPENING - LOWER MAIN SILL -

STA 903.5 - INSPECTIONS

(SHEET 1 OF 2)

BOEING PROPRIETARY -

Copyright © Unpublished Work - See page 1 for details.

Original Issue: July 28, 2011

767-53A0228

43 of 54

BOEING SERVICE BULLETIN 767-53A0228

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

STEP TASK NAME IDENTIFICATION QTY MORE DATA

LOWER MAIN SILL IN- - - (a)

NER CHORD

1 Inspect

2 Inspect STRUCTURE - - (b)

(a) Do a detailed inspection of the upper surface of the lower main sill inner chord for cracks, corrosion

damage, or other irregularity. Use 5-10x magnification.

(b) Do a detailed inspection of all visible surfaces of the structure within 2 inches in all directions around the

lower main sill inspection area shown in step 1. This inspection is to detect cracks, corrosion damage, or

other irregularity.

FIGURE 3: LEFT SIDE - AFT OVERWING EMERGENCY EXIT HATCH OPENING - LOWER MAIN SILL -

STA 903.5 - INSPECTIONS

(SHEET 2 OF 2)

BOEING PROPRIETARY -

Copyright © Unpublished Work - See page 1 for details.

Original Issue: July 28, 2011

767-53A0228

44 of 54

BOEING SERVICE BULLETIN 767-53A0228

ALERT ALERT
This Figure applies only to: Group 3; Group 4, Configuration 3.

FIGURE 4: LEFT SIDE - OVERWING EMERGENCY EXIT HATCH OPENING - LOWER MAIN SILL - STA

903.5 - INSPECTIONS

(SHEET 1 OF 2)

BOEING PROPRIETARY -

Copyright © Unpublished Work - See page 1 for details.

Original Issue: July 28, 2011

767-53A0228

45 of 54

BOEING SERVICE BULLETIN 767-53A0228

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

STEP TASK NAME IDENTIFICATION QTY MORE DATA

LOWER MAIN SILL IN- - - (a)

NER CHORD

1 Inspect

2 Inspect STRUCTURE - - (b)

(a) Do a detailed inspection of the upper surface of the lower main sill inner chord for cracks, corrosion

damage, or other irregularity. Use 5-10x magnification.

(b) Do a detailed inspection of all visible surfaces of the structure within 2 inches in all directions around the

lower main sill inspection area shown in step 1. This inspection is to detect cracks, corrosion damage, or

other irregularity.

FIGURE 4: LEFT SIDE - OVERWING EMERGENCY EXIT HATCH OPENING - LOWER MAIN SILL - STA

903.5 - INSPECTIONS

(SHEET 2 OF 2)

BOEING PROPRIETARY -

Copyright © Unpublished Work - See page 1 for details.

Original Issue: July 28, 2011

767-53A0228

46 of 54

BOEING SERVICE BULLETIN 767-53A0228

ALERT ALERT
This Figure applies only to: Group 1; Group 4, Configuration 1.

FIGURE 5: RIGHT SIDE - OVERWING EMERGENCY EXIT HATCH OPENING - LOWER MAIN SILL - STA

883.5 - INSPECTIONS

(SHEET 1 OF 2)

BOEING PROPRIETARY -

Copyright © Unpublished Work - See page 1 for details.

Original Issue: July 28, 2011

767-53A0228

47 of 54

BOEING SERVICE BULLETIN 767-53A0228

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

STEP TASK NAME IDENTIFICATION QTY MORE DATA

LOWER MAIN SILL IN- - - (b)

NER CHORD

1 Inspect

LOWER MAIN SILL IN- - - (a)

NER CHORD

2 Inspect

3 Inspect STRUCTURE - - (c)

(a) Do a surface HFEC inspection of the upper surface of the lower main sill inner chord for cracks in accordance with 767 NDT Part 6, 51-00-01 or 767 NDT Part 6, 51-00-19.

(b) Do a detailed inspection of the upper surface of the lower main sill inner chord for cracks, corrosion

damage, or other irregularity. Use 5-10x magnification.

(c) Do a detailed inspection of all visible surfaces of the structure within 2 inches in all directions around the

lower main sill inspection area shown in step 1. This inspection is to detect cracks, corrosion damage, or

other irregularity.

FIGURE 5: RIGHT SIDE - OVERWING EMERGENCY EXIT HATCH OPENING - LOWER MAIN SILL - STA

883.5 - INSPECTIONS

(SHEET 2 OF 2)

BOEING PROPRIETARY -

Copyright © Unpublished Work - See page 1 for details.

Original Issue: July 28, 2011

767-53A0228

48 of 54

BOEING SERVICE BULLETIN 767-53A0228

ALERT ALERT
This Figure applies only to: Group 2; Group 4, Configuration 2.

