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Commercial Airplanes 767 Service Bulletin ALERT Number: 767-53A0139 Original Issue: November 12, 2009 ATA System: 5383 SUBJECT: FUSELAGE - Section 48 - STA 1582 Aft Pressure Bulkhead Replacement Export of this technology is controlled under the United States Export Administration Regulations (EAR) (15 CFR 730-774). An export license may be required before it is used for development, production or use by foreign persons from specific countries. The controller of this data has the individual responsibility to abide by all export laws.
9E991ECCN:
BOEING PROPRIETARY, CONFIDENTIAL, AND/OR TRADE SECRET Copyright © 2009 The Boeing Company Unpublished Work - All Rights Reserved Boeing claims copyright in each page of this document only to the extent that the page contains copyrightable subject matter. Boeing also claims copyright in this document as a compilation and/or collective work.
This document includes proprietary information owned by The Boeing Company and/or one or more third parties.
Treatment of the document and the information it contains is governed by contract with Boeing. For more information, contact The Boeing Company, P.O. Box 3707, Seattle, Washington 98124.
Boeing, the Boeing signature, the Boeing symbol, 707, 717, 727, 737, 747, 757, 767, 777, 787, Dreamliner, BBJ, DC-8, DC-9, DC-10, KC-10, KDC-10, MD-10, MD-11, MD-80, MD-88, MD-90, P-8A, Poseidon and the Boeing livery are all trademarks owned by The Boeing Company; and no trademark license is granted in connection with this document unless provided in writing by Boeing.
BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: November 12, 2009 767-53A0139 1 of 180
4.0
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Original Issue: November 12, 2009 767-53A0139 2 of 180 BOEING SERVICE BULLETIN 767-53A0139
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Table of Contents
Summary5
1. PLANNING INFORMATION9
A. Effectivity9
1. Airplanes9
2. Spares Affected ........................................ 1 1 B. Concurrent Requirements ...................................... 1 1 C. Reason ................................................ 1 1 D. Description .............................................. 1 2 E. Compliance .............................................. 1 2 F. Approval ............................................... 1 4 G. Manpower .............................................. 1 4 H. Weight and Balance Changes .................................... 1 6 I. Electrical Load Data ......................................... 1 6 J. References .............................................. 1 6
1. Existing Data .......................................... 1 6
2. Data supplied with this Service Bulletin ............................ 1 7
3. Installation Drawings Used in the Preparation of this Service Bulletin ............ 1 9 K. Publications Affected ........................................ 2 0 L. Interchangeability and Intermixability of Parts ........................... 2 0
2. MATERIAL INFORMATION ........................................ 2 1 A. Material - Price and Availability ................................... 2 1 B. Industry Support Information .................................... 2 1 C. Parts Necessary For Each Airplane ................................. 2 1
1. Kits/Parts ............................................ 2 1
2. Parts and Materials Supplied by the Operator ........................ 3 5
3. Parts Modified and Reidentified ................................ 3 6
4. Parts Removed and Not Replaced .............................. 3 6 D. Parts Necessary to Change Spares ................................. 3 6 E. Special Tooling - Price and Availability ............................... 3 6 F. Special Tooling Necessary to do this Service Bulletin ....................... 3 8
