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Commercial Airplanes 767 Service Bulletin ALERT Number: 767-21A0253 Original Issue: October 12, 2012 ATA System: 2158 SUBJECT: AIR CONDITIONING - Equipment Cooling System - Installation of Flight Deck Air Relief System and 3-Way Valve Logic Change 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 © 2012 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Unpublished Work.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, KDC-10, MD-10, MD-11, MD-80, MD-88, MD-90, P-8A, 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. BOEING is a trademark of Boeing Management Company.
Original Issue: October 12, 2012 767-21A0253 1 of 66
3.0
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: October 12, 2012 767-21A0253 2 of 66 BOEING SERVICE BULLETIN 767-21A0253
ALERTALERT
BLANK PAGE
Table of Contents
Summary5
1. PLANNING INFORMATION9
A. Effectivity9
1. Airplanes9
2. Spares Affected9
B. Concurrent Requirements9
C. Reason ................................................ 1 0 D. Description .............................................. 1 0 E. Compliance .............................................. 1 1 F. Approval ............................................... 1 1 G. Manpower .............................................. 1 1 H. Weight and Balance Changes .................................... 1 2 I. Electrical Load Data ......................................... 1 2 J. References .............................................. 1 2
1. Existing Data: ......................................... 1 2
2. Data Supplied with this Service Bulletin: ........................... 1 2
3. Installation Drawings Used in the Preparation of this Service Bulletin: ........... 1 3 K. Publications Affected ........................................ 1 3 L. Interchangeability and Intermixability of Parts ........................... 1 3 M. Software Accomplishment Summary ................................ 1 3
2. MATERIAL INFORMATION ........................................ 1 5 A. Material - Price and Availability ................................... 1 5 B. Industry Support Information .................................... 1 5 C. Parts Necessary for Each Airplane ................................. 1 5
1. Kits/Parts ............................................ 1 5
2. Parts and Materials Supplied by the Operator ........................ 2 0
3. Parts Modified and Reidentified ................................ 2 0
4. Parts Removed and Not Replaced .............................. 2 0 D. Parts Necessary to Change Spares ................................. 2 0 E. Special Tooling - Price and Availability ............................... 2 0 F. Special Tooling Necessary to do this Service Bulletin ....................... 2 0
3. ACCOMPLISHMENT INSTRUCTIONS .................................. 2 1 A. GENERAL INFORMATION ..................................... 2 1 B. WORK INSTRUCTIONS ....................................... 2 2 FIGURE 1: EXISTING DUCT REPLACEMENT .............................. 2 3 FIGURE 2: ADDITIONAL DUCT AND VALVE INSTALLATION ..................... 2 9 FIGURE 3: WIRE DELETION IN PANEL P50 ............................... 3 6 FIGURE 4: WIRE DELETION BETWEEN PANEL P36 AND PANEL P50 ................ 3 7 FIGURE 5: WIRE AND CONNECTOR ADDITION BETWEEN PANEL P36 AND NEW VALVE (WIRE DIAGRAM) ........................................... 3 8 FIGURE 6: WIRE CHANGE FOR EXISTING MANIFOLD INTERCONNECT VALVE (WIRE DIAGRAM) . 40 FIGURE 7: WIRE CHANGE IN PANEL P36 (WIRE DIGRAM) ...................... 4 3 FIGURE 8: CHANGE TO RELAY INSTALLATION IN PANEL P36 .................... 4 6 FIGURE 9: INSTALLATION OF NEW ALTITUDE SWITCH AND PITOT TUBE ............. 5 0 FIGURE 10: CONNECTION OF EXISTING WIRING TO ALTITUDE SWITCH .............. 5 3 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: October 12, 2012 767-21A0253 3 of 66 BOEING SERVICE BULLETIN 767-21A0253
ALERTALERT
FIGURE 11: INSTALLATION OF WIRE BETWEEN PANELS AND EQUIPMENT ............ 5 4 FIGURE 12: INSTALLATION OF WIRE WITHIN PANEL P36 ....................... 6 1 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: October 12, 2012 767-21A0253 4 of 66 BOEING SERVICE BULLETIN 767-21A0253
ALERTALERT
Commercial Airplanes 767 Service Bulletin ALERT SummaryNumber: 767-21A0253Original Issue: October 12, 2012 ATA System: 2158 SUBJECT: AIR CONDITIONING - Equipment Cooling System - Installation of Flight Deck Air Relief System and 3-Way Valve Logic Change
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 is sent to reduce malfunctions of flight compartment display units. Blanking, blurring, or loss of color caused by moisture or condensation being collected inside the display units can occur during operation in hot and humid environments. Flight compartment indication blanking can cause unscheduled maintenance and airplane downtime. More importantly, loss of the primary attitude information on both primary display units could lead to flight crew confusion and difficulty in the transition to standby attitude indication. If this service bulletin is not done, and primary display blanking occurs, the flight crew would be required to transition from primary attitude indication to standby attitude indication during a critical phase of flight which could contribute to an unsafe flight condition.
