# Boeing Alert Service Bulletin 767-53A0268: No revision named

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- Document: [Boeing Alert Service Bulletin 767-53A0268](https://openairdocs.org/service-documents/boeing/767-53a0268.md)
- Title as filed: SB-767-53A0268-00
- Pages: 35
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## Text

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### Page 1

Commercial 
Airplanes
767
Service Bulletin
ALERT
Number: 767-53A0268
Original Issue: April 01, 2015
ATA System: 5363
SUBJECT: FUSELAGE - Section 48 - STA 1582 Aft Pressure Bulkhead Web Inspection at Web
to Pressure Chord Joint
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Unpublished Work.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.
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767-53A0268
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3.0

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### Page 3

Table of Contents
Summary ...................................................... 5
1. PLANNING INFORMATION ........................................ 9
A. Effectivity ................................................ 9
1. Airplanes ............................................. 9
2. Spares Affected ........................................ 1 6
B. Concurrent Requirements ...................................... 1 6
C. Reason ................................................ 1 6
D. Description .............................................. 1 7
E. Compliance .............................................. 1 7
F. Approval ............................................... 2 0
G. Manpower .............................................. 2 1
H. Weight and Balance Changes .................................... 2 1
I. Electrical Load Data ......................................... 2 1
J. References .............................................. 2 2
1. Existing Data: ......................................... 2 2
2. Data Supplied with this Service Bulletin: ........................... 2 2
3. Installation Drawings Used in the Preparation of this Service Bulletin: ........... 2 2
K. Publications Affected ........................................ 2 2
L. Interchangeability and Intermixability of Parts ........................... 2 2
M. Software Accomplishment Summary ................................ 2 2
2. MATERIAL INFORMATION ........................................ 2 3
A. Material - Price and Availability ................................... 2 3
B. Industry Support Information .................................... 2 3
C. Parts Necessary for Each Airplane ................................. 2 3
1. Kits/Parts ............................................ 2 3
2. Parts and Materials Supplied by the Operator ........................ 2 3
3. Parts Modified and Reidentified ................................ 2 3
4. Parts Removed and Not Replaced .............................. 2 3
D. Parts Necessary to Change Spares ................................. 2 3
E. Special Tooling - Price and Availability ............................... 2 3
F. Special Tooling Necessary to do this Service Bulletin ....................... 2 3
3. ACCOMPLISHMENT INSTRUCTIONS .................................. 2 5
A. GENERAL INFORMATION ..................................... 2 5
B. WORK INSTRUCTIONS ....................................... 2 6
FIGURE 1: HIGH FREQUENCY EDDY CURRENT (HFEC) INSPECTION OF THE AFT PRESSURE
BULKHEAD WEB ....................................... 2 8
APPENDIX A: LOGIC DIAGRAM FOR PARAGRAPH 1.E. COMPLIANCE TABLE 1: INSPECTION FOR ANY
CRACK AT STA 1582 AFT PRESSURE BULKHEAD [Group 2, Configuration 1] ..... 3 0
APPENDIX B: LOGIC DIAGRAM FOR PARAGRAPH 1.E. COMPLIANCE TABLE 2: INSPECTION FOR ANY
CRACK AT STA 1582 AFT PRESSURE BULKHEAD [Group 3, Configuration 1] ..... 3 2
APPENDIX C: LOGIC DIAGRAM FOR PARAGRAPH 1.E. COMPLIANCE TABLE 3: INSPECTION FOR ANY
CRACK AT STA 1582 AFT PRESSURE BULKHEAD [Group 1; Group 2-3, Configuration 2]
.................................................. 3 4
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### Page 5

Commercial 
Airplanes
767
Service Bulletin
ALERT
SummaryNumber: 767-53A0268Original Issue: April 01, 2015
ATA System: 5363
SUBJECT: FUSELAGE - Section 48 - STA 1582 Aft Pressure Bulkhead Web Inspection at Web
to Pressure Chord Joint
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
Widespread Fatigue Damage (WFD) analysis of the 767, as required by 14 CFR 26.21(b), has resulted in the
conclusion that existing MPD Section 9, Airworthiness Limitation Item (ALI) inspection program is not sufficient
to preclude the occurrence of WFD in the aft pressure bulkhead to pressure chord joint as the airplane ages.
The aft pressure bulkhead web to pressure chord joint has multiple adjacent identical details which have the
potential for Multi-Site Damage (MSD) and the potential for WFD. 14 CFR 26.21 requires evaluation of such
designs for the potential for WFD and implementation of the appropriate service actions to ensure that WFD is
precluded before the Limit of Validity (LOV). Boeing has not received any reports of cracks in the bulkhead web
to pressure chord joint. Accomplishment of the inspection described in this service bulletin will enable detection
and repair of cracks if they should occur, at the STA 1582 Aft Pressure Bulkhead Web to Pressure Chord joint.
If Widespread Fatigue cracking is not found and repaired, the cracks can rapidly link up and can result in possible
rapid decompression and loss of structural integrity.
The aft pressure bulkhead web to pressure chord joint affected by this service bulletin has been determined to
be structure that is susceptible to WFD.
Boeing Service Related Problem (SRP) 767-SRP-53-0469 is related to this service bulletin.
Boeing 767 MPD 622T001-9 Section 9, SSI 53-80-l01A is related to this service bulletin.
Boeing Service Bulletin 767-53A0087 is related to this service bulletin.
Boeing Service Bulletin 767-53A0139 is related to this service bulletin.
This table is provided to operators for planning purposes only. Refer to the applicable sections for more
information.
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### Page 6

