Boeing ASB 747-21A2422: Revision 2, text

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Commercial Airplane Group 747 Service Bulletin Number: 747-21A2422 Date: August 21, 2003 Revision 2: November 16, 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BOEING PROPRIETARY, CONFIDENTIAL, AND/OR TRADE SECRET Copyright © 2003 The Boeing Company Unpublished Work - All Rights Reserved Boeing claims copyright in each page of this document only to the extent that the page contains copyrightable subject matter.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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Table of Contents Revision Transmittal Sheet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

1. PLANNING INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 A. Effectivity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

1. Airplanes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

2. Spares Affected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 B. Concurrent Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 C. Reason . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 D. Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 E. Compliance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 F. Approval . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 G. Manpower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 H. Weight and Balance Changes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 I. Electrical Load Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 J. References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

1. Existing Data: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

2. Data supplied with this Service Bulletin: . . . . . . . . . . . . . . . . . . . . . . . . . 23

3. Installation Drawings Used in the Preparation of this Service Bulletin: . . . . . . . . . . 23

4. Process Data: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 K. Publications Affected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 L. Interchangeability and Intermixability of Parts . . . . . . . . . . . . . . . . . . . . . . . . . 24

2. MATERIAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 A. Material - Price and Availability. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 B. Industry Support Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 C. Parts Necessary For Each Airplane . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

1. Kits/Parts: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

2. Parts and Materials Supplied by the Operator: . . . . . . . . . . . . . . . . . . . . . . 27

3. Parts Modified and Reidentified: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

4. Parts Removed and Not Replaced: . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 D. Parts Necessary to Change Spares . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 E. Special Tooling - Price and Availability. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 F. Special Tooling Necessary to do this Service Bulletin . . . . . . . . . . . . . . . . . . . . . 28

3. ACCOMPLISHMENT INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 A. GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 B. WORK INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 FIGURE 1: DUCT ACCESS, ALL AIRPLANE GROUPS . . . . . . . . . . . . . . . . . . . . . . . . 30 FIGURE 2: DUCT ASSEMBLY REWORK, GROUP 1 AIRPLANES . . . . . . . . . . . . . . . . . . 32 FIGURE 3: DUCT ASSEMBLY REWORK, GROUP 2 AIRPLANES . . . . . . . . . . . . . . . . . . 34 FIGURE 4: DUCT ASSEMBLY REWORK, GROUP 3 AIRPLANES . . . . . . . . . . . . . . . . . . 36 FIGURE 5: DUCT ASSEMBLY REWORK, GROUP 4 AIRPLANES . . . . . . . . . . . . . . . . . . 38 APPENDIX A: PROCESS DATA - APPLICATION OF BMS 8-300 BY TAPING WITH BMS 5-157 TAPE.

40 APPENDIX B: BAC 5412 METHOD VII - BONDING DUCT JOINTS. . . . . . . . . . . . . . . . . . 45 APPENDIX C: BAC 5412 METHOD VIII - TAPED TELESCOPING JOINTS. . . . . . . . . . . . . . 46

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Commercial Airplane Group 747 Service Bulletin Number: 747-21A2422 Revision Transmittal Sheet Date: August 21, 2003 Revision 2: November 16, 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 initial release 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 this service bulletin include:

— 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 tape, 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.

— Airplane RD233 is moved from Group 2 to Group 3.

— Duct assembly part number 65B41764-1026 has been changed to 654B41764-2026. The 65B41764-2026 is the same as the 65B41764-1026, except that it is wrapped with 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 21, 2003 Revision 1: January 20, 2005 Revision 2: November 16, 2006

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Commercial Airplane Group 747 Service Bulletin Number: 747-21A2422 Summary Date: August 21, 2003 Revision 2: November 16, 2006 ATA System: 2122 SUBJECT: AIR CONDITIONING - Distribution - Duct Insulation, BMS 8-39 Foam, Replacement

CONCURRENT REQUIREMENTS None

BACKGROUND Airplanes affected by this service bulletin have a single duct assembly installed that does not meet the flammability requirements of Federal Aviation Regulation, FAR 25.853, relating to the 12-second vertical burn requirement. This is a result of the combination of BMS 8-39 foam insulation and BAC 5010, Type 98, adhesive.

