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Page 1Open in PDF

August 14, 2003 Revision 2: December 19, 2006 747-21A2421 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 1 of 809

Commercial Airplane Group 747 Service Bulletin Number: 747-21A2421 Date: August 14, 2003 Revision 2: December 19, 2006 ATA System: 2122 SUBJECT: AIR CONDITIONING - Distribution - Duct Insulation BMS 8-39 Foam, Replacement

BOEING PROPRIETARY, CONFIDENTIAL, AND/OR TRADE SECRET Copyright © 2003 The Boeing Company Unpublished Work - All Rights Reserved Boeing claims copyright in each page of this document only to the extent that the page contains copyrightable subject matter.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, 707, 717, 727, 737, 747, 757, 767, 777, BBJ, BOEING BUSINESS JET, DC-8, DC-9, DC-10, MD-10, MD-11, MD-80, MD-90, the Boeing logo and the Boeing livery are among the trademarks owned by Boeing or its subsidiaries. No intellectual property license (express or implied) is granted in connection with this document or otherwise.

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BLANK PAGE August 14, 2003 Revision 2: December 19, 2006 747-21A2421 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 2 of 809 BOEING SERVICE BULLETIN 747-21A2421

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Table of Contents August 14, 2003 Revision 2: December 19, 2006 747-21A2421 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 3 of 809 BOEING SERVICE BULLETIN 747-21A2421

Table of Contents Revision Transmittal Sheet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

1. PLANNING INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 A. Effectivity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

1. Airplanes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

2. Spares Affected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 B. Concurrent Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 C. Reason . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 D. Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 E. Compliance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 F. Approval . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 G. Manpower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 H. Weight and Balance Changes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 I. Electrical Load Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 J. References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

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

2. Data supplied with this Service Bulletin: . . . . . . . . . . . . . . . . . . . . . . . . . 28

3. Installation Drawings Used in the Preparation of this Service Bulletin: . . . . . . . . . . 29

4. Process Data: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 K. Publications Affected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 L. Interchangeability and Intermixability of Parts . . . . . . . . . . . . . . . . . . . . . . . . . 30

2. MATERIAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 A. Material - Price and Availability. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 B. Industry Support Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 C. Parts Necessary For Each Airplane . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

1. Kits/Parts: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

2. Parts and Materials Supplied by the Operator: . . . . . . . . . . . . . . . . . . . . . . 32

3. Parts Modified and Reidentified: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

4. Parts Removed and Not Replaced: . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54 D. Parts Necessary to Change Spares . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55 E. Special Tooling - Price and Availability. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55 F. Special Tooling Necessary to do this Service Bulletin . . . . . . . . . . . . . . . . . . . . . 55

3. ACCOMPLISHMENT INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57 A. GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57 B. WORK INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58 FIGURE 1: AIR CONDITIONING, FLIGHT DECK, STA 323 - STA 500 . . . . . . . . . . . . . . . . . 496 FIGURE 2: AIR CONDITIONING - FLIGHT DECK, STA 323 - STA 520 . . . . . . . . . . . . . . . . 498 FIGURE 3: AIR CONDITIONING - FLIGHT DECK, STA 323 - STA 520 . . . . . . . . . . . . . . . . 500 FIGURE 4: AIR CONDITIONING - FLIGHT DECK, STA 323 - STA 520 . . . . . . . . . . . . . . . . 502 FIGURE 5: FLIGHT DECK, AIR CONDITIONING, SECTION 42 . . . . . . . . . . . . . . . . . . . . 504 FIGURE 6: FLIGHT DECK, AIR CONDITIONING, SECTION 42 . . . . . . . . . . . . . . . . . . . . 507 FIGURE 7: FLIGHT DECK, AIR CONDITIONING, SECTION 42 . . . . . . . . . . . . . . . . . . . . 511 FIGURE 8: FLIGHT DECK, AIR CONDITIONING, SECTION 42 . . . . . . . . . . . . . . . . . . . . 513 FIGURE 9: FLIGHT DECK, AIR CONDITIONING, SECTION 42 . . . . . . . . . . . . . . . . . . . . 515 FIGURE 10: FLIGHT DECK, AIR CONDITIONING, SECTION 42 . . . . . . . . . . . . . . . . . . . 517