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 ChangesNoWeight 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 Air-
plane Flight Manual)
Paragraph 2.C.1., Kits/PartsNoKits/Parts Required
Paragraph 2.C.2., Parts and Materials Supplied
by the Operator
NoOperator Supplied Parts/Material
Paragraph 2.F., Special Tooling Necessary to
do this Service Bulletin
NoSpecial Tooling Required
ACTION
Get access to the forward side of the aft pressure bulkhead at STA 1582. Remove the aft galley and the main
water tank(s) in the lower lobe. Do a Surface High Frequency Eddy Current (HFEC) inspection of all visible
locations of the aft pressure bulkhead web at the aft/inboard row of fasteners common to the aft pressure
bulkhead web and pressure chord around the entire circumference of the pressure chord for any crack. If any
crack is found, contact Boeing to get instructions for the repair for this service bulletin, and do the work instructed
by Boeing. If no crack is found, repeat the inspection.
EFFECTIVITY
All 767-200 and 767-300 Airplanes. Refer to Paragraph 1.A.1., Airplanes, for the list of affected airplane(s).
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 AD 2004-05-16 is related to this service bulletin.
The effective date of AD 2004-05-16 is April 13, 2004.
Federal Aviation Administration (FAA) Airworthiness Directive AD 2012-09-08 is related to this service bulletin.
The effective date of AD 2012-09-08 is June 18, 2012.
Federal Aviation Administration (FAA) Airworthiness Directive AD 2014-14-04 is related to this service bulletin.
The effective date of AD 2014-14-04 is September 5, 2014.
This service bulletin affects SSI 53-80-I01A of 767 MPD 622T001-9 Section 9, which is mandated by AD
2014-14-04. All other MPD inspections outside the of the affected area are not affected and must continue.
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### Page 7

Refer to Paragraph 1.E., Compliance.
INDUSTRY SUPPORT INFORMATION
Boeing warranty remedies are not available for the inspection given in this service bulletin.
MANPOWER
Elapsed HoursTotal Task HoursAirplanes
17.2555.00Group 1, 2 and 3 Airplanes with one water tank
removal required
17.7557.00Group 1, 2 and 3 Airplanes with two water tank
removals required
Refer to Paragraph 1.G., Manpower.
MATERIAL INFORMATION
None.
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### Page 8 (OCR)

BOEING SERVICE BULLETIN 767-53A0268
ALERT  ALERT
• BULKHEAD WEB
POSSIBLE
WEB CRACK
TYPICAL
INSPECTION
AREA - RIVETS
STA
1582
TYPICAL
RADIAL
STIFFENER
INNER
CHORD
PRESSURE
RING
PRESSURE
CHORD
INBD
FAILSAFE
FRAME
CHORD
FWD  TYPICAL INSPECTION AREA
FWD
NOTE:
SOME AFFECTED AIRPLANE CONFIGURATIONS
HAVE SHORT STIFFENERS AT THE AFT PRESSURE
BULKHEAD TO PRESSURE CHORD JOINT.
SHORT STIFFENERS ARE NOT SHOWN FOR
CLARITY.
DO A HIGH FREQUENCY EDDY CURRENT INSPECTION
OF THE WEB AT THE INDICATED FASTENERS
COMMON TO THE AFT PRESSURE BULKHEAD WEB
AND PRESSURE CHORD AROUND THE ENTIRE
CIRCUMFERENCE OF THE PRESSURE CHORD. IF ANY
CRACK IS FOUND, CONTACT BOEING TO GET  2377532
INSTRUCTIONS FOR THIS SERVICE BULLETIN AND DO
THE WORK INSTRUCTED BY BOEING.
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### Page 9

Commercial 
Airplanes
767
Service Bulletin
ALERT
Number: 767-53A0268
Original Issue: April 01, 2015
ATA System: 5363
SUBJECT: FUSELAGE - Section 48 - STA 1582 Aft Pressure Bulkhead Web Inspection at Web
to Pressure Chord Joint
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
This service bulletin is applicable to all 767-200 and 767-300 Airplanes in 3 Group(s). The Variable
Numbers and Group Information for the applicable airplanes is given below.
Refer to Service Bulletin Index D624T001 Part 3 for Airplane Variable Number, Line Number, and
Serial Number data.
NOTE: The Variable Number table below includes all affected airplanes up to Line Number 1068.
Affected airplanes after Line Number 1068 will be added to the service bulletin's
MyBoeingFleet.com (MBF) "get effectivity" result when they are added to the MBF Fleet
Profile Page.
DESCRIPTIONCONFIGURATIONGROUP
Airplanes Line Numbers 1-175 with replaced aft pressure bulkhead
in accordance with SB 767-53A0139.
-1
Airplanes Line Numbers 176-423.-2
Airplanes with original production aft pressure bulkhead installed.1
Airplanes with aft pressure bulkhead replaced in accordance with a
Boeing Organization Design Authorization (ODA) approval via FAA
Form 8100-9.
2
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### Page 10

