Boeing ASB 767-51A0027: Revision 1, text

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Commercial Airplane Group 767 Service Bulletin Number: 767-51A0027 Date: December 09, 2004 Revision 1: October 12, 2006 ATA System: 5141 SUBJECT: STRUCTURES - Airframe Drainage - Horizontal Stabilizer Center Section - Gutter Installation

BOEING PROPRIETARY, CONFIDENTIAL, AND/OR TRADE SECRET Copyright © 2004 The Boeing Company Unpublished Work - All Rights Reserved Boeing claims copyright in each page of this document only to the extent that the page contains copyrightable subject matter.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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 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: . . . . . . . . . . . . . . . . . . . . . . . . . 26

3. Installation Drawings Used in the Preparation of this Service Bulletin: . . . . . . . . . . 26 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: . . . . . . . . . . . . . . . . . . . . . . 29

3. Parts Modified and Reidentified: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

4. Parts Removed and Not Replaced: . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 D. Parts Necessary to Change Spares . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 E. Special Tooling - Price and Availability. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 F. Special Tooling Necessary to do this Service Bulletin . . . . . . . . . . . . . . . . . . . . . 30

3. ACCOMPLISHMENT INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 A. GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 B. WORK INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 FIGURE 1: GUTTER PREPARATION AND PROTECTION . . . . . . . . . . . . . . . . . . . . . . . 35 FIGURE 2: REWORK SIDE BRACE FITTINGS - HORIZONTAL STABILIZER CENTER SECTION . . 36 FIGURE 3: GUTTER INSTALLATION - UPPE R SURFACE, HORIZONTAL STABILIZER CENTER SECTION - LEFT SIDE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 FIGURE 4: GUTTER INSTALLATION - UPPE R SURFACE, HORIZONTAL STABILIZER CENTER SECTION - RIGHT SIDE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42 FIGURE 5: SPLICE INSTALLATION - HORIZONTAL STABILIZER CENTER SECTION. . . . . . . . 45 FIGURE 6: DISCONNECT HYDRAULIC LINES - HORIZONTAL STABILIZER CENTER SECTION . . 50 FIGURE 7: GUTTER PREPARATION - LOCATOR IDENTIFICATION . . . . . . . . . . . . . . . . . 52 FIGURE 8: GUTTER INSTALLATION - UPPE R SURFACE, HORIZONTAL STABILIZER CENTER SECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

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FIGURE 9: GUTTER SEALING - HORIZONTAL STABILIZER CENTER SECTION. . . . . . . . . . . 59 FIGURE 10: CONNECT HYDRAULIC LINES - HORIZONTAL STABILIZER CENTER SECTION . . . 61

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Commercial Airplane Group 767 Service Bulletin Number: 767-51A0027 Revision Transmittal Sheet Date: December 09, 2004 Revision 1: October 12, 2006 ATA System: 5141 SUBJECT: STRUCTURES - Airframe Drainage - Horizontal Stabilizer Center Section - Gutter Installation 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 initial release of this service bulletin.

Federal Aviation Administration (FAA) Notice of Proposed Rule Making 2005-NM-058-AD is related to this service bulletin.

REASON FOR REVISION This revision is sent to improve the work instructions as a result of access restrictions found during the service bulletin validation. Additionally, based on one other operator report revision 1 is sent to provide instructions to install the gutter as a one piece assembly. Instructions throughout the service bulletin are changed to provide two options to install the gutter as one piece or as two pieces.

As a part of a service bulletin validation program, this change was completed on airplane VN097 by Service Bulletin 767-51A0027 before the release of Revision 1 of this service bulletin. In the validation the gutter was installed in two pieces. The change completed on airplane VN097 by Service Bulletin 767-51A0027 is equivalent to the release of Revision 1 of this service bulletin.

Changes to this service bulletin include:

– References to a FAA Notice of Proposed Rule Making are added throughout the service bulletin.

– Material Information - A new 180T3250-9 gutter assembly is added. The 180T3250-4 gutter assembly is optional to the 180T3250-9 gutter assembly. The Boeing drawing number and parts modified and reidentified are changed. The quantity of optional rivets supplied by the operator is reduced.

– Accomplishment Instructions - An additional access door is added. Maintenance manual references to test the elevator control system, elevator power control actuator and autopilot systems are added. A stabilizer tool reference has been removed as it is acceptable to use another lock tool. A maintenance manual reference to install the service platform is changed.

– Figure 1 is changed to add a dimension for the gutter assembly cut location.

– Figure 2 is changed to give rework instructions if cracks are found and to add an alternative high frequency eddy current inspection for cracks. The two possible side brace fittings installed after the rework are identified.

– Figures 3 and 4 are changed to remove the option to install rivets and to change the quantity of hi loks used to install the gutter assembly at each hydraulic bracket.

– Figure 6 is added to disconnect and move the hydraulic lines at the hydraulic control brackets.

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– Figure 7 is added to identify a locator mark on the gutter when installing the gutter as one piece.

– Figure 8 is added to install the gutter as one piece.

– Figure 9 is added to apply sealant between the upper spar chord and gutter when installing the gutter as one piece.

– Figure 10 is added to connect the hydraulic lines at the hydraulic control brackets.