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FIGURE 11: FLIGHT DECK, AIR CONDITIONING, SECTION 42 . . . . . . . . . . . . . . . . . . . 519 FIGURE 12: AIR CONDITIONING - FLIGHT DECK, STA 260 - STA 340 . . . . . . . . . . . . . . . 521 FIGURE 13: AIR CONDITIONING - FLIGHT DECK, STA 260 - STA 340 . . . . . . . . . . . . . . . 523 FIGURE 14: DUCT INSTALLATION - CONDITIONED AIR, STATEROOM . . . . . . . . . . . . . . 525 FIGURE 15: DUCT INSTALLATION - CONDITIONED AIR, STATEROOM . . . . . . . . . . . . . . 529 FIGURE 16: DUCT INSTALLATION - CONDITIONED AIR, STA 206 TO STA 464 . . . . . . . . . . 532 FIGURE 17: DUCT INSTALLATION - CONDITIONED AIR, STA 206 TO STA 464 . . . . . . . . . . 535 FIGURE 18: DUCT INSTALLATION - CONDITIONED AIR, STA 516 TO STA 737 . . . . . . . . . . 538 FIGURE 19: DUCT INSTALLATION - ZONE 11, STA 475.75 TO STA 516.0 . . . . . . . . . . . . . 541 FIGURE 20: DUCT INSTALLATION - ZONE 11, STA 475.75 TO STA 516.0 . . . . . . . . . . . . . 543 FIGURE 21: DUCT INSTALLATION - AIR DISTRIBUTION SYSTEM, ZONE 2 . . . . . . . . . . . . 545 FIGURE 22: DUCT INSTALLATION - AIR DISTRIBUTION SYSTEM, ZONE 2 . . . . . . . . . . . . 547 FIGURE 23: DUCT INSTALLATION - AIR DISTRIBUTION SYSTEM, ZONE 2 . . . . . . . . . . . . 550 FIGURE 24: DUCT INSTALLATION - AIR DISTRIBUTION SYSTEM, ZONE 2 . . . . . . . . . . . . 552 FIGURE 25: DUCT INSTALLATION - AIR DISTRIBUTION SYSTEM, ZONE 2 . . . . . . . . . . . . 554 FIGURE 26: DUCT INSTALLATION - ZONE 3, AIR DISTRIBUTION SYSTEM . . . . . . . . . . . . 556 FIGURE 27: DUCT INSTALLATION - ZONE 3, AIR DISTRIBUTION SYSTEM . . . . . . . . . . . . 558 FIGURE 28: DUCT INSTALLATION - ZONE 4, AIR DISTRIBUTION SYSTEM . . . . . . . . . . . . 560 FIGURE 29: DUCT INSTALLATION - ZONE 4, AIR DISTRIBUTION SYSTEM . . . . . . . . . . . . 562 FIGURE 30: DUCT INSTALLATION - ZONE 4, AIR DISTRIBUTION SYSTEM . . . . . . . . . . . . 564 FIGURE 31: DUCT INSTALLATION - ZONE 4, AIR DISTRIBUTION SYSTEM . . . . . . . . . . . . 566 FIGURE 32: LEFT SIDE RISER INSTALLATION - AIR DISTRIBUTION SYSTEM . . . . . . . . . . 