DESCRIPTIONCONFIGURATIONGROUP
Airplanes Line Numbers 424 and on (767-200/300 only).-3
Airplanes with original production aft pressure bulkhead installed.1
Airplanes with aft pressure bulkhead replaced in accordance with a
Boeing Organization Designation Authorization (ODA) approval via
FAA Form 8100-9.
2
Airplane Models:
767-200, 767-300
GroupVariable Number
1VA001 - VA020
1VA301 - VA315
1VA501 - VA526
2VA527 - VA530
1VA701 - VA712
2VA713 - VA719
1VA801 - VA810
1VB001 - VB002
1VB051 - VB055
1VB101 - VB125
1VB201 - VB202
1VB251 - VB253
1VB281 - VB284
1VB301 - VB302
1VB321 - VB324
2VB325 - VB332
1VB371 - VB373
1VB401
3VB441 - VB444
1VE001 - VE002
2VE003
1VE021 - VE023
1VE041 - VE043
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GroupVariable Number
1VE061 - VE068
2VE069
1VE083 - VE084
2VE085 - VE086
1VE101 - VE103
2VE104
1VE116 - VE117
2VE118
1VE121 - VE123
2VE124 - VE126
1VE141 - VE142
2VE143 - VE151
3VE152
2VE171 - VE172
2VF001 - VF002
2VF041 - VF042
2VF051
2VF061 - VF062
2VF071 - VF072
2VF091 - VF093
2VF101 - VF102
2VF161
3VF162
3VF171 - VF172
3VF180 - VF184
3VF251
1VK001 - VK004
2VK005 - VK011
3VK012 - VK016
2VK021 - VK022
1VK031 - VK037
2VK038 - VK053
3VK054 - VK056
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GroupVariable Number
2VK081 - VK099
3VK100 - VK113
2VK131 - VK133
2VK141 - VK142
3VK143 - VK148
3VK161 - VK164
3VK171
3VK181
3VK186
1VL001
2VL002 - VL006
1VL011
3VL701 - VL703
3VL751 - VL755
3VL806 - VL807
3VL871 - VL873
3VL891 - VL900
3VL911 - VL914
3VL931 - VL932
3VL941
2VN001 - VN019
3VN020 - VN041
2VN051 - VN062
3VN063 - VN064
2VN081 - VN092
3VN093 - VN099
2VN111 - VN124
3VN125 - VN127
2VN130 - VN132
3VN133 - VN137
2VN151 - VN158
2VN163 - VN168
2VN171 - VN173
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GroupVariable Number
3VN174
2VN191 - VN193
3VN194 - VN198
2VN211 - VN212
2VN221 - VN224
3VN225
2VN231 - VN234
2VN241
3VN242 - VN243
2VN251 - VN259
3VN260 - VN276
2VN291
3VN292 - VN293
2VN301 - VN306
3VN307 - VN314
2VN371 - VN372
2VN376
2VN381
3VN382 - VN388
3VN421 - VN427
3VN436
2VN471 - VN472
2VN491 - VN496
3VN497 - VN513
2VN531 - VN532
2VN536 - VN537
2VN541 - VN542
3VN546 - VN547
2VN551
3VN556 - VN557
3VN561 - VN562
2VN631 - VN633
3VN634 - VN638
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GroupVariable Number
2VN651 - VN652
3VN653 - VN658
2VN671 - VN672
3VN676
2VN681 - VN683
3VN684 - VN691
2VN731
3VN732
2VN751 - VN753
3VN791 - VN792
3VN811 - VN813
3VN921 - VN922
3VN931 - VN936
3VN951 - VN953
3VN966 - VN972
3VR051 - VR060
3VR081
3VR084
3VR086 - VR089
3VR106 - VR109
3VR401
3VR421 - VR423
3VR426
3VR441
3VR461
3VR471 - VR472
3VS051 - VS056
3VS061
3VS066 - VS070
3VS073 - VS078
3VS091 - VS104
3VS111 - VS113
3VS131 - VS133
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GroupVariable Number
3VS136 - VS137
3VS176 - VS177
3VS186 - VS187
3VS196 - VS203
3VS206 - VS208
3VS211
3VS216 - VS217
3VS231
3VS246 - VS248
3VS261 - VS263
3VS266 - VS274
3VS291 - VS293
3VS301 - VS303
3VS306 - VS311
3VS316
3VS321 - VS324
3VS331 - VS333
3VS336 - VS337
3VS366 - VS367
3VS381 - VS382
3VS391 - VS392
3VS401
3VS426 - VS428
3VS466 - VS472
3VS486
3VS496 - VS497
3VS506 - VS507
3VS526
3VS546 - VS549
3VS701 - VS736
3VS751 - VS759
3VS821 - VS825
3VS841 - VS844
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GroupVariable Number
3VS861
3VS881 - VS883
3VS891
3VS896
3VS901 - VS912
3VS916
3VS921 - VS928
3VS931 - VS933
3VS941
3VS951 - VS954
3VS961 - VS969
3VS971 - VS977
3VS981 - VS984
3VT001 - VT013
3VT021
3VT031 - VT033
3VV001
2. Spares Affected
None.
B. Concurrent Requirements
None.
C. Reason
Widespread Fatigue Damage (WFD) analysis of the 767, as required by 14 CFR 26.21(b), has resulted
in the conclusion that existing MPD Section 9, Airworthiness Limitation Item (ALI) inspection program
is not sufficient to preclude the occurrence of WFD in the aft pressure bulkhead to pressure chord joint
as the airplane ages. The aft pressure bulkhead web to pressure chord joint has multiple adjacent
identical details which have the potential for Multi-Site Damage (MSD) and the potential for WFD. 14
CFR 26.21 requires evaluation of such designs for the potential for WFD and implementation of the
appropriate Service Actions to ensure that WFD is precluded before the Limit of Validity (LOV). Boeing
has not received any reports of cracks in the bulkhead web to pressure chord joint. Accomplishment
of the inspection described in this service bulletin will enable detection and repair of cracks if they
should occur, at the STA 1582 Aft Pressure Bulkhead Web to Pressure Chord joint. If Widespread
Fatigue cracking is not found and repaired, the cracks can rapidly link up and can result in possible
rapid decompression and loss of structural integrity.
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### Page 17