This combination of materials may present a potential fire hazard.

This service bulletin provides instructions to replace the existing duct with a new duct assembly. Instructions are also provided to rework the duct assembly by removing the existing BMS 8-39, polyurethane foam insulation, and replacing it with BMS 8-300, polyimide foam insulation.

There have been no reports of this duct burning on 747 airplanes.

Boeing Service Related Problem (SRP) 747 SRP-21-0143 is related to this service bulletin.

ACTION (PRR 85901-18RS, Part B and C) Replace or rework duct assembly, in the forward, lower, cargo bay. Perform functional test.

EFFECTIVITY Refer to Paragraph 1.A.1. Airplanes, for the list of the 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.

INDUSTRY SUPPORT INFORMATION Upon request, one replacement duct for each affected airplanes will be provided at no-charge. Man-hour reimbursement will be provided for airplanes in warranty as of April 20, 2001. Please refer to Paragraph 2.B., Industry Support Information.

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MANPOWER

MATERIAL INFORMATION Boeing Supplied Parts Operator Supplied Materials Refer to Paragraph 2.A., Material - Price and Availability.

Total Task-Hours Elapsed Time (Hours)

3.75 2.25

REWORK OR REPLACE

DUCT ASSEMBLY

FORWARD CARGO DOOR V62344

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1. PLANNING INFORMATION A. Effectivity

1. Airplanes Refer to Service Bulletin Index Document D6-30300 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 PRR 85901-18RS (Part B and C) for data about this change.

Airplane models:

747-100 747-100B 747-200B 747-200C 747-200F 747-300 747-400F 747SP 747SR

IDENTIFICATION BY CUSTOMER, CUSTOMER CODE, GROUP AND VARIABLE NUMBER AAR A/C ENG. SALES & LEASING (AFD) 2 RB681–RB682

AERO CONTROLS (AEO) 2 RA722–RA723

GROUP CONFIGURATION DESCRIPTION 1 - Duct Assembly 65B41764-2 installed in production.

2 - Duct Assembly 65B41764-5 installed in production.

3 - Duct Assembly 65B41764-6 installed in production.

4 - Duct Assembly 65B41764-6 installed in production.

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AEROLINEAS ARGENTINAS (ARG) 2 RD122–RD127 AFRICA UNITED HOLDING CO. (UHD) 2R B 0 1 0

AFX (AXL) 2 RD201 3 RR221

AGES AIRCRAFT SALES & LEASING (AGJ) 2R B 0 0 4

AIR ATLANTA ICELANDIC (AID) 2 RD141 RD414 RD647–RD648 RD771 RS211 RS222 RS233 RS235 RS237 3 RR332

AIR CANADA (ACN) 2 RA749–RA750 RD531

AIR CHINA (BEJ) 2 RD781

AIR FRANCE (AFA) 2 RD657–RD658 RD721–RD722 3 RR306

AIR GULF FALCON (GFG) 2R A 5 3 5 R A 5 3 7

AIR INDIA (AIN) 2R A 7 2 9 R A 7 3 1

AIR PLUS COMET (PLD) 2 RD053

AIR PULLMANTUR (PUL) 2 RD655

AIR UNIVERSAL (UVL) 2 RD649

ALBARAKA (AAB) 1R B 1 0 2

ALL NIPPON AIRWAYS (ANA) 2 RB691–RB693 RB695

AMERICAN AIRLINES (AAL) 2R A 2 6 6

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ARKIA ISRAELI AIRLINES (ARK) 1 RA253