Operators of 767-300F airplanes have reported display unit malfunctions such as blanking, blurring, or loss of color caused by moisture or condensation being collected inside the display units during operation in hot and humid environments. The reports have included single display unit and multiple display unit malfunctions. Boeing is aware of instances that are the likely causes of display unit malfunctions related to moisture or condensation ingress. These instances are as follows; an unserviceable air conditioning pack water separation system that allowed water to be delivered to the flight compartment in the air conditioned air, a malfunction of an air conditioning pack which caused ice to be delivered to the flight compartment in the air conditioned air; and the most frequent instance was display units being cold soaked by the air conditioned air delivered from the air conditioning packs by the Electrical/Electronic cooling system through the 3-way valve in hot and humid conditions.
As a result of these findings, the control logic of the 3-way valve is changed so that the valve will open after five minutes at an altitude above 10,000 feet, and close at an altitude below 10,000 feet. Limiting the 3-way valve to open after five minutes above 10,000 feet will decrease the amount of moisture or condensation that can collect in the display units because of the reduced water content in the atmosphere at higher altitudes.
The control logic for the 3-way valve was intended to be incorporated on affected airplanes in production.
However, the noise in the flight compartment caused by the increased airflow of the 3-way valve logic system made the Traffic Alert and Collision Avoidance System (TCAS) difficult to hear. Because a solution to reduce the noise in the flight deck was not available before delivery, the 3-way valve logic system was disabled.
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: October 12, 2012 767-21A0253 5 of 66
This service bulletin installs a new Flight Deck Air Relief System (FDARS) to reduce the noise in the flight compartment and restores the 3-way valve logic to reduce the amount of moisture or condensation that can collect in the flight compartment display units and thus reduce malfunction occurrences.
Boeing Service Related Problem (SRP) 767-SRP-21-0179 is related to this service bulletin.
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 AffectedYesPublications 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 Material Paragraph 2.F., Special Tooling Necessary to do this Service Bulletin NoSpecial Tooling Required ACTION (PRR B12900-260) In the area forward of the main equipment bay and under the flight deck floor, replace a duct for equipment cooling with a duct that has an outlet port for the Flight Deck Air Relief System (FDARS) components. Install mounting brackets, FDARS ducts, orifice, outlet valve and screen. Change wiring within panel P36 and among panels and new outlet valve. Install 10,000 foot altitude switch and connect it to existing pitot tubing and wiring.
Do an operational test.
EFFECTIVITY 767-300F Airplane(s). 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.
Boeing recommends that the change given in this service bulletin be done within 72 months after the original issue date of this service bulletin.
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: October 12, 2012 767-21A0253 6 of 66 BOEING SERVICE BULLETIN 767-21A0253
ALERTALERT
INDUSTRY SUPPORT INFORMATION Boeing warranty remedies are available for airplanes in warranty as of July 29, 2009. Please refer to Paragraph
2.B., Industry Support Information.
MANPOWER Elapsed HoursTotal Task HoursAirplanes
42.0076.35All
MATERIAL INFORMATION Boeing Supplied Kits/Parts.
Refer to Paragraph 2.A., Material - Price and Availability.
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: October 12, 2012 767-21A0253 7 of 66 BOEING SERVICE BULLETIN 767-21A0253
ALERTALERT
BOEING SERVICE BULLETIN 767-21A0253
ALERT ALERT
REPLACE DUCT
ADD MOUNTING BRACKETS
DUCTS, ORIFICE, OUTLET VALVE, AND SCREEN.
NOT SHOWN - ADD 10,000 FT
ALTITUDE SWITCH AND MODIFY WIRING.
FWD NBD 2182195 Original Issue: October 12, 2012 PROPRIETARY - Copyright © Unpublished Export Controlled ECCN: 9E991 - BOEING 767-21A0253 Work - See page 1 for details. 8 of 66
Commercial Airplanes 767 Service Bulletin ALERT Number: 767-21A0253 Original Issue: October 12, 2012 ATA System: 2158 SUBJECT: AIR CONDITIONING - Equipment Cooling System - Installation of Flight Deck Air Relief System and 3-Way Valve Logic Change
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 for the airplane(s) shown below. An equivalent change is on subsequent production airplanes. Refer to PRR B12900-260 for data about this change.
DESCRIPTIONCONFIGURATIONGROUP 767-300F Airplanes identified below.-1 Airplane Models:
767-300F GroupVariable Number 1VR280 - VR283
2. Spares Affected None.
B. Concurrent Requirements None.
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: October 12, 2012 767-21A0253 9 of 66
C. Reason This service bulletin is sent to reduce malfunctions of flight compartment display units. Blanking, blurring, or loss of color caused by moisture or condensation being collected inside the display units can occur during operation in hot and humid environments. Flight compartment indication blanking can cause unscheduled maintenance and airplane downtime. More importantly, loss of the primary attitude information on both primary display units could lead to flight crew confusion and difficulty in the transition to standby attitude indication. If this service bulletin is not done, and primary display blanking occurs, the flight crew would be required to transition from primary attitude indication to standby attitude indication during a critical phase of flight which could contribute to an unsafe flight condition.