The aft pressure bulkhead web to pressure chord joint affected by this service bulletin has been
determined to be structure that is susceptible to WFD.
Boeing Service Related Problem (SRP) 767-SRP-53-0469 is related to this service bulletin.
Boeing 767 MPD 622T001-9 Section 9, SSI 53-80-l01A is related to this service bulletin.
Boeing Service Bulletin 767-53A0087 is related to this service bulletin.
Boeing Service Bulletin 767-53A0139 is related to this service bulletin.
D. Description
Get access to the forward side of the aft pressure bulkhead at STA 1582. Remove the aft galley and
the main water tank(s) in the lower lobe. Do a Surface High Frequency Eddy Current (HFEC) inspection
of all visible locations of the aft pressure bulkhead web at the aft/inboard row of fasteners common to
the aft pressure bulkhead web and pressure chord around the entire circumference of the pressure
chord for any crack. If any crack is found, contact Boeing to get instructions for the repair for this service
bulletin, and do the work instructed by Boeing. If no crack is found, repeat the inspection.
The work in this service bulletin is done in the maintenance zone(s) given below.
Affected Maintenance Zones
ZoneModel
165, 166, 251, 252, 253, 254767-200, 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 AD 2004-05-16 is related to this service
bulletin. The effective date of AD 2004-05-16 is April 13, 2004.
Federal Aviation Administration (FAA) Airworthiness Directive AD 2012-09-08 is related to this service
bulletin. The effective date of AD 2012-09-08 is June 18, 2012.
Federal Aviation Administration (FAA) Airworthiness Directive AD 2014-14-04 is related to this service
bulletin. The effective date of AD 2014-14-04 is September 5, 2014.
This service bulletin affects SSI 53-80-I01A of 767 MPD 622T001-9 Section 9, which is mandated by
AD 2014-14-04. All other MPD inspections outside the of the affected area are not affected and must
continue.
Logic diagrams showing compliance tasks and compliance times are included as an aid in APPENDIX
A, APPENDIX B and APPENDIX C.
Do the required actions in accordance with Paragraph 3. Accomplishment Instructions.
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### Page 18