FIGURE 6: RIGHT SIDE - FORWARD OVERWING EMERGENCY EXIT HATCH OPENING - LOWER MAIN

SILL - STA 883.5 - INSPECTIONS

(SHEET 1 OF 2)

BOEING PROPRIETARY -

Copyright © Unpublished Work - See page 1 for details.

Original Issue: July 28, 2011

767-53A0228

49 of 54

BOEING SERVICE BULLETIN 767-53A0228

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

STEP TASK NAME IDENTIFICATION QTY MORE DATA

LOWER MAIN SILL IN- - - (b)

NER CHORD

1 Inspect

LOWER MAIN SILL IN- - - (a)

NER CHORD

2 Inspect

3 Inspect STRUCTURE - - (c)

(a) Do a surface HFEC inspection of the upper surface of the lower main sill inner chord for cracks in accordance with 767 NDT Part 6, 51-00-01 or 767 NDT Part 6, 51-00-19.

(b) Do a detailed inspection of the upper surface of the lower main sill inner chord for cracks, corrosion

damage, or other irregularity. Use 5-10x magnification.

(c) Do a detailed inspection of all visible surfaces of the structure within 2 inches in all directions around the

lower main sill inspection area shown in step 1. This inspection is to detect cracks, corrosion damage, or

other irregularity.

FIGURE 6: RIGHT SIDE - FORWARD OVERWING EMERGENCY EXIT HATCH OPENING - LOWER MAIN

SILL - STA 883.5 - INSPECTIONS

(SHEET 2 OF 2)

BOEING PROPRIETARY -

Copyright © Unpublished Work - See page 1 for details.

Original Issue: July 28, 2011

767-53A0228

50 of 54

BOEING SERVICE BULLETIN 767-53A0228

ALERT ALERT
This Figure applies only to: Group 2; Group 4, Configuration 2.

FIGURE 7: RIGHT SIDE - AFT OVERWING EMERGENCY EXIT HATCH OPENING - LOWER MAIN SILL -

STA 903.5 - INSPECTIONS

(SHEET 1 OF 2)

BOEING PROPRIETARY -

Copyright © Unpublished Work - See page 1 for details.

Original Issue: July 28, 2011

767-53A0228

51 of 54

BOEING SERVICE BULLETIN 767-53A0228

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

STEP TASK NAME IDENTIFICATION QTY MORE DATA

LOWER MAIN SILL IN- - - (a)

NER CHORD

1 Inspect

2 Inspect STRUCTURE - - (b)

(a) Do a detailed inspection of the upper surface of the lower main sill inner chord for cracks, corrosion

damage, or other irregularity. Use 5-10x magnification.

(b) Do a detailed inspection of all visible surfaces of the structure within 2 inches in all directions around the

lower main sill inspection area shown in step 1. This inspection is to detect cracks, corrosion damage, or

other irregularity.

FIGURE 7: RIGHT SIDE - AFT OVERWING EMERGENCY EXIT HATCH OPENING - LOWER MAIN SILL -

STA 903.5 - INSPECTIONS

(SHEET 2 OF 2)

BOEING PROPRIETARY -

Copyright © Unpublished Work - See page 1 for details.

Original Issue: July 28, 2011

767-53A0228

52 of 54

BOEING SERVICE BULLETIN 767-53A0228

ALERT ALERT
This Figure applies only to: Group 3; Group 4, Configuration 3.

FIGURE 8: RIGHT SIDE - OVERWING EMERGENCY EXIT HATCH OPENING - LOWER MAIN SILL - STA

903.5 - INSPECTIONS

(SHEET 1 OF 2)

BOEING PROPRIETARY -

Copyright © Unpublished Work - See page 1 for details.

Original Issue: July 28, 2011

767-53A0228

53 of 54

BOEING SERVICE BULLETIN 767-53A0228

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

STEP TASK NAME IDENTIFICATION QTY MORE DATA

LOWER MAIN SILL IN- - - (a)

NER CHORD

1 Inspect

2 Inspect STRUCTURE - - (b)

(a) Do a detailed inspection of the upper surface of the lower main sill inner chord for cracks, corrosion

damage, or other irregularity. Use 5-10x magnification.

(b) Do a detailed inspection of all visible surfaces of the structure within 2 inches in all directions around the

lower main sill inspection area shown in step 1. This inspection is to detect cracks, corrosion damage, or

other irregularity.

FIGURE 8: RIGHT SIDE - OVERWING EMERGENCY EXIT HATCH OPENING - LOWER MAIN SILL - STA

903.5 - INSPECTIONS

(SHEET 2 OF 2)

BOEING PROPRIETARY -

Copyright © Unpublished Work - See page 1 for details.

Original Issue: July 28, 2011

767-53A0228

54 of 54

BOEING SERVICE BULLETIN 767-53A0228

ALERT ALERT