568 FIGURE 33: RIGHT SIDE RISER INSTALLATION - AIR DISTRIBUTION SYSTEM . . . . . . . . . 571 FIGURE 34: LEFT SIDE RISER INSTALLATION - AIR DISTRIBUTION SYSTEM . . . . . . . . . . 575 FIGURE 35: RIGHT SIDE RISER INSTALLATION - AIR DISTRIBUTION SYSTEM . . . . . . . . . 577 FIGURE 36: LEFT SIDE RISER INSTALLATION - AIR DISTRIBUTION SYSTEM . . . . . . . . . . 579 FIGURE 37: RIGHT SIDE RISER INSTALLATION - AIR DISTRIBUTION SYSTEM . . . . . . . . . 581 FIGURE 38: LEFT SIDE RISER INSTALLATION - AIR DISTRIBUTION SYSTEM . . . . . . . . . . 583 FIGURE 39: RIGHT SIDE RISER INSTALLATION - AIR DISTRIBUTION SYSTEM . . . . . . . . . 585 FIGURE 40: FAN INSTALLATION - INDIVIDUAL AIR SYSTEM. . . . . . . . . . . . . . . . . . . . 587 FIGURE 41: FAN INSTALLATION - INDIVIDUAL AIR SYSTEM. . . . . . . . . . . . . . . . . . . . 589 FIGURE 42: ANEMOSTAT INSTALLATION - STA 165, AIR DISTRIBUTION SYSTEM . . . . . . . 591 FIGURE 43: HUMIDIFIER DUCT INSTALLATION - CREW CABIN, ZONE 1 . . . . . . . . . . . . . 593 FIGURE 44: HEAT EXCHANGER INSTALLATION - AIR COND SYSTEM, LOWER LOBE GALLEY 595 FIGURE 45: HEAT EXCHANGER INSTALLATION - AIR COND SYSTEM, LOWER LOBE GALLEY 597 FIGURE 46: HEAT EXCHANGER INSTALLATION - AIR COND SYSTEM, LOWER LOBE GALLEY 599 FIGURE 47: INSULATION INSTL - CONDITIONED AIR PLENUM . . . . . . . . . . . . . . . . . . 601 FIGURE 48: INSULATION INSTL - CONDITIONED AIR MIX BAY, STA 1000 - STA 1265 . . . . . . 603 FIGURE 49: RECIRCULATION FAN INSTALLATION - FLIGHT DECK . . . . . . . . . . . . . . . . 605 FIGURE 50: RECIRCULATION FAN INSTALLATION - FLIGHT DECK . . . . . . . . . . . . . . . . 607 FIGURE 51: RECIRCULATION FAN INSTALLATION - FLIGHT DECK . . . . . . . . . . . . . . . . 609 FIGURE 52: RECIRCULATION FAN INSTALLATION - FLIGHT DECK . . . . . . . . . . . . . . . . 611 FIGURE 53: RECIRCULATION FAN INSTALLATION - FLIGHT DECK . . . . . . . . . . . . . . . . 613 FIGURE 54: DUCT INSTALLATION - CONDITIONED AIR MANIFOLD, STA 1000 - STA 1265 . . . 615 FIGURE 55: DUCT INSTALLATION - GASPER AIR SYSTEM, MAIN DECK . . . . . . . . . . . . . 617 FIGURE 56: DUCT INSTALLATION - GASPER AIR SYSTEM, MAIN DECK . . . . . . . . . . . . . 621

