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Commercial Airplanes 767 Service Bulletin ALERT Number: 767-53A0267 Original Issue: August 13, 2015 ATA System: 5380 SUBJECT: FUSELAGE - Aft Pressure Bulkhead - Replacement of Station 1582 Aft Pressure Bulkhead Export of this technology is controlled under the United States Export Administration Regulations (EAR) (15 CFR 300-774). 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 © 2015 Boeing.
Unpublished Work. All Rights Reserved.
Treatment of this document and its content is governed by contract with Boeing. Rights to use this document are licensed on a per aircraft basis and such rights may not be transferable. For more information, contact The Boeing Company.
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, KC-46, KDC-10, MD-10, MD-11, MD-80, MD-88, MD-90, P-8, Poseidon and Boeing liveries 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.
Original Issue: August 13, 2015 767-53A0267 1 of 205
6.0
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: August 13, 2015 767-53A0267 2 of 205 BOEING SERVICE BULLETIN 767-53A0267
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BLANK PAGE
Table of Contents
Summary5
1. PLANNING INFORMATION9
A. Effectivity9
1. Airplanes9
2. Spares Affected11
B. Concurrent Requirements11
C. Reason12
D. Description12
E. Compliance13
F. Approval13
G. Manpower14
H. Weight and Balance Changes16
I. Electrical Load Data16
J. References16
1. Existing Data:16
2. Data Supplied with this Service Bulletin:16
3. Installation Drawings Used in the Preparation of this Service Bulletin:19
K. Publications Affected20
L. Interchangeability and Intermixability of Parts20
M. Software Accomplishment Summary20
2. MATERIAL INFORMATION21
A. Material - Price and Availability21
B. Industry Support Information21
C. Parts Necessary for Each Airplane21
1. Kits/Parts21
2. Parts and Materials Supplied by the Operator32
3. Parts Modified and Reidentified32
4. Parts Removed and Not Replaced32
D. Parts Necessary to Change Spares32
E. Special Tooling - Price and Availability33
F. Special Tooling Necessary to do this Service Bulletin35
3. ACCOMPLISHMENT INSTRUCTIONS37
A. GENERAL INFORMATION37
B. WORK INSTRUCTIONS38
FIGURE 1: AFT PRESSURE BULKHEAD ASSEMBLY PREPARATION54
FIGURE 2: AFT PRESSURE BULKHEAD ASSEMBLY PREPARATION59
FIGURE 3: REMOVAL OF AUXILIARY PITOT SYSTEM TUBES AND SEALS61
FIGURE 4: REMOVAL OF PRESSURE SEALS65
FIGURE 5: APU FUEL LINE BULKHEAD FITTING REMOVAL68
FIGURE 6: APU FUEL LINE BULKHEAD FITTING INSTALLATION71
FIGURE 7: AFT SECTION 48 (TAIL CONE) FASTENER REMOVAL74
FIGURE 8: STA 1809.5 CENTER BULKHEAD REMOVAL77
FIGURE 9: FORWARD SECTION 48 PARTS REMOVAL84
FIGURE 10: AFT PRESSURE BULKHEAD PRESSURE RING FASTENER REMOVAL86
FIGURE 11: AFT PRESSURE BULKHEAD ATTACHMENT TO THE PRESSURE RING AT STA 1582 . 88 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
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FIGURE 12: FORWARD SECTION 48 INSTALLATION90
FIGURE 13: LEFT STA 1809.5 CENTRE BULKHEAD INSTALLATION109
FIGURE 14: RIGHT STA 1809.5 CENTER BULKHEAD INSTALLATION121
FIGURE 15: AFT SECTION 48 (TAIL CONE) INSTALLATION133
FIGURE 16: PRESSURE SEAL INSTALLATION138
FIGURE 17: INSTALLATION OF AUXILIARY PITOT SYSTEM TUBES AND PRESSURE SEALS . . 141
FIGURE 18: MAKE AND INSTALL STA 1809.5 BULKHEAD STABILIZATION TOOLS145
FIGURE 19: REMOVE STA 1809.5 BULKHEAD STABILIZATION TOOLS155
FIGURE 20: STA 1582 FLOOR BEAM DETACHMENT157
FIGURE 21: STA 1582 FLOOR BEAM SUPPORT161
FIGURE 22: STA 1582 FLOOR BEAM ATTACHMENT164
FIGURE 23: LEFT SIDE HORIZONTAL STABILIZER FAIRING SKIN REMOVAL169
FIGURE 24: LEFT SIDE HORIZONTAL STABILIZER FAIRING SKIN INSTALLATION172
FIGURE 25: RIGHT SIDE HORIZONTAL STABILIZER FAIRING SKIN REMOVAL176
FIGURE 26: RIGHT SIDE HORIZONTAL STABILIZER FAIRING SKIN INSTALLATION179
FIGURE 27: PREPARATION OF THE VERTICAL FIN182
FIGURE 28: INSTALLATION OF THE VERTICAL FIN189
APPENDIX A: APU WIRING TEST PROCEDURE198
APPENDIX B: ALIGNMENT PINS203
APPENDIX C: LOGIC DIAGRAM FOR PARAGRAPH 1.E. COMPLIANCE: TABLE 1: REPLACEMENT OF THE
STA 1582 AFT PRESSURE BULKHEAD204
APPENDIX D: PART DEMAND INTENT205
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: August 13, 2015 767-53A0267 4 of 205 BOEING SERVICE BULLETIN 767-53A0267
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Commercial Airplanes 767 Service Bulletin ALERT SummaryNumber: 767-53A0267Original Issue: August 13, 2015 ATA System: 5380 SUBJECT: FUSELAGE - Aft Pressure Bulkhead - Replacement of Station 1582 Aft Pressure Bulkhead
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 instruction for the replacement of the Station (STA) 1582 aft pressure bulkhead due to Widespread Fatigue Damage (WFD). The WFD analysis of the 767, as required by 14 CFR 26.21(b), has resulted in the conclusion that the existing MPD Section 9, Airworthiness Limitation Item (ALI) inspection program is not sufficient to preclude the occurrence of WFD in the aft pressure bulkhead before the Limit of Validity (LOV) as the airplane ages. If widespread fatigue cracking at aft pressure bulkhead radial web lap splices is not found and repaired, the cracks can rapidly link up and become large, and can result in possible rapid decompression and loss of structural integrity.