ASIANA AIRLINES (AAR) 4 RM861 RR746–RR748

ATLAS AIR (TLS) 2 RB684 RD361–RD366 RD411 RD641–RD642 RD646 RD691–RD692 RD752–RD753 3 RJ333 RR301 RR303 4 RM891–RM899 RM901–RM903

AVIATION EXPOSURE MANAGEMENT (EXU) 2 RD131–RD132 RD143

BAHRAIN ROYAL FLIGHT (BHR) 3 RG009

BANC OF AMERICA LEASING (SBC) 1 RA106 2 RD001–RD002

BOEING (TBC) 3 RR222–RR223 BOEING AIRCRAFT HOLDING CO. (BHC) 2 RD181 RD451–RD454

BOEING CAPITAL CORPORATION (ZMF) 2 RB687 RD072 3 RJ132 RR201

BOEING WICHITA MOD CENTER (WMC) 2 RD455 C.A.L. CARGO AIR LINES (CRG) 3 RJ331–RJ332 C.I.T. LEASING CORPORATION (TCI) 2 RB011 RD047

CARGAIR (CGL) 2 RD203

CARGOLUX AIRLINES (CLX) 4 RM881–RM885 RR701 RR721–RR724

CATHAY PACIFIC AIRWAYS (CAT) 2 RD358 RD581–RD583 3 RR531 4 RM856 RR951–RR952

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CHINA AIRLINES (CHI) 4 RL411–RL413

DUBAI AIR WING (DAW) 2 RD622 RG191

EL AL ISRAEL AIRLINES (ELA) 2 RD442 3 RJ152 RR225–RR226

EUROPEAN AVIATION AIR CHARTER (EUL) 2 RD135–RD138

EVA AIR (EVA) 4 RL401

EVERGREEN INTERNATIONAL A/L (EVR) 2 RB604 RB607 RD004 RD041–RD043 3 RA028 RA631 RA633 RJ131 RJ133

EXPORT RESTRICTED AIRPLANES (YWV) 1 RA101–RA103 RA112 RA161–RA162 2 RA163 RD513 RG171 3 RR001–RR004 4 RM852 RR855

Boeing ASB 747-21A2422: Revision 2

Text

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MANPOWER

REWORK OR REPLACE

DUCT ASSEMBLY

FORWARD CARGO DOOR V62344

AFX (AXL) 2 RD201 3 RR221

AGES AIRCRAFT SALES & LEASING (AGJ) 2R B 0 0 4

AIR CHINA (BEJ) 2 RD781

AIR GULF FALCON (GFG) 2R A 5 3 5 R A 5 3 7

AIR INDIA (AIN) 2R A 7 2 9 R A 7 3 1

AIR PLUS COMET (PLD) 2 RD053

AIR PULLMANTUR (PUL) 2 RD655

AIR UNIVERSAL (UVL) 2 RD649

ALBARAKA (AAB) 1R B 1 0 2

AMERICAN AIRLINES (AAL) 2R A 2 6 6

ARKIA ISRAELI AIRLINES (ARK) 1 RA253

BAHRAIN ROYAL FLIGHT (BHR) 3 RG009

BOEING CAPITAL CORPORATION (ZMF) 2 RB687 RD072 3 RJ132 RR201

CARGAIR (CGL) 2 RD203

DUBAI AIR WING (DAW) 2 RD622 RG191

EVA AIR (EVA) 4 RL401

GA TELESIS (GTG) 2 RG163

GE (GEC) 1R A 0 1 6

GE CAPITAL CORPORATION (GEF) 1 RA007 RA013 RA027

GLOBAL AIR LEASING (GAO) 2 RG164

GLOBAL PEACE INITIATIVE (GPI) 2 RG174 GRACE CATHEDRAL INC. (GCI) 2 RG193

GUGGENHEIM AVIATION PARTNERS (GPR) 2R B 6 9 7

INTERNATIONAL AIR LEASES (IAL) 2R B 0 0 6