3. ACCOMPLISHMENT INSTRUCTIONS .................................. 3 9 A. GENERAL INFORMATION ..................................... 3 9 B. WORK INSTRUCTIONS ....................................... 4 0 FIGURE 1: AFT PRESSURE BULKHEAD ASSEMBLY PREPARATION ................ 5 4 FIGURE 2: AFT PRESSURE BULKHEAD ASSEMBLY PREPARATION [Group 2] ........... 5 9 FIGURE 3: REMOVAL OF AUXILIARY PITOT SYSTEM TUBES AND SEALS ............. 6 1 FIGURE 4: REMOVAL OF PRESSURE SEALS .............................. 6 5 FIGURE 5: APU FUEL LINE BULKHEAD FITTING REMOVAL ..................... 6 8 FIGURE 6: APU FUEL LINE BULKHEAD FITTING INSTALLATION ................... 7 1 FIGURE 7: AFT SECTION 48 (TAIL CONE) FASTENER REMOVAL .................. 7 4 FIGURE 8: STA 1809.5 CENTER BULKHEAD REMOVAL ........................ 7 7 FIGURE 9: FORWARD SECTION 48 PARTS REMOVAL ........................ 8 5 FIGURE 10: AFT PRESSURE BULKHEAD PRESSURE RING FASTENER REMOVAL ......... 8 7 FIGURE 11: AFT PRESSURE BULKHEAD ATTACHMENT TO THE PRESSURE RING AT STA 1582 . 89 FIGURE 12: FORWARD SECTION 48 INSTALLATION .......................... 9 1
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Original Issue: November 12, 2009 767-53A0139 3 of 180 BOEING SERVICE BULLETIN 767-53A0139
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FIGURE 13: LEFT STA 1809.5 CENTER BULKHEAD INSTALLATION ................. 1 1 0 FIGURE 14: RIGHT STA 1809.5 CENTER BULKHEAD INSTALLATION ................ 1 2 2 FIGURE 15: AFT SECTION 48 (TAIL CONE) INSTALLATION ...................... 1 3 4 FIGURE 16: PRESSURE SEAL INSTALLATION ............................. 1 3 9 FIGURE 17: INSTALLATION OF AUXILIARY PITOT SYSTEM TUBES AND PRESSURE SEALS . . 142 FIGURE 18: BULKHEAD INSPECTIONS PRIOR TO REPLACEMENT ................. 1 4 7 FIGURE 19: MAKE AND INSTALL STA 1809.5 BULKHEAD STABILIZATION TOOLS ......... 1 5 0 FIGURE 20: REMOVE STA 1809.5 BULKHEAD STABILIZATION TOOLS ............... 1 6 0 FIGURE 21: STA 1582 FLOOR BEAM DETACHMENT .......................... 1 6 2 FIGURE 22: STA 1582 FLOOR BEAM SUPPORT ............................ 1 6 6 FIGURE 23: STA 1582 FLOOR BEAM ATTACHMENT .......................... 1 7 0 APPENDIX A: APU WIRING TEST PROCEDURE ............................. 1 7 5 APPENDIX B: ALIGNMENT PINS ...................................... 1 8 0
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Original Issue: November 12, 2009 767-53A0139 4 of 180 BOEING SERVICE BULLETIN 767-53A0139
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Commercial Airplanes 767 Service Bulletin ALERT SummaryNumber: 767-53A0139Original Issue: November 12, 2009 ATA System: 5383 SUBJECT: FUSELAGE - Section 48 - STA 1582 Aft Pressure Bulkhead 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 service bulletin gives instructions for the removal and replacement of the STA 1582 aft pressure bulkhead.
Service Bulletin 767-53A0026, "Fuselage - Section 48 - Body Station 1582 Pressure Bulkhead Inspection" was previously released to give instructions to inspect for cracks in the the STA 1582 aft pressure bulkhead radial web lap splices and tear strap splices. Aft pressure bulkhead radial web lap splice multiple site damage (MSD) cracks that are not found and repaired can link together and become large. This condition could result in rapid decompression of the passenger compartment and possible damage or interference with airplane control systems that penetrate the bulkhead, and consequent loss of controllability of the airplane.
Operators have told Boeing that MSD fatigue cracks have been found in the STA 1582 aft pressure bulkhead radial web lap splices on multiple airplanes with 31,746 to 36,597 flight cycles. On four airplanes, the crack findings demonstrated MSD fatigue cracking common to the radial web lap splices. Design changes to improve the durability of the bulkhead were made in production at line number 176, and again at line number 424. Service Bulletin 767-53A0026 Revision 5 was released to give instructions to inspect for these types of cracks.
Accomplishment of the aft pressure bulkhead replacement given in this service bulletin will end the repeat inspections currently required by Boeing Service Bulletin 767-53A0026 and FAA Airworthiness Directive 2005-03-11.
Accomplishment of the aft pressure bulkhead replacement given in this service bulletin will also end the repeat inspections currently required by Boeing Service Bulletin 767-53A0087, "Fuselage - Section 48 - BS 1582 Aft Pressure Bulkhead Web Inspection at Web to Pressure Chord Joint" and FAA Airworthiness Directive 2004-05-16.
Inspections of the replacement aft pressure bulkhead are to be done as specified in the Boeing Document D622T001 "767 Maintenance Planning Data" and Airworthiness Limitations - Structural Inspections as specified in Section 9 of Boeing Document D622T001, with threshold modifications identified in Paragraph 1.E., Compliance.