Boeing has not received any reports of cracks in the aft pressure bulkhead web on line number 176 through
423.
The Aft Pressure Bulkhead has been determined to be structure that is susceptible to Widespread Fatigue Damage (WFD).
Federal Aviation Administration (FAA) AD 2012-09-08 was released to mandate replacement of the initial configuration aft pressure bulkhead which was installed on line number 1 through 175 per service bulletin 767-53A0139. Design changes were made to improve the durability of the bulkhead in production at line number 176, and again at line number 424. However, the configuration of aft pressure bulkheads installed on line number 176 through 423, have the same web gage of 0.032 inch as the initial configuration aft pressure bulkhead and does not provide adequate strength to preclude WFD before the Limit of Validity (LOV).
Boeing Service Related Problem (SRP) 767-SRP-53-0469 is related to this service bulletin.
Accomplishment of the aft pressure bulkhead replacement given in this service bulletin will end the inspections at aft pressure bulkhead web for indications of "oil cans" and previous "oil can" repairs currently required by Boeing Service Bulletin 767-53A0105 and AD 2004-14-19.
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: August 13, 2015 767-53A0267 5 of 205
Accomplishment of the aft pressure bulkhead replacement given in this service bulletin will end the repeat inspections at aft pressure bulkhead web lap splices currently required by Boeing Service Bulletin 767-53A0147 and AD 2009-06-19.
Accomplishment of the aft pressure bulkhead replacement given in this service bulletin will also end the repeat inspections of web at pressure chord joint currently required by Boeing Service Bulletin 767-53A0087 and AD 2004-05-16.
This table is provided to operators for planning purposes only. Refer to the applicable sections for more information.
ReferenceAffectedPlanning Data Paragraph 1.A.2., Spares AffectedNoSpares Affected Paragraph 1.E., Compliance and Paragraph
1.F., Approval YesAD Related Paragraph 1.H., Weight and Balance ChangesYesWeight and Balance Change Paragraph 1.I., Electrical Load DataNoElectrical Load Changed Paragraph 1.K., Publications AffectedNoPublications Affected Paragraph 1.K., Publications AffectedNoAirplane Flight Operations Affected (Flight Crew Operations Manual and/or FAA Approved Airplane Flight Manual) Paragraph 2.C.1., Kits/PartsYesKits/Parts Required Paragraph 2.C.2., Parts and Materials Supplied by the Operator YesOperator Supplied Parts/Material Paragraph 2.F., Special Tooling Necessary to do this Service Bulletin YesSpecial Tooling Required ACTION 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.
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
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Federal Aviation Administration (FAA) Airworthiness Directive AD 2004-14-19 is related to this service bulletin.
The effective date of AD 2004-14-19 is August 20, 2004.
Federal Aviation Administration (FAA) Airworthiness Directive AD 2009-06-19 is related to this service bulletin.
The effective date of AD 2009-06-19 is April 28, 2009.
Federal Aviation Administration (FAA) Airworthiness Directive AD 2004-05-16 is related to this service bulletin.
The effective date of AD 2004-05-16 is April 13, 2004.
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 Refer to Paragraph 1.G., Manpower.
MATERIAL INFORMATION Boeing Supplied Kits/Parts.
Refer to Paragraph 2.A., Material - Price and Availability.
Operators are encouraged to complete the survey provided in APPENDIX D of this service bulletin to help Boeing predict the quantity and timing of the Boeing Supplied Kits/Parts.