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: December 09, 2004 Revision 1: October 12, 2006

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Commercial Airplane Group 767 Service Bulletin Number: 767-51A0027 Summary Date: December 09, 2004 Revision 1: October 12, 2006 ATA System: 5141 SUBJECT: STRUCTURES - Airframe Drainage - Horizontal Stabilizer Center Section - Gutter Installation

CONCURRENT REQUIREMENTS None.

BACKGROUND This service bulletin gives instructions to install a gutter on the horizontal stabilizer center section. This gutter will channel water that enters Section 48 at the side of body seals away from the elevator control system components aft of the horizontal stabilizer. This will make it less likely that ice can accumulate on the elevator control system components. Ice on the elevator systems can restrict elevator movement which limits the ability of the flight crew to make elevator control inputs, resulting in reduced controllability of the airplane.

Boeing has received three reports of stiff or jammed elevator controls. Analysis of all three reports indicated that ice had formed on the elevator control components aft of the horizontal stabilizer, which restricted the movement of the elevator controls. Water was found to get into Section 48 of the airplane through the fairing panels at the side of the body. The ice then formed from water that had accumulated on the horizontal stabilizer center section. In one case, the water accumulated due to a leak in the Auxiliary Power Unit (APU) inlet duct. In another case, the water came from a leak in a galley water drain line.

Airplane line numbers 1 through 110 have side of body seal doors that do not allow water to enter Section 48 and therefore, are not subject to this service bulletin. After line number 921, a gutter is installed on the horizontal stabilizer center section in production.

Accomplishment of the modification shown in this service bulletin will make it less likely that movement of the elevator control system will be restricted due to the accumulation of ice on the elevator control system components aft of the horizontal stabilizer center section.

As a part of a service bulletin validation program, this change was completed on airplane VN097 by Service Bulletin 767-51A0027 before the release of Revision 1 of this service bulletin. The change completed on airplane VN097 by Service Bulletin 767-51A0027 is equivalent to the release of Revision 1 of this service bulletin.

The related 767-400ER Boeing service bulletin is 767-51A0028.

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

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ACTION (PRR B12901-51S) Get access to the horizontal stabilizer center section through the service doors 312AR and 313AL. Disconnect 6 hydraulic lines. Rework the horizontal stabilizer side brace fittings to enlarge the drain holes.

Option 1: Install the gutter as two pieces along the rear spar upper chord of the horizontal stabilizer center section, on the controls brackets. Seal the gap between the gutter sections. Install two splices to re-join the gutter sections using shims between mating surfaces. Apply sealant between the gutter, the rear upper spar chord and splices.

Option 2: Install the gutter as one piece along the rear spar upper chord of the horizontal stabilizer center section, on the controls brackets. Apply sealant between the gutter and the rear upper spar chord.

Do system tests of the elevator control system, elevator power control actuator and autopilot systems.

EFFECTIVITY 767-200, 767-300 and 767-300F airplanes line number 111 through 921. Refer to Paragraph 1.A.1., Airplanes for the list of affected airplanes.

COMPLIANCE Boeing recommends that operators accomplish the modifications shown in this bulletin within five years after the issue date of initial release of this service bulletin.

FAA Notice of Proposed Rule Making 2005-NM-058-AD is related to 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 available for airplanes in warranty as of April 27, 2001. Please refer to Paragraph

2.B., Industry Support Information.

MANPOWER Refer to Paragraph 1.G., Manpower.

MATERIAL INFORMATION Boeing Supplied Kits/Parts.

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

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STABILIZER CENTER SECTION

TO THE HORIZONTAL

INSTALL GUTTER ASSEMBLY FWD UP 422228

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1. PLANNING INFORMATION A. Effectivity

1. Airplanes Refer to Service Bulletin Index Document D624T001 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 B12901-51S for data about this change.

Airplane models:

767-200 767-300 767-300F

IDENTIFICATION BY CUSTOMER, CUSTOMER CODE, GROUP AND VARIABLE NUMBER AA 767 LLC (SVX) 1V E 0 6 7

ABX AIR (ABX) 1 VB117–VB123 VB125

AEROFLOT (ARO) 1 VL896 VN471–VN472 VS216–VS217 VS321–VS324 VS392

AEROMEXICO (AMX) 1 VF071 VF093 VS211

GROUP CONFIGURATION DESCRIPTION 1 - 767-200, 767-300 and 767-300F airplanes, line number 111 through 921.

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AEROSVIT (UKA) 1 VN155 VN157

AIR ALGERIE (ALG) 1 VK131–VK133

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

AIR ATLANTA ICELANDIC (AID) 1 VN153

AIR CANADA (ACN) 1 VA713–VA719 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 VN638 VS291–VS293

AIR MADAGASCAR (MAD) 1 VN167 VN731

AIR MAURITIUS (MAU) 1 VF001–VF002

AIR NEW ZEALAND (ANZ) 1 VN653–VN658 VS113

AIR NIUGINI (NIU) 1 VN651

AIR PACIFIC (APC) 1 VN676

AIR SAHARA (SAQ) 1 VN495

AIR SEYCHELLES (ASY) 1 VL941 VS526

AIR TRANSPORT INTERNATIONAL (TIN) 1 VA512–VA513

AIR ZIMBABWE (ZMB) 1 VF061–VF062

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