Group 2, Configuration 1:
Table 1: Surface High Frequency Eddy Current Inspection for Any Crack at STA 1582 Aft Pressure
Bulkhead
Repeat Interval
(Not to Exceed)
Compliance Time (Whichever
Occurs Later)
ActionCondition
-Within 3,000
flight cycles af-
ter the original
issue date of
this service bul-
letin.
Before 50,000
total flight cy-
cles.
Do PART 2: SURFACE
HIGH FREQUENCY ED-
DY CURRENT INSPEC-
TION OF THE AFT
PRESSURE BULKHEAD
WEB, for any crack. (a)
(b)
All Airplanes.
-Before further flight.Contact Boeing to get in-
structions for the repair
for this service bulletin,
and do the work instruct-
ed by Boeing.
CONDITION 1: ANY
CRACK FOUND
3,000 flight cycles.-Repeat PART 2: HIGH
FREQUENCY EDDY
CURRENT INSPECTION
OF THE AFT PRES-
SURE BULKHEAD WEB,
for any crack. (a) (b)
CONDITION 2: NO
CRACK FOUND
(a) It is not necessary to do inspections in accordance with this service bulletin in areas where existing repairs
approved by the Boeing ODA via FAA 8100-9 form cover the affected inspection areas. Damage Tolerance
Inspection instructions specified in approval for existing repairs must continue. Inspection outside of the
repaired area must continue in accordance with this service bulletin.
(b) Inspection of the web in accordance with this service bulletin does not require removal of permanently
attached structure such as stiffeners, splice plates, or clips.
Group 3, Configuration 1:
Table 2: Surface High Frequency Eddy Current Inspection for Any Crack at STA 1582 Aft Pressure
Bulkhead
Repeat Interval
(Not to Exceed)
Compliance Time (Whichever
Occurs Later)
ActionCondition
-Within 3,000
flight cycles af-
ter the original
issue date of
this service bul-
letin.
Before 62,000
total flight cy-
cles.
Do PART 2: SURFACE
HIGH FREQUENCY ED-
DY CURRENT INSPEC-
TION OF THE AFT
PRESSURE BULKHEAD
WEB, for any crack. (a)
(b)
All Airplanes.
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Group 3, Configuration 1:
Table 2: Surface High Frequency Eddy Current Inspection for Any Crack at STA 1582 Aft Pressure
Bulkhead
Repeat Interval
(Not to Exceed)
Compliance Time (Whichever
Occurs Later)
ActionCondition
-Before further flight.Contact Boeing to get in-
structions for the repair
for this service bulletin,
and do the work instruct-
ed by Boeing.
CONDITION 1: ANY
CRACK FOUND
4,400 flight cycles.-Repeat PART 2: SUR-
FACE HIGH FREQUEN-
CY EDDY CURRENT IN-
SPECTION OF THE AFT
PRESSURE BULKHEAD
WEB, for any crack. (a)
(b)
CONDITION 2: NO
CRACK FOUND
(a) It is not necessary to do inspections in accordance with this service bulletin in areas where existing repairs
approved by the Boeing ODA via FAA 8100-9 form cover the affected inspection areas. Damage Tolerance
Inspection instructions specified in approval for existing repairs must continue. Inspections outside of the
repaired area must continue in accordance with this service bulletin.
(b) Inspection of the web in accordance with this service bulletin does not require removal of permanently
attached structure such as stiffeners, splice plates, or clips.
Group 1; Group 2-3, Configuration 2:
Table 3: Surface High Frequency Current Inspection for Any Crack at STA 1582 Aft Pressure Bulkhead
Repeat Interval
(Not to Exceed)
Compliance Time (Whichever
Occurs Later)
ActionCondition
-Within 3,000
flight cycles af-
ter the original
issue date of
this service bul-
letin.
Within 37,500
flight cycles af-
ter aft pressure
bulkhead re-
placement.
Do PART 2: SURFACE
HIGH FREQUENCY ED-
DY CURRENT INSPEC-
TION OF THE AFT
PRESSURE BULKHEAD
WEB, for any crack. (a)
(b)
All Airplanes.
-Before further flight.Contact Boeing to get in-
structions for the repair
for this service bulletin,
and do the work instruct-
ed by Boeing.
CONDITION 1: ANY
CRACK FOUND
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Group 1; Group 2-3, Configuration 2:
Table 3: Surface High Frequency Current Inspection for Any Crack at STA 1582 Aft Pressure Bulkhead
Repeat Interval
(Not to Exceed)
Compliance Time (Whichever
Occurs Later)
ActionCondition
4,400 flight cycles.-Repeat PART 2: SUR-
FACE HIGH FREQUEN-
CY EDDY CURRENT IN-
SPECTION OF THE AFT
PRESSURE BULKHEAD
WEB, for any crack. (a)
(b)
CONDITION 2: NO
CRACK FOUND
(a) It is not necessary to do inspections in accordance with this service bulletin in areas where existing repairs
approved by the Boeing ODA via FAA 8100-9 form cover the affected inspection areas. Damage Tolerance
Inspection instructions specified in approval for existing repairs must continue. Inspection outside of the
repaired region must continue as instructed per this service bulletin
(b) Inspection of the web in accordance with this service bulletin does not require removal of permanently
attached structure such as stiffeners, splice plates, or clips.
F. Approval
This service bulletin was examined by the Federal Aviation Administration (FAA). The changes specified
in this service bulletin comply with the applicable regulations and are FAA approved, as well as European
Aviation Safety Agency (EASA)/Joint Aviation Authorities (JAA) approved for all EASA/JAA approved
airplanes listed in the service bulletin effectivity. This service bulletin and its approval were based on
the airplane in its original Boeing delivery configuration or as modified by other approved Boeing
changes.
If an airplane has a non-Boeing modification or repair that affects a component or system also affected
by this service bulletin, the operator is responsible for obtaining appropriate regulatory agency approval
before incorporating this service bulletin.
The Manager of the FAA Seattle Aircraft Certification Office (SACO) approves the accomplishment of
the inspections defined in this Service Bulletin (SB) along with the corresponding compliance times
specified in Paragraph 1.E., Compliance of this SB, Original Issue, as an Alternative Method Of
Compliance (AMOC) to the inspections defined in D622T001-DTR Structural Significant Item (SSI)
53-80-I01A and Section 9 of the Maintenance Planning Document (MPD) D622T001-9, required by
paragraphs (i) and (k) of Airworthiness Directive (AD) 2014-14-04. This AMOC only applies to the areas
inspected in accordance with this SB. All other inspections outside of this SB inspection region are not
affected and must continue. All provisions of AD 2014-14-04 that are not specifically referenced in this
paragraph remain fully applicable and must be complied with.
The Manager of the FAA SACO approves the accomplishment of the inspections defined in this SB
along with the corresponding compliance times specified in Paragraph 1.E., Compliance of this SB,
Original Issue, as an AMOC to the inspections defined in SB 767-53A0087 required by paragraphs (a)
and (b) of AD 2004-05-16. This AMOC only applies to the areas inspected in accordance with this SB.
All other inspections outside of this SB inspection region are not affected and must continue.
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In Addition, the Manager of the FAA SACO approves the accomplishment of the inspections defined
in this SB along with the corresponding compliance times specified in Paragraph 1.E., Compliance of
this SB, Original Issue, as an AMOC to the inspections defined in SB 767-53A0139 required by paragraph
(h) of AD 2012-09-08. This AMOC only applies to the areas inspected in accordance with this SB. All
other inspections outside of this SB inspection region are not affected and must continue.
G. Manpower
The table below shows an estimate of the task hours necessary to do this Inspection 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, 2 AND 3 AIRPLANES (WITH ONE WATER TANK REMOVAL REQUIRED):
Elapsed HoursTask HoursNumber of PersonsTask
4.7519.004Open Access
7.0014.002FIGURE 1
5.5022.004Close Access
17.2555.00TOTAL FOR EACH AIRPLANE (a)
(a) The manpower estimate does not include repairs, if necessary.
GROUP 1, 2 AND 3 AIRPLANES (WITH TWO WATER TANK REMOVALS REQUIRED):
Elapsed HoursTask HoursNumber of PersonsTask
5.0020.004Open Access
7.0014.002FIGURE 1
5.7523.004Close Access
17.7557.00TOTAL FOR EACH AIRPLANE (a)
(a) The manpower estimate does not include repairs, if necessary.
H. Weight and Balance Changes
None.
I. Electrical Load Data
Not changed.
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J. References
1. Existing Data:
a. Boeing Service Bulletin 767-53A0087, 767-53A0139
b. Boeing Service Letter 767-SL-51-036
c. Boeing Service Related Problem (SRP) 767-SRP-53-0469
d. Federal Aviation Administration (FAA) Airworthiness Directive (AD) 2004-05-16, 2004-05-16
, 2012-09-08, 2014-14-04
e. Service Bulletin Index D624T001
f. 767 Aircraft Maintenance Manual (AMM) 25-31-04, 25-52-01, 25-52-03, 38-11-01, 38-11-64,
38-32-11
g. 767 Maintenance Planning Data (MPD) 622T001-9Section 9
h. 767 Non-Destructive Testing (NDT) Manual Part 6, 51-00-01, Part 6, 51-00-19, Part 6, 53-80-05
2. Data Supplied with this Service Bulletin:
None.
3. Installation Drawings Used in the Preparation of this Service Bulletin:
None.
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 but no new DTIs are necessary.
L. Interchangeability and Intermixability of Parts
Accomplishment of this service bulletin does not affect interchangeability or intermixability of parts.
M. Software Accomplishment Summary
Not affected.
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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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### Page 25