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FIGURE 57: DUCT INSTALLATION - GASPER AIR SYSTEM, MAIN DECK . . . . . . . . . . . . . . 624 FIGURE 58: DUCT INSTALLATION - GASPER AIR SYSTEM, MAIN DECK . . . . . . . . . . . . . . 626 FIGURE 59: DUCT INSTALLATION - GASPER AIR SYSTEM, MAIN DECK . . . . . . . . . . . . . . 628 FIGURE 60: DUCT INSTALLATION - GASPER AIR SYSTEM, MAIN DECK . . . . . . . . . . . . . . 631 FIGURE 61: DUCT INSTALLATION - ZONE 3 FEEDER . . . . . . . . . . . . . . . . . . . . . . . . 634 FIGURE 62: THIS FIGURE IS NOT USED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6 3 6 FIGURE 63: DUCT INSTALLATION - AIR CONDITIONING SYS, CREW REST COMPARTMENT . . 637 FIGURE 64: DUCT INSTALLATION - AIR CONDITIONING SYS, CREW REST COMPARTMENT . . 639 FIGURE 65: THIS FIGURE IS NOT USED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6 4 1 FIGURE 66: DUCT INSTALLATION - AIR CONDITIONING SYS, CREW REST COMPARTMENT . . 642 FIGURE 67: DUCT INSTALLATION - P8 PANEL COOLING, FLIGHT DECK . . . . . . . . . . . . . 644 FIGURE 68: DUCT INSTALLATION - ZONE 2, STA 456 - STA 516 . . . . . . . . . . . . . . . . . . 646 FIGURE 69: DUCT INSTALLATION - AIR DISTRIBUTION SYSTEM, ZONE 2. . . . . . . . . . . . . 648 FIGURE 70: DUCT INSTALLATION - AIR DISTRIBUTION SYSTEM, ZONE 2. . . . . . . . . . . . . 650 FIGURE 71: DUCT INSTALLATION - INDIVIDUAL AIR SYSTEM, ZONE D AND E . . . . . . . . . . 652 FIGURE 72: DUCT INSTALLATION - INDIVIDUAL AIR SYSTEM, ZONE D AND E . . . . . . . . . . 654 FIGURE 73: DUCT INSTALLATION - INDIVIDUAL AIR SYSTEM, ZONE D AND E . . . . . . . . . . 656 FIGURE 74: DUCT INSTALLATION - INDIVIDUAL AIR SYSTEM, ZONE D AND E . . . . . . . . . . 658 FIGURE 75: DUCT INSTALLATION - AIR DISTRIBUTION, ZONE 4, FEEDER . . . . . . . . . . . . 662 FIGURE 76: DUCT INSTALLATION - AIR DISTRIBUTION, ZONE 2 . . . . . . . . . . . . . . . . . . 664 FIGURE 77: DUCT INSTALLATION - AIR DISTRIBUTION, ZONE 2 . . . . . . . . . . . . . . . . . . 666 FIGURE 78: DUCT INSTALLATION - AIR DISTRIBUTION SYSTEM, ZONE 3 . . . . . . . . . . . . 668 FIGURE 79: DUCT INSTALLATION - AIR DISTRIBUTION SYSTEM, ZONE 3 . . . . . . . . . . . . 670 FIGURE 80: DUCT INSTALLATION - AIR DISTRIBUTION, UPPER DECK COMPARTMENT . . . . . 672 FIGURE 81: DUCT INSTALLATION - AIR DISTRIBUTION, UPPER DECK COMPARTMENT . . . . . 674 FIGURE 82: DUCT INSTALLATION - AIR DISTRIBUTION, UPPER DECK COMPARTMENT . . . . . 676 FIGURE 83: DUCT INSTALLATION - AIR DISTRIBUTION, UPPER DECK COMPARTMENT . . . . . 679 FIGURE 84: DUCT INSTALLATION - AIR DISTRIBUTION, UPPER DECK COMPARTMENT . . . . . 681 FIGURE 85: DUCT INSTALLATION - AIR DISTRIBUTION, UPPER DECK COMPARTMENT . . . . . 683 FIGURE 86: DUCT INSTALLATION - AIR DISTRIBUTION, UPPER DECK COMPARTMENT . . . . . 685 FIGURE 87: DUCT INSTALLATION - AIR DISTRIBUTION, UPPER DECK COMPARTMENT . . . . . 687 FIGURE 88: DUCT INSTALLATION - AIR DISTRIBUTION, UPPER DECK COMPARTMENT . . . . . 689 FIGURE 89: DUCT INSTALLATION - AIR DISTRIBUTION, UPPER DECK COMPARTMENT . . . . . 691 FIGURE 90: DUCT INSTALLATION - AIR DISTRIBUTION, UPPER DECK COMPARTMENT . . . . . 695 FIGURE 91: DUCT INSTALLATION - AIR DISTRIBUTION, UPPER DECK COMPARTMENT . . . . . 699 FIGURE 92: DUCT INSTALLATION - AIR DISTRIBUTION, UPPER DECK COMPARTMENT . . . . . 701 FIGURE 93: DUCT INSTALLATION - INDIVIDUAL AIR SYSTEM, LAVATORIES . . . . . . . . . . . 703 FIGURE 94: DUCT INSTALLATION - INDIVIDUAL AIR SYSTEM, LAVATORIES . . . . . . . . . . . 705 FIGURE 95: DUCT INSTALLATION - INDIVIDUAL AIR SYSTEM, LAVATORIES . . . . . . . . . . . 707 FIGURE 96: DUCT INSTALLATION - INDIVIDUAL AIR SYSTEM, LAVATORIES . . . . . . . . . . . 709 FIGURE 97: DUCT INSTALLATION - INDIVIDUAL AIR SYSTEM, LAVATORIES . . . . . . . . . . . 711 FIGURE 98: DUCT INSTALLATION - AIR DISTRIBUTION SYS, LOWER AFT CARGO COMPARTMENT 713 FIGURE 99: DUCT INSTALLATION - AIR DISTRIBUTION SYS, LOWER AFT CARGO COMPARTMENT 716 FIGURE 100: DUCT INSTALLATION - CONDITIONED AIR, MAIN DECK CREW REST . . . . . . . 720

