Boeing ASB 767-49A0035: Revision 2, text

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Commercial Airplane Group 767 Service Bulletin Number: 767-49A0035 Date: January 16, 2003 Revision 2: June 02, 2006 ATA System: 4915 SUBJECT: AIRBORNE AUXILIARY POWER - Power Plant - APU Air Intake Duct - Dripshield Modification

BOEING PROPRIETARY, CONFIDENTIAL, AND/OR TRADE SECRET Copyright © 2003 The Boeing Company Unpublished Work - All Rights Reserved Boeing claims copyright in each page of this document only to the extent that the page contains copyrightable subject matter.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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 A. Effectivity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

1. Airplanes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

2. Spares Affected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 B. Concurrent Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 C. Reason . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 D. Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 E. Compliance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 F. Approval . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 G. Manpower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 H. Weight and Balance Changes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 I. Electrical Load Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 J. References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

1. Existing Data: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

2. Data supplied with this Service Bulletin: . . . . . . . . . . . . . . . . . . . . . . . . . 25

3. Installation Drawings Used in the Preparation of this Service Bulletin: . . . . . . . . . . 25 K. Publications Affected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 L. Interchangeability and Intermixability of Parts . . . . . . . . . . . . . . . . . . . . . . . . . 26

2. MATERIAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 A. Material - Price and Availability. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 B. Industry Support Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 C. Parts Necessary For Each Airplane . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

1. Kits/Parts: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

2. Parts and Materials Supplied by the Operator: . . . . . . . . . . . . . . . . . . . . . . 30

3. Parts Modified and Reidentified: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

4. Parts Removed and Not Replaced: . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 D. Parts Necessary to Change Spares . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 E. Special Tooling - Price and Availability. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 F. Special Tooling Necessary to do this Service Bulletin . . . . . . . . . . . . . . . . . . . . . 31

3. ACCOMPLISHMENT INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 A. GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 B. WORK INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 FIGURE 1: Modify The Aft Air-intake Duct Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . 35 FIGURE 2: Install Forward Brackets On The Aft Air-Intake Duct Assembly . . . . . . . . . . . . . . . 38 FIGURE 3: Install Aft Brackets On The Aft Air-Intake Duct Assembly . . . . . . . . . . . . . . . . . . 42 FIGURE 4: Air-Intake Duct And Dripshield Installation . . . . . . . . . . . . . . . . . . . . . . . . . 47 APPENDIX A: WET POTTING OF INSERTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 1

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Commercial Airplane Group 767 Service Bulletin Number: 767-49A0035 Revision Transmittal Sheet Date: January 16, 2003 Revision 2: June 02, 2006 ATA System: 4915 SUBJECT: AIRBORNE AUXILIARY POWER - Power Plant - APU Air Intake Duct - Dripshield Modification This revision includes all pages of the service bulletin.

COMPLIANCE INFORMATION RELATED TO THIS REVISION No more work is necessary on airplanes changed as shown in the previous revisions of this service bulletin.

REASON FOR REVISION The data given in Information Notice 767-49-0035 IN 02 is included in this revision. The Information Notice advised operators that it was unnecessary to remove the forward intake duct. The steps to remove the forward intake duct have been removed from the Accomplishment Instructions and from Figure 1.

Validation information has been added to the Reason and Background paragraphs.

The manpower required for the airplane rework has been reduced from 3.0 hours to 2.0 hours.

A note has been added to Figure 1 to make it easier to remove the aft air-intake duct.

A note to show the reason for the large fastener holes has been added to Figure 2.

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.

REVISION HISTORY Original Issue: January 16, 2003 Revision 1: December 11, 2003 Revision 2: June 2, 2006

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Commercial Airplane Group 767 Service Bulletin Number: 767-49A0035 Summary Date: January 16, 2003 Revision 2: June 02, 2006 ATA System: 4915 SUBJECT: AIRBORNE AUXILIARY POWER - Power Plant - APU Air Intake Duct - Dripshield Modification

CONCURRENT REQUIREMENTS None.

BACKGROUND Boeing Service Related Problem (SRP) 767-27-0147 is related to this service bulletin.

Incorporation of this change will prevent APU air intake duct water leakage from contributing to stiff operation of the elevator pitch control system and any other related pitch control issues.

Two instances of stiff operation of the elevator pitch control system have been reported. An investigation revealed that water can occasionally leak from the joint, in the air-intake duct for the Auxiliary Power Unit (APU), aft of Station 1809.5. The water can leak from the duct joint onto the elevator center-auto-pilot servo Linear Variable Differential Transducer (LVDT).