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. Manual titles are referred to by acronyms. Refer to Paragraph 1.J., References, for
definition of the acronyms.
2. Obey all of the warnings and cautions given in the specified manual sections.
3. Unless shown differently, these dimensions and tolerances are used:
– Linear dimensions are in inches
– Tolerance on linear dimensions, other than rivet and bolt edge margins, is plus
or minus 0.03 inch
– Tolerance on rivet and bolt edge margin is plus or minus 0.05 inch
– Angular tolerance is plus or minus 2 degrees
– Hole dimensions for standard solid rivets and fasteners are in Structural Repair
Manual (SRM) Chapter 51
– Torque Values:
— Values for structural fasteners are given in 767 Structural Repair Manual,
Chapter 51.
— Values for airframe maintenance tasks are included in Chapter 20 of 767
Aircraft Maintenance Manual (AMM).
— Values for electrical maintenance tasks are included in Chapter 20 of
Standard Wiring Practices Manual (SWPM).
— Values for engine maintenance tasks are included in Chapter 70 of 767
Aircraft Maintenance Manual (AMM).
— Non-standard torque values for maintenance tasks are included in the
applicable installation step.
4. 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.
5. 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.
6. Refer to APPENDIX A, APPENDIX B and APPENDIX C for logic diagram(s). Logic
diagrams are provided as an aid only. Information contained in Paragraph 1.E.,
Compliance is the primary source for compliance times. Information in Paragraph
3.B., Work Instructions is the primary source for tasks required for compliance.
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7. The instructions in Paragraph 3.B., Work Instructions and the figures can include
operation of tools or test equipment. Boeing Engineering Tool Drawings, the Illustrated
Tool and Equipment Manual, and the Special Tool and Ground Handling Drawing
Index contain data on versions of the tools or test equipment that you can use. It is
permitted to use replaced tools. It is not permitted to use superseded tools.
8. 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.
9. Where the work instructions include installation of a kept part, a new or serviceable
part with the same part number can be installed as an alternative to the kept part.
10. Use of colors in Figures is based on guidance from the ATA e-Business Program
(ATA) iSpec 2200.
11. The compliance times for the actions in Paragraph 3.B., WORK INSTRUCTIONS
are in Paragraph 1.E., Compliance.
12. Some steps in the Work Instructions are identified as Required for Compliance (RC).
If this service bulletin is mandated by an Airworthiness Directive (AD), then the steps
identified as RC and steps indented under an RC step must be done to comply with
the AD. Alternative procedures for steps not identified with RC can be used if the
RC steps and indented steps can still be done as specified, and the airplane can be
put back in a serviceable condition. An Alternative Method of Compliance (AMOC)
is not necessary for deviations to steps that are not identified as RC.
B. WORK INSTRUCTIONS
1. Do PART 1: OPEN ACCESS.
2. RC - Do PART 2: SURFACE HIGH FREQUENCY EDDY CURRENT INSPECTION OF THE AFT
PRESSURE BULKHEAD WEB, for any crack.
a. CONDITION 1: ANY CRACK FOUND
(1) RC - Contact Boeing to get instructions for the repair for this service bulletin and do the
work instructed by Boeing.
b. CONDITION 2: NO CRACK FOUND
(1) RC - Repeat PART 2: SURFACE HIGH FREQUENCY EDDY CURRENT INSPECTION
OF THE AFT PRESSURE BULKHEAD WEB, for any crack.
3. Do PART 3: CLOSE ACCESS.
4. Put the airplane back to a serviceable condition.
PART 1: OPEN ACCESS
1. Remove and keep the aft galley. Refer to 767 AMM 25-31-04 as an accepted procedure.
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2. Remove and keep insulation from around splice plates that splice pressure chords on the aft
pressure bulkhead in the main deck compartment. Refer to 767 AMM 25-52-03 as an accepted
procedure.
3. Remove and keep the end wall in the bulk cargo compartment. Refer to 767 AMM 25-52-01 as an
accepted procedure.
4. Remove and keep the right side potable water tank. If installed, remove and keep the left side
potable water tank. Refer to 767 AMM 38-11-01 as an accepted procedure.
5. If necessary for access, remove and keep the waste tank. On some affected airplanes, the waste
tanks are installed forward of the affected area. On these airplanes, waste tank removal is not
necessary for access to the aft pressure bulkhead. Refer to 767 AMM 38-32-11 as an accepted
procedure.
6. Remove and keep insulation from around splice plates that splice pressure chords on the aft
pressure bulkhead in the bulk cargo compartment. Refer to 767 AMM 25-52-03 as an accepted
procedure.
PART 2: SURFACE HIGH FREQUENCY EDDY CURRENT INSPECTION OF THE AFT PRESSURE
BULKHEAD WEB
1. Do a surface HFEC Inspection of the aft pressure bulkhead web for any crack at the aft most
fastener row at all visible locations common to the pressure chord in accordance with FIGURE 1.
PART 3: CLOSE ACCESS
1. Install insulation to splice plates that splice pressure chords on the aft pressure bulkhead in the
bulk cargo compartment. Refer to 767 AMM 25-52-03 as an accepted procedure.
2. If removed, install the waste tank. Refer to 767 AMM 38-32-11 as an accepted procedure.
3. Install the right side potable water tank. If removed, install the left side potable water tank. Refer
to 767 AMM 38-11-64 as an accepted procedure.
4. Install the end wall in the bulk cargo compartment. Refer to 767 AMM 25-52-01 as an accepted
procedure.
5. Install insulation to splice plates that splice pressure chords on the aft pressure bulkhead in the
main deck compartment. Refer to 767 AMM 25-52-03 as an accepted procedure.
6. Install the aft galley. Refer to 767 AMM 25-31-04 as an accepted procedure.
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### Page 28 (OCR)