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FIGURE 101: DUCT INSTALLATION - CONDITIONED AIR, RIGHT HAND CREW REST . . . . . . 722 FIGURE 102: DUCT INSTALLATION - INDIVIDUAL AIR SYSTEM, PASSENGER CABIN . . . . . . 724 FIGURE 103: DUCT INSTALLATION - INDIVIDUAL AIR SYSTEM, PASSENGER CABIN . . . . . . 726 FIGURE 104: DUCT INSTALLATION - INDIVIDUAL AIR SYSTEM, PASSENGER CABIN . . . . . . 729 FIGURE 105: DUCT INSTALLATION - INDIVIDUAL AIR SYSTEM, PASSENGER CABIN . . . . . . 731 FIGURE 106: DUCT INSTALLATION - INDIVIDUAL AIR SYSTEM, PASSENGER CABIN . . . . . . 733 FIGURE 107: DUCT INSTALLATION - INDIVIDUAL AIR SYSTEM, PASSENGER CABIN . . . . . . 735 FIGURE 108: DUCT INSTALLATION - INDIVIDUAL AIR SYSTEM, PASSENGER CABIN . . . . . . 737 FIGURE 109: DUCT INSTALLATION - INDIVIDUAL AIR SYSTEM, PASSENGER CABIN . . . . . . 739 FIGURE 110: DUCT INSTALLATION - INDIVIDUAL AIR SYSTEM, PASSENGER CABIN . . . . . . 742 FIGURE 111: DUCT INSTALLATION - INDIVIDUAL AIR SYSTEM, PASSENGER CABIN . . . . . . 745 FIGURE 112: DUCT INSTALLATION - INDIVIDUAL AIR SYSTEM, UPPER DECK LOUNGE/ FLIGHT DECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 747 FIGURE 113: DUCT INSTALLATION - INDIVIDUAL AIR SYSTEM, PASSENGER CABIN . . . . . . 752 FIGURE 114: DUCT INSTALLATION - INDIVIDUAL AIR SYSTEM, MAIN CABIN . . . . . . . . . . 756 FIGURE 115: HEATING INSTALLATION - PASSENGER CABIN DOOR . . . . . . . . . . . . . . . 758 FIGURE 116: AIR DISTRIBUTION INSTALLATION - MAIN DECK, CREW REST . . . . . . . . . . 761 FIGURE 117: DUCT INSTALLATION - INDIVIDUAL AIR SYSTEM, LAVATORIES . . . . . . . . . . 763 FIGURE 118: DUCT INSTALLATION - INDIVIDUAL AIR SYSTEM, LAVATORIES . . . . . . . . . . 767 FIGURE 119: DUCT INSTALLATION - AIR DISTRIBUTION SYSTEM, ZONE 2 . . . . . . . . . . . 770 FIGURE 120: DUCT INSTALLATION - AIR DISTRIBUTION SYSTEM, ZONE 2 . . . . . . . . . . . 772 FIGURE 121: DUCT INSTALLATION - AIR DISTRIBUTION SYSTEM, ZONE 2 . . . . . . . . . . . 774 FIGURE 122: DUCT INSTALLATION - AIR DISTRIBUTION SYS, PASSENGER CABIN . . . . . . . 776 FIGURE 123: DUCT INSTALLATION - AIR DISTRIBUTION SYS, PASSENGER CABIN (SHEET 3). 779 FIGURE 124: DUCT INSTALLATION - AIR DISTRIBUTION SYSTEM, PASSENGER CABIN . . . . 783 FIGURE 125: DUCT INSTALLATION - AIR DISTRIBUTION SYSTEM, PASSENGER CABIN . . . . 785 FIGURE 126: DUCT INSTALLATION - AIR DISTRIBUTION SYSTEM, PASSENGER CABIN . . . . 787 FIGURE 127: DUCT INSTALLATION - AIR DISTRIBUTION SYSTEM, PASSENGER CABIN . . . . 789 FIGURE 128: DUCT INSTALLATION - AIR DISTRIBUTION SYSTEM, PASSENGER CABIN . . . . 791 FIGURE 129: DUCT INSTALLATION - AIR DISTRIBUTION SYSTEM, PASSENGER CABIN . . . . 793 FIGURE 130: DUCT INSTALLATION - AIR CONDITIONING SYS CREW REST COMPARTMENT . 795 FIGURE 131: DUCT INSTALLATION - AIR DISTRIBUTION SYSTEM, PASSENGER CABIN . . . . 797 FIGURE 132: DUCT INSTALLATION - FLIGHT DECK, CONDITIONED AIR . . . . . . . . . . . . . 799 APPENDIX A: PROCESS DATA - APPLICATION OF BMS 8-300 BY TAPING WITH BMS 5-157 TAPE.