Boeing Service Related Problem (SRP) 767-SRP-53-0228 is related to this service bulletin.
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Original Issue: November 12, 2009 767-53A0139 5 of 180
ACTION (PRR B12901-74S) Remove equipment for access to the forward and aft sides of the STA 1582 aft pressure bulkhead. Remove the vertical fin, the tail cone (with the APU installed), the left and right STA 1809.5 center bulkhead, and the horizontal stabilizer. Disconnect and remove the forward portion of Section 48 (with the aft pressure bulkhead attached) from Section 46 at STA 1582. Remove the aft pressure bulkhead from Section 48 and install a new aft pressure bulkhead in accordance with this service bulletin. Attach the modified forward part of Section 48 to Section 46 at STA 1582. Reinstall the horizontal stabilizer and reassemble the STA 1809.5 bulkhead. Reinstall the tail cone and the vertical fin. Install the equipment that was removed for access to the aft pressure bulkhead. Test disturbed systems in accordance with this service bulletin.
EFFECTIVITY 767-200 and 767-300 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 this service bulletin. The Airworthiness Directive will make the compliance tasks and times given in this service bulletin mandatory.
Federal Aviation Administration (FAA) Airworthiness Directive 2005-03-11 is related to this service bulletin. FAA Airworthiness Directive 2004-05-16 is affected by this service bulletin.
Refer to Paragraph 1.E., Compliance.
INDUSTRY SUPPORT INFORMATION Boeing warranty remedies are not available for the configuration changes given in this service bulletin.
MANPOWER Elapsed HoursTotal Task HoursAirplanes
265.51541All Refer to Paragraph 1.G., Manpower.
MATERIAL INFORMATION Boeing Supplied Kits/Parts.
Refer to Paragraph 2.A., Material - Price and Availability.
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Original Issue: November 12, 2009 767-53A0139 8 of 180 BOEING SERVICE BULLETIN 767-53A0139
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BLANK PAGE
Commercial Airplanes 767 Service Bulletin ALERT Number: 767-53A0139 Original Issue: November 12, 2009 ATA System: 5383 SUBJECT: FUSELAGE - Section 48 - STA 1582 Aft Pressure Bulkhead 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 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 PRRB12901-74S for data about this change Conversion Airplanes: If the aft pressure bulkhead replacement will be done on an affected airplane listed in this paragraph that has been modified by an approved "Boeing Converted Freighter Modification" of a 767-200 passenger airplane to a 767-200 Special Freighter (SF) airplane or of a 767-300 passenger airplane to a 767-300 Boeing Converted Freighter (BCF), contact Boeing for additional instructions.
DESCRIPTIONCONFIGURATIONGROUP Airplanes line number 1 - 175 without a dual-loop APU fire detection system, except Group 3 airplanes.
-1 Airplanes line number 1 - 175 with a dual-loop APU fire detection system.
-2 Airplanes line number 158 and 165, which do not have a dual-loop APU fire detection system, but have been modified to include dedicated static pressure inputs to the elevator feel computer per PRRB11770.
-3 Airplane Models:
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Original Issue: November 12, 2009 767-53A0139 9 of 180
767-200, 767-300 GroupVariable Number 1VA001 - VA020 1VA301 - VA315 1VA501 - VA526 1VA701 - VA712 2VA801 1VA802 2VA803 - VA804 1VA805 2VA806 - VA810 1VB001 - VB002 1VB051 - VB055 1VB101 - VB125 1VB201 - VB202 1VB251 - VB253 1VB281 - VB284 1VB301 - VB302 1VB321 - VB324 2VB371 - VB373 1VB401 1VE001 - VE002 1VE021 - VE023 1VE041 - VE043 2VE061 1VE062 2VE063 - VE064 1VE065 2VE066 - VE068 2VE083 - VE084 1VE101 - VE103 1VE116 - VE117 1VE121 - VE123 1VE141 - VE142
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Original Issue: November 12, 2009 767-53A0139 10 of 180 BOEING SERVICE BULLETIN 767-53A0139
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GroupVariable Number 2VK001 - VK004 1VK031 - VK037 3VL001 3VL011
2. Spares Affected None.
B. Concurrent Requirements None.
C. Reason This service bulletin gives instructions for the removal and replacement of the STA 1582 aft pressure bulkhead. Service Bulletin 767-53A0026, "Fuselage - Section 48 - Body Station 1582 Pressure Bulkhead Inspection" was previously released to give instructions to inspect for cracks in the the STA 1582 aft pressure bulkhead radial web lap splices and tear strap splices. Aft pressure bulkhead radial web lap splice multiple site damage (MSD) cracks that are not found and repaired can link together and become large. This condition could result in rapid decompression of the passenger compartment and possible damage or interference with airplane control systems that penetrate the bulkhead, and consequent loss of controllability of the airplane.