BOEING SERVICE BULLETIN 767-53A0268
ALERT  ALERT
BULKHEAD WEB
TYPICAL RADIAL
STIFFENER
STA
1582
INNER
CHORD
'PRESSURE
CHORD
PRESSURE
RING
FAILSAFE  INBD
CHORD
FRAME
TYPICAL INSPECTION AREA
WD
NOTE:
SOME AFFECTED AIRPLANE CONFIGURATIONS
HAVE SHORT STIFFENERS AT THE AFT PRESSURE
BULKHEAD TO PRESSURE CHORD JOINT.
SHORT STIFFENERS ARE NOT SHOWN FOR  CLARITY.  2377581
FIGURE 1: HIGH FREQUENCY EDDY CURRENT (HFEC) INSPECTION OF THE AFT PRESSURE BULKHEAD
WEB
(SHEET 1 OF 2)
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### Page 29

The step numbers shown below agree with the numbers shown in the circle symbols in the figure. The QTY
numbers shown below are the number of parts necessary for this figure.
More DataQtyIdentificationNameTaskStep
(a) (b) (c) (d) (e)--Bulkhead WebInspect1
(a) Do a Surface HFEC Inspection for any crack in accordance with 767 NDT Manual Part 6, 51-00-01, 767
NDT Manual Part 6, 51-00-19 or 767 NDT Manual Part 6, 53-80-05.
(b) Inspect all visible locations of web around the entire bulkhead circumference.
(c) Temporarily pull back insulation in area of inspection.
(d) It is not necessary to do inspections in accordance with this service bulletin in areas where existing repairs
approved by the Boeing ODA via FAA 8100-9 form cover the affected inspection areas. Damage Tolerance
Inspection instructions specified in approval for existing repairs must continue. Inspection outside of the
repaired region must continue as instructed per this service bulletin.
(e) Inspection of the web in accordance with this service bulletin does not require removal of permanently
attached structure such as stiffeners, splice plates, or clips.
FIGURE 1: HIGH FREQUENCY EDDY CURRENT (HFEC) INSPECTION OF THE AFT PRESSURE BULKHEAD
WEB
(SHEET 2 OF 2)
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This Appendix applies only to: Group 2, Configuration 1.
Logic diagrams are provided as an aid only. Information contained in Paragraph 1.E., Compliance is the primary
source for compliance times. Information contained in Paragraph 3.B., Work Instructions is the primary source
for tasks required for compliance.
1. The table below gives the description for the parts and conditions called out in the logic diagrams.
Description Table
DescriptionTitle
SURFACE HIGH FREQUENCY EDDY CURRENT INSPECTION OF AFT
PRESSURE BULKHEAD WEB.
PART 2
ANY CRACK FOUND.CONDITION 1
NO CRACK FOUND.CONDITION 2
2. The table below gives the description for the flag notes called out in the logic diagram.
Flag Notes
DescriptionFlag Note Letter
It is not necessary to do inspections in accordance with this service bulletin
in areas where existing repairs approved by the Boeing ODA via FAA 8100-
9 form cover the affected inspection areas. Damage Tolerance Inspection
instructions specified in approval for existing repairs must continue. Inspection
outside of the repaired area must continue in accordance with this service
bulletin.
(a)
Inspection of the web in accordance with this service bulletin does not require
removal of permanently attached structure such as stiffeners, splice plates,
or clips.
(b)
APPENDIX A:  LOGIC DIAGRAM FOR PARAGRAPH 1.E. COMPLIANCE TABLE 1: INSPECTION FOR ANY
CRACK AT STA 1582 AFT PRESSURE BULKHEAD
(SHEET 1 OF 2)
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### Page 31 (OCR)

BOEING SERVICE BULLETIN 767-53A0268
ALERT  ALERT
WHICHEVER OCCURS LATER
WITHIN 3,000 FLIGHT
BEFORE 50,000 TOTAL  CYCLES AFTER
FLIGHT CYCLES.  ORIGINAL ISSUE DATE
OF THIS SERVICE
BULLETIN.
(a)
DO PART 2
(b)
CONDITION 1  CONDITION 2
NOT TO EXCEED
BEFORE FURTHER  FLIGHT  3,000 FLIGHT
CYCLES
CONTACT BOEING TO  (a)
THIS SERVICE BULLETIN,  GET INSTRUCTIONS FOR  REPEAT PART 2
AND DO THE WORK
INSTRUCTED BY BOEING
2396053
APPENDIX A: LOGIC DIAGRAM FOR PARAGRAPH 1.E. COMPLIANCE TABLE 1: INSPECTION FOR ANY
CRACK AT STA 1582 AFT PRESSURE BULKHEAD
(SHEET 2 OF 2)
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### Page 32