800 APPENDIX B: TIE STRAP SELECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 805 APPENDIX C: BAC 5412 METHOD VII - BONDING DUCT JOINTS . . . . . . . . . . . . . . . . . 806 APPENDIX D: BAC5412 METHOD VIII - TAPED TELESCOPING JOINTS . . . . . . . . . . . . . . 807 APPENDIX E: AIR DISTRIBUTION SYSTEM PRESSURE CHECK - CHART 1. . . . . . . . . . . . 808 APPENDIX F: AIR DISTRIBUTION SYSTEM PRESSURE CHECK - CHART 2. . . . . . . . . . . . 809

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Commercial Airplane Group 747 Service Bulletin Number: 747-21A2421 Revision Transmittal Sheet Date: August 14, 2003 Revision 2: December 19, 2006 ATA System: 2122 SUBJECT: AIR CONDITIONING - Distribution - Duct Insulation BMS 8-39 Foam, Replacement This Revision includes all pages of the service bulletin.

COMPLIANCE INFORMATION RELATED TO THIS REVISION More work is necessary on airplanes changed as shown in the original issue or Revision 01 of this service bulletin, if accomplished after September 02, 2005. If the intent of this Revision 02 was accomplished after September 02, 2005, then no more work is required.

REASON FOR REVISION This revision is sent to give operators approval to use BMS 5-157 tape instead of the non-compliant BMS 5-149 tape. This change gives operators new instructions to apply BMS 8-300 insulation to the Environmental Control System (ECS) ducts with BMS 5-157 tape. The BMS 5-157 tape must fully cover the BMS 8-300 insulation. The new configuration for the ECS duct insulation meets the flammability requirements of 14CFR 25.856(a), Amendment 111. Airplanes that have the intent of this service bulletin done after September 02, 2005, must satisfy the new requirements by fully covering the brown hypalon cover of the BMS 8-300 insulation with BMS 5-157 tape.