A dripshield can be installed under the aft air-intake duct to prevent water from reaching the LVDT.

As a part of a service bulletin validation program, this change was completed on airplane VN027 by Revision 01 of this service bulletin.

ACTION (PRR B12901-029S) The 015T1729-8 Top Kits have been placed under management control, such that one 015T1729-8 Top Kit is available to each operator to use as a first incorporation unit in order to generate a spare unit for component rework. This will minimize airplane downtime and lessen the impact to maintenance operations.

Follow accomplishment instructions under “Component Work - Aft Air-Intake Duct Assembly Modification” to rework an existing Aft Air-intake Duct assembly into the equivalent production aft Air-intake Duct assembly. Use components from the 015T1729-7 Top Kit.

Follow accomplishment instructions under “Airplane Work - Duct Replacement And Dripshield Installation” to install a new Dripshield on either a new 353T0252-11 Aft Air-intake Duct, from a 015T1729-8 Top Kit, or a reworked Aft Air-intake Duct made from a 015T1729-7 Top Kit.

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EFFECTIVITY All 767airplanes, line numbers 1 through 890, except 767-400ER airplanes.

COMPLIANCE Boeing recommends incorporation of this service bulletin at a convenient opportunity when airplane and manpower are available, not to exceed 18 months after the receipt of revision one of this service bulletin.

INDUSTRY SUPPORT INFORMATION Boeing warranty remedies are available for airplanes in warranty as of April 27, 2001. Please refer to Paragraph 2.B., Industry Support Information.

MANPOWER

MATERIAL INFORMATION Boeing Supplied Kits/Parts.

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

Airplanes Total Task Hours Elapsed Hours Airplane Work - Duct Replacement And Dripshield Installation

2.0 2.0 Components Total Task Hours Elapsed Hours Component Work - Aft Air- Intake Duct Assembly Modification

1.0 1.0

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FWD

DUCT ASSEMBLY

AFT AIR-INTAKE

REWORK AN EXISTING

EITHER REPLACE OR STA 1843

INSTALL A NEW

DRIPSHIELD SEE A A V86832

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1. PLANNING INFORMATION A. Effectivity

1. Airplanes Refer to Service Bulletin Index Document D6-24T001 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 B12901-29S for data about this change.

Airplane models:

767-200 767-300 767-300F

IDENTIFICATION BY CUSTOMER, CUSTOMER CODE, GROUP AND VARIABLE NUMBER 767 AIRCRAFT ONE, INC. (ONI) 1 VA510–VA512

ABX AIR (ABX) 1 VA301 VA304 VA803 VA807–VA809 VB101–VB123 VB125 VB302

AEROFLOT (ARO) 1 VN471–VN472 VS216–VS217 VS321–VS324 VS392

AEROMEXICO (AMX) 1 VF071–VF072 VF091 VF093 VS211

GROUP CONFIGURATION DESCRIPTION 1 - All 767airplanes, line numbers 1 through 890, except 767-400ER airplanes.

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AEROSVIT (UKA) 1V N 1 5 5 V N 1 5 7

AEROTURBINE (AUB) 1 VB051 VB054–VB055 VB321–VB322

AIR ALGERIE (ALG) 1 VK131–VK133

AIR ATLANTA EUROPE LIMITED (AUP) 1 VB326–VB327 VL011

AIR ATLANTA ICELANDIC (AID) 1V N 1 5 3 V N 5 5 7

AIR CANADA (ACN) 1 VA701–VA709 VA711–VA719 VB001–VB002 VB201–VB202 VN051–VN054 VN056–VN062 VN531 VN536 VN541–VN542 VN546–VN547 VN751–VN752 VN811–VN812 VN931–VN936 VS381–VS382 VS546–VS549

AIR CHINA (BEJ) 1 VE064 VE083–VE086 VK161–VK164 VN388 VS206 VS208 VS274 VS307

AIR DO (HIA) 1 VS176–VS177

AIR EUROPA (ARE) 1 VN421 VS291–VS293

AIR GABON (GBN) 1 VE021

AIR MADAGASCAR (MAD) 1V N 1 6 7 V N 7 3 1

AIR MAURITIUS (MAU) 1 VF001–VF002

AIR NEW ZEALAND (ANZ) 1 VN652–VN658 VS112–VS113

AIR NIUGINI (NIU) 1V N 6 5 1

AIR PACIFIC (APC) 1V N 6 7 6

AIR SAHARA (SAQ) 1V N 4 9 5

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