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: August 13, 2015 767-53A0267 7 of 205 BOEING SERVICE BULLETIN 767-53A0267
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Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: August 13, 2015 767-53A0267 8 of 205 BOEING SERVICE BULLETIN 767-53A0267
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BLANK PAGE
Commercial Airplanes 767 Service Bulletin ALERT Number: 767-53A0267 Original Issue: August 13, 2015 ATA System: 5380 SUBJECT: FUSELAGE - Aft Pressure Bulkhead - Replacement of Station 1582 Aft Pressure Bulkhead
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 D624T001 Part 3 for Airplane Variable Number, Line Number, and Serial Number data.
This service bulletin is applicable to 767-200 and -300 Airplanes, line numbers 176 - 423 in 3 Groups. The Variable Numbers and Group Information for the applicable airplanes are given below.
DESCRIPTIONCONFIGURATIONGROUP Airplane Line numbers 176-401 with Non-Dual bottle fire extinguisher-1 Airplane Line numbers 186-416 with APC Dual Bottle fire extinguisher-2 Airplane Line numbers 202-423 which have dedicated Static pressure inputs -3 Airplane Models:
767-200, 767-300 GroupVariable Number 1VA527 - VA530 1VA713 - VA719 1VB325 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: August 13, 2015 767-53A0267 9 of 205
GroupVariable Number 2VB326 1VB327 - VB332 1VE003 1VE069 1VE085 - VE086 1VE104 1VE118 1VE124 - VE126 1VE143 - VE151 1VE171 - VE172 3VF001 - VF002 3VF041 - VF042 3VF051 3VF061 - VF062 3VF071 - VF072 3VF091 - VF093 3VF101 - VF102 2VF161 2VK005 - VK011 2VK021 - VK022 2VK038 - VK053 1VK081 - VK099 1VK131 - VK133 1VK141 - VK142 2VL002 - VL006 3VN001 - VN017 3VN019 3VN051 - VN062 3VN081 - VN091 3VN111 - VN124 3VN130 - VN132 3VN151 - VN158 3VN163 - VN168 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
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GroupVariable Number 3VN171 - VN173 3VN192 - VN193 2VN211 - VN212 2VN221 - VN224 3VN231 - VN234 2VN241 2VN251 - VN259 3VN291 2VN301 - VN306 3VN372 3VN376 3VN381 3VN471 - VN472 3VN491 - VN496 3VN531 - VN532 3VN536 3VN541 - VN542 3VN551 3VN631 - VN633 3VN651 - VN652 2VN671 - VN672 3VN681 - VN683 2VN731 3VN751 - VN753
2. Spares Affected None.
B. Concurrent Requirements None.
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: August 13, 2015 767-53A0267 11 of 205 BOEING SERVICE BULLETIN 767-53A0267
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C. Reason This service bulletin gives instruction for the replacement of the Station (STA) 1582 aft pressure bulkhead due to Widespread Fatigue Damage (WFD). The WFD analysis of the 767, as required by 14 CFR
26.21(b), has resulted in the conclusion that the existing MPD Section 9, Airworthiness Limitation Item (ALI) inspection program is not sufficient to preclude the occurrence of WFD in the aft pressure bulkhead before the Limit of Validity (LOV) as the airplane ages. If widespread fatigue cracking at aft pressure bulkhead radial web lap splices is not found and repaired, the cracks can rapidly link up and become large, and can result in possible rapid decompression and loss of structural integrity.
Boeing has not received any reports of cracks in the aft pressure bulkhead web on line number 176 through 423.
The Aft Pressure Bulkhead has been determined to be structure that is susceptible to Widespread Fatigue Damage (WFD).
Federal Aviation Administration (FAA) AD 2012-09-08 was released to mandate replacement of the initial configuration aft pressure bulkhead which was installed on line number 1 through 175. Design changes were made to improve the durability of the bulkhead in production at line number 176, and again at line number 424. However, the configuration of aft pressure bulkheads installed on line number 176 through 423, have the same web gage of 0.032 inch as the initial configuration aft pressure bulkhead and does not provide adequate strength to preclude WFD before the Limit of Validity (LOV).
Boeing Service Related Problem (SRP) 767-SRP-53-0469 is related to this service bulletin.
Accomplishment of the aft pressure bulkhead replacement given in this service bulletin will end the inspections at aft pressure bulkhead web for indications of "oil cans" and previous "oil can" repairs currently required by Boeing Service Bulletin 767-53A0105 and AD 2004-14-19.
Accomplishment of the aft pressure bulkhead replacement given in this service bulletin will end the repeat inspections at aft pressure bulkhead web lap splices currently required by Boeing Service Bulletin 767-53A0147 and AD 2009-06-19.
Accomplishment of the aft pressure bulkhead replacement given in this service bulletin will also end the repeat inspections of web at pressure chord joint currently required by Boeing Service Bulletin 767-53A0087 and AD 2004-05-16.
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 aft 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.
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: August 13, 2015 767-53A0267 12 of 205 BOEING SERVICE BULLETIN 767-53A0267