Narrative:

Actuator service bulletin X says the actuator must work with cabin pressure controller -11; -12; or -13 for ETOPS aircraft. Air carrier has not modified its -6 or its -8 pressure controllers to the proper dash number. Also pressure controller actuator service bulletin Y says pressure controller service bulletin Z must be done concurrently to allow the pressure controllers to work with the updated pressure controllers. Air carrier service bulletin Z has an engineering sheet that says the implementation mode of 'accomplish at next shop visit when parts are available.' for years parts were never ordered so the pressure controllers were not updated. The pressure controllers are being used with the updated actuator controllers. Under the parts manual of pressure controllers are -6; -8; -9; -11; -13 controllers. Anything less than a -13 controller does not appear to be correct for ETOPS aircraft. Also the valve stops in the pressure controller actuators are being jammed and/or broken with the wrong pressure controllers driving them. The maintenance record cards from the shop will show this. The pressure controller units should all be modified to -13 or -15 configuration. Boeing aircraft recommends modifying every pressure controller into a -15 unit. B757 and B767 fleets may have wrong cabin pressure controllers on ETOPS aircraft. Service bulletin X says pressure controller actuators must be compatible with cabin pressure controller -11; -12; -13. Air carrier has -6 and -8 cabin pressure controllers with pressure controller actuators.callback conversation with reporter revealed the following information: reporter stated that the B757 and B767-300 cabin pressure controllers (black boxes) on ETOPS aircraft have not been upgraded due to parts not being ordered. His carrier has recently brought the modification work of the controller actuators back in-house to accomplish mfg service bulletin X. However; part of the actuator south/B requires that the pressure controller unit modification 'must be done concurrently' under south/B Z. These un-modified cabin pressure controllers are still being installed with the upgraded pressure controller actuators. This practice is contrary to honeywell's recommendations. Reporter stated; this combination of upgraded controller actuator with a non-modified pressure controller unit continues to cause numerous and ongoing pilot write-ups about aircraft over-pressure control problems in flight and on the ground at the gates; especially during pushbacks. The modified actuator over-drives the outflow valve door(south) and jams them shut. This requires the pilot to go to manual control mode of operation to override the outflow valve door. Honeywell is now the licensee of the original pressure controller equipment. Reporter added that his engineering group does not believe there are any problems and has changed the wording of the original south/B modification implementation from 'accomplish at next shop visit;' to read as 'south/B is for information only.' the honeywell rep he has talked with strongly disagrees with engineering's position on this issue. Honeywell will only do a -15 pressure controller upgrade as recommended by boeing.

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Original NASA ASRS Text

Title: A MAINT INSPECTOR REPORTS B757/B767 FLEETS MAY HAVE THE WRONG CABIN PRESSURE CONTROLLERS ON ETOPS ACFT. PARTS HAVE NOT BEEN ORDERED TO DO SERVICE BULLETIN UPDATES.

Narrative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

Data retrieved from NASA's ASRS site as of May 2009 and automatically converted to unabbreviated mixed upper/lowercase text. This report is for informational purposes with no guarantee of accuracy. See NASA's ASRS site for official report.