This Appendix applies only to: Group 3, Configuration 1.
Logic diagrams are provided as an aid only. Information contained in Paragraph 1.E., Compliance is the primary
source for compliance times. Information contained in Paragraph 3.B., Work Instructions is the primary source
for tasks required for compliance.
1. The table below gives the description for the parts and conditions called out in the logic diagrams.
Description Table
DescriptionTitle
SURFACE HIGH FREQUENCY EDDY CURRENT INSPECTION OF AFT
PRESSURE BULKHEAD WEB.
PART 2
ANY CRACK FOUND.CONDITION 1
NO CRACK FOUND.CONDITION 2
2. The table below gives the description for the flag notes called out in the logic diagram.
Flag Notes
DescriptionFlag Note Letter
It is not necessary to do inspections in accordance with this service bulletin
in areas where existing repairs approved by the Boeing ODA via FAA 8100-
9 form cover the affected inspection areas. Damage Tolerance Inspection
instructions specified in approval for existing repairs must continue. Inspection
outside of the repaired area must continue in accordance with this service
bulletin.
(a)
Inspection of the web in accordance with this service bulletin does not require
removal of permanently attached structure such as stiffeners, splice plates,
or clips.
(b)
APPENDIX B:  LOGIC DIAGRAM FOR PARAGRAPH 1.E. COMPLIANCE TABLE 2: INSPECTION FOR ANY
CRACK AT STA 1582 AFT PRESSURE BULKHEAD
(SHEET 1 OF 2)
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### Page 33 (OCR)

BOEING SERVICE BULLETIN 767-53A0268
ALERT  ALERT
WHICHEVER OCCURS LATER
WITHIN 3,000 FLIGHT
BEFORE 62,000 TOTAL  CYCLES AFTER
FLIGHT CYCLES.  ORIGINAL ISSUE DATE
OF THIS SERVICE
BULLETIN.
a)
DO PART 2
CONDITION 1  CONDITION 2
NOT TO EXCEED
BEFORE FURTHER
FLIGHT  4,400 FLIGHT  CYCLES
CONTACT BOEING TO  >
GET INSTRUCTIONS FOR
THIS SERVICE BULLETIN,  REPEAT PART 2
AND DO THE WORK
INSTRUCTED BY BOEING
2396055
APPENDIX B: LOGIC DIAGRAM FOR PARAGRAPH 1.E. COMPLIANCE TABLE 2: INSPECTION FOR ANY
CRACK AT STA 1582 AFT PRESSURE BULKHEAD
(SHEET 2 OF 2)
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### Page 34

This Appendix applies only to: Group 1; Group 2-3, Configuration 2.
Logic diagrams are provided as an aid only. Information contained in Paragraph 1.E., Compliance is the primary
source for compliance times. Information contained in Paragraph 3.B., Work Instructions is the primary source
for tasks required for compliance.
1. The table below gives the description for the parts and conditions called out in the logic diagrams.
Description Table
DescriptionTitle
SURFACE HIGH FREQUENCY EDDY CURRENT INSPECTION OF AFT
PRESSURE BULKHEAD WEB.
PART 2
ANY CRACK FOUND.CONDITION 1
NO CRACK FOUND.CONDITION 2
2. The table below gives the description for the flag notes called out in the logic diagram.
Flag Notes
DescriptionFlag Note Letter
It is not necessary to do inspections in accordance with this service bulletin
in areas where existing repairs approved by the Boeing ODA via FAA 8100-
9 form cover the affected inspection areas. Damage Tolerance Inspection
instructions specified in approval for existing repairs must continue. Inspection
outside of the repaired area must continue in accordance with this service
bulletin.
(a)
Inspection of the web in accordance with this service bulletin does not require
removal of permanently attached structure such as stiffeners, splice plates,
or clips.
(b)
APPENDIX C:  LOGIC DIAGRAM FOR PARAGRAPH 1.E. COMPLIANCE TABLE 3: INSPECTION FOR ANY
CRACK AT STA 1582 AFT PRESSURE BULKHEAD
(SHEET 1 OF 2)
Export Controlled ECCN: 9E991 - BOEING
PROPRIETARY - Copyright © Unpublished
Work - See page 1 for details.
Original Issue: April 01, 2015
767-53A0268
34 of 35
BOEING SERVICE BULLETIN 767-53A0268
ALERTALERT

### Page 35 (OCR)

BOEING SERVICE BULLETIN 767-53A0268
ALERT  ALERT
WHICHEVER OCCURS LATER
WITHIN 37,500 FLIGHT  WITHIN 3,000 FLIGHT
CYCLES AFTER AFT  CYCLES AFTER
PRESSURE BULKHEAD  ORIGINAL ISSUE DATE
REPLACEMENT.  OF THIS SERVICE
BULLETIN.
(a)
DO PART 2
CONDITION 1
CONDITION 2
BEFORE FURTHER
FLIGHT
NOT TO EXCEED
4,400 FLIGHT
CYCLES
CONTACT BOEING TO
GET INSTRUCTIONS FOR
THIS SERVICE BULLETIN,
AND DO THE WORK
INSTRUCTED BY BOEING  REPEAT PART 2
2399740
APPENDIX C: LOGIC DIAGRAM FOR PARAGRAPH 1.E. COMPLIANCE TABLE 3: INSPECTION FOR ANY
CRACK AT STA 1582 AFT PRESSURE BULKHEAD
(SHEET 2 OF 2)
Original Issue: April 01, 2015
PROPRIETARY - Copyright © Unpublished  Export Controlled ECCN: 9E991 - BOEING  767-53A0268
Work - See page 1 for details.  35 of 35

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