Operators of 767-300F airplanes have reported display unit malfunctions such as blanking, blurring, or loss of color caused by moisture or condensation being collected inside the display units during operation in hot and humid environments. The reports have included single display unit and multiple display unit malfunctions. Boeing is aware of instances that are the likely causes of display unit malfunctions related to moisture or condensation ingress. These instances are as follows; an unserviceable air conditioning pack water separation system that allowed water to be delivered to the flight compartment in the air conditioned air, a malfunction of an air conditioning pack which caused ice to be delivered to the flight compartment in the air conditioned air; and the most frequent instance was display units being cold soaked by the air conditioned air delivered from the air conditioning packs by the Electrical/Electronic cooling system through the 3-way valve in hot and humid conditions. As a result of these findings, the control logic of the 3-way valve is changed so that the valve will open after five minutes at an altitude above 10,000 feet, and close at an altitude below 10,000 feet. Limiting the 3-way valve to open after five minutes above 10,000 feet will decrease the amount of moisture or condensation that can collect in the display units because of the reduced water content in the atmosphere at higher altitudes.
The control logic for the 3-way valve was intended to be incorporated on affected airplanes in production.
However, the noise in the flight compartment caused by the increased airflow of the 3-way valve logic system made the Traffic Alert and Collision Avoidance System (TCAS) difficult to hear. Because a solution to reduce the noise in the flight deck was not available before delivery, the 3-way valve logic system was disabled.
This service bulletin installs a new Flight Deck Air Relief System to reduce the noise in the flight compartment and restores the 3-way valve logic to reduce the amount of moisture or condensation that can collect in the flight compartment display units and thus reduce malfunction occurrences.
Boeing Service Related Problem (SRP) 767-SRP-21-0179 is related to this service bulletin.
D. Description In the area forward of the main equipment bay and under the flight deck floor, replace a duct for equipment cooling with a duct that has an outlet port for the Flight Deck Air Relief System (FDARS) components. Install mounting brackets, FDARS ducts, orifice, outlet valve and screen. Change wiring within panel P36 and among panels and new outlet valve. Install 10,000 foot altitude switch and connect it to existing pitot tubing and wiring. Do an operational test.
The changes in this service bulletin will not change the Engine Indication and Crew Alerting System (EICAS).
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: October 12, 2012 767-21A0253 10 of 66 BOEING SERVICE BULLETIN 767-21A0253
ALERTALERT
Affected Maintenance Zones ZoneModel 117, 118, 119767-300F 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.
Boeing recommends that the change given in this service bulletin be done within 72 months after the original issue date of this service bulletin.
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. 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.
G. Manpower The table below shows an estimate of the task hours necessary to do this change 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.
Elapsed HoursTask HoursNumber of PersonsTask
0.750.751Open Access
1.601.601FIGURE 1
1.751.751FIGURE 2
0.100.101FIGURE 3
0.100.101FIGURE 4
12.3824.752FIGURE 5
5.1010.202FIGURE 6 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: October 12, 2012 767-21A0253 11 of 66 BOEING SERVICE BULLETIN 767-21A0253
ALERTALERT
Elapsed HoursTask HoursNumber of PersonsTask
16.8833.752FIGURE 7
1.501.501FIGURE 8
0.500.501FIGURE 9
0.100.101FIGURE 10
0.500.501Test
0.750.751Close Access
42.0076.35TOTAL FOR EACH AIRPLANE H. Weight and Balance Changes Change in Moment (Pound-Inches) Change in Weight (Pounds)Airplane + 966.1+ 7.0All I. Electrical Load Data Not changed.
J. References
1. Existing Data:
a. Engineering Change Memo PRR B12900-260
b. Boeing Service Related Problem (SRP) 767-SRP-21-0179
c. Service Bulletin Index D624T001
d. Standard Overhaul Practices Manual (SOPM) 20-50-10
e. Standard Wiring Practices Manual (SWPM) 20-10-11, 20-10-12, 20-10-19, 20-20-10, 20-61-11, 20-81-19, 20-81-22, 20-90-11
f. 767 Aircraft Maintenance Manual (AMM) 20-10-12, 20-10-33, 21-22-02, 21-58-00, 24-22-00, 25-00-00
g. 767 Wiring Diagram Manual (WDM) 21-58-16, 21-58-41
2. Data Supplied with this Service Bulletin:
None.
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: October 12, 2012 767-21A0253 12 of 66 BOEING SERVICE BULLETIN 767-21A0253