Operators have told Boeing that MSD fatigue cracks have been found in the STA 1582 aft pressure bulkhead radial web lap splices on multiple airplanes with 31,746 to 36,597 flight cycles. On four airplanes, the crack findings demonstrated MSD fatigue cracking common to the radial web lap splices.
Design changes to improve the durability of the bulkhead were made in production at line number 176, and again at line number 424. Service Bulletin 767-53A0026 Revision 5 was released to give instructions to inspect for these types of cracks.
Accomplishment of the aft pressure bulkhead replacement given in this service bulletin will end the repeat inspections currently required by Boeing Service Bulletin 767-53A0026 and FAA Airworthiness Directive 2005-03-11.
Accomplishment of the aft pressure bulkhead replacement given in this service bulletin will also end the repeat inspections currently required by Boeing Service Bulletin 767-53A0087, "Fuselage - Section 48 - BS 1582 Aft Pressure Bulkhead Web Inspection at Web to Pressure Chord Joint" and FAA Airworthiness Directive 2004-05-16.
Inspections of the replacement aft pressure bulkhead are to be done as specified in the Boeing Document D622T001 "767 Maintenance Planning Data" and Airworthiness Limitations - Structural Inspections as specified in Section 9 of Boeing Document D622T001, with threshold modifications identified in Paragraph 1.E., Compliance.
Boeing Service Related Problem (SRP) 767-SRP-53-0228 is related to this service bulletin.
BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: November 12, 2009 767-53A0139 11 of 180 BOEING SERVICE BULLETIN 767-53A0139
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D. Description Remove equipment for access to the forward and aft sides of the STA 1582 aft pressure bulkhead.
Remove the vertical fin, the tail cone (with the APU installed), the left and right STA 1809.5 center bulkhead, and the horizontal stabilizer. Disconnect and remove the forward portion of Section 48 (with the aft pressure bulkhead attached) from Section 46 at STA 1582. Remove the aft pressure bulkhead from Section 48 and install a new aft pressure bulkhead in accordance with this service bulletin. Attach the modified forward part of Section 48 to Section 46 at STA 1582. Reinstall the horizontal stabilizer and reassemble the STA 1809.5 bulkhead. Reinstall the tail cone and the vertical fin. Install the equipment that was removed for access to the ft pressure bulkhead. Test disturbed systems in accordance with this service bulletin.
The work in this service bulletin is done in the maintenance zone(s) given below.
Group 1-2:
Affected Maintenance Zones ZoneModel 165, 166, 251, 252, 253, 254, 311, 312, 313, 314, 315, 316, 321, 322, 323, 324, 325, 326, 331, 332, 333, 334, 335, 336, 337, 338, 341, 342, 343, 344, 345, 346, 347, 348 767-200, 767-300 Group 3:
Affected Maintenance Zones ZoneModel 165, 166, 251, 252, 253, 254, 311, 312, 313, 314, 315, 316, 321, 322, 323, 324, 325, 326, 331, 332, 333, 334, 335, 336, 337, 338, 341, 342, 343, 344, 345, 346, 347, 348 767-300 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.
Federal Aviation Administration (FAA) Airworthiness Directive 2005-03-11 is related to this service bulletin. FAA Airworthiness Directives 2004-05-16 is affected by this service bulletin.
Boeing recommends that the aft pressure bulkhead replacement given in Paragraph 3.B., PART 2, PART 3, and PART 4 of this service bulletin be done when the airplane has flown 43,000 total flight-cycles, or within 5,000 flight-cycles after the original issue date on this service bulletin, whichever is later.
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Original Issue: November 12, 2009 767-53A0139 12 of 180 BOEING SERVICE BULLETIN 767-53A0139