Changes to the service bulletin include:

— A Boeing recommended compliance time is given.

— Paragraph 2.C.2 Parts and Material Supplied by the Operator has changed to remove the reference to BMS 5-149 tape and to add reference to BMS 5-157, Type 1, Class 1, Grade B, Form 1, Composition MPVF (Metallized Polyvinyl Fluoride) tape.

— Paragraph 2.C.2 Parts and Material Supplied by the Operator has changed to remove the reference to BMS 5-7 Type 1 Adhesive.

— Appendix A. is changed to give the new instructions to install the BMS 8-300 insulation using BMS 5-157 tape.

Paragraph 1.A., Effectivity, shows changes of airplane operators. Each operator should examine the Effectivity paragraph for changes.

Vertical lines are put on the left edge of each page, except in Paragraph 1.A., Effectivity, to show the location of important changes.

Pages with no vertical lines have no important changes.

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REVISION HISTORY Original Issue: August 14, 2003 Revision 1 December 21, 2004 Revision 2 December 19, 2006

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Commercial Airplane Group 747 Service Bulletin Number: 747-21A2421 Summary Date: August 14, 2003 Revision 2: December 19, 2006 ATA System: 2122 SUBJECT: AIR CONDITIONING - Distribution - Duct Insulation BMS 8-39 Foam, Replacement

CONCURRENT REQUIREMENTS None.

BACKGROUND Some 747 airplanes were assembled with air distribution ducts wrapped with BMS 8-39, polyurethane foam insulation. The fire retardant properties of this polyurethane foam insulation can degrade with age and become a possible fire hazard.

BMS 8-39 polyurethane foam insulation meets all flammability requirements, including Federal Aviation Regulation (FAR) 25.853, upon delivery. It has been found that there can be deterioration of these fire retardant properties with age. This, along with dust, dirt and other carbon particulate contamination of the BMS 8-39 insulation on these ducts, adds an available fuel source to the insulation. This can cause the duct assemblies to no longer meet FAR 25.853.

This service bulletin provides rework instructions for the affected duct assemblies and environmental control system (ECS) related parts. Replacement of the old insulation material on these ECS parts and duct assemblies with a new insulation material that meets FAR 25.853 requirements will improve fire safety. The existing BMS 8-39 polyurethane insulation is removed and new BMS 8-300 polyimide foam insulation is installed.

There have been two reports of burned BMS 8-39 polyurethane foam insulation on the 767 airplane.

Boeing Service Related Problem (SRP) 747-SRP-21-0130 is related to this service bulletin.

ACTION (PRR 85901-18RS) Rework the affected duct and ECS related assemblies in the areas as described by the Figure titles. The existing insulation will be removed and replaced with a new, BMS 8-300 insulation. Perform the functional tests as required.

EFFECTIVITY See paragraph 1.A. Effectivity.

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COMPLIANCE Boeing recommends this change be accomplished during the next heavy maintenance visit, not to exceed 30,000 flight-hours from the date on this service bulletin.

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.

INDUSTRY SUPPORT INFORMATION Boeing warranty remedies are not available for the configuration changes given in this service bulletin.

MANPOWER Man-hours required to accomplish this change are averaged at 7.25 hours for each duct assembly. Functional test require a crew of two 7.5 man-hours, with an elapsed time of 3.75 hours.

MATERIAL INFORMATION Operator Supplied Materials.

Refer to Paragraph 2.A., Material - Price and Availability.

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REWORK AS REQUIRED, ECS DUCT ASSEMBLIES

AND COMPONENTS BY REMOVING EXISTING BMS 8-39 INSULATION AND REPLACING WITH BMS 8-300 INSULATION.

(SEE FIGURES FOR SYSTEM LOCATIONS) N59155

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