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Section - Gutter Installation BOEING PROPRIETARY, CONFIDENTIAL, AND/OR TRADE SECRET Copyright © 2004 The Boeing Company Unpublished Work - All Rights Reserved Boeing claims copyright in each page of this document only to the extent that the page contains copyrightable subject matter.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. December 09, 2004 Revision 1: October 12, 2006 767-51A0027 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 1 of 62 BOEING SERVICE BULLETIN 767-51A0027 BLANK PAGE BLANK PAGE December 09, 2004 Revision 1: October 12, 2006 767-51A0027 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 2 of 62 BOEING SERVICE BULLETIN 767-51A0027 Table of Contents Revision Transmittal Sheet . 5 Summary . 7 1.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 - UPPER SURFACE, HORIZONTAL STABILIZER CENTER SECTION - LEFT SIDE . 38 FIGURE 4: GUTTER INSTALLATION - UPPER 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 - UPPER SURFACE, HORIZONTAL STABILIZER CENTER SECTION . 53 Table of Contents December 09, 2004 Revision 1: October 12, 2006 767-51A0027 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 3 of 62 BOEING SERVICE BULLETIN 767-51A0027 FIGURE 9: GUTTER SEALING - HORIZONTAL STABILIZER CENTER SECTION. 59 FIGURE 10: CONNECT HYDRAULIC LINES - HORIZONTAL STABILIZER CENTER SECTION . 61 Table of Contents December 09, 2004 Revision 1: October 12, 2006 767-51A0027 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 4 of 62 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. December 09, 2004 Revision 1: October 12, 2006 767-51A0027 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 5 of 62 BOEING SERVICE BULLETIN 767-51A0027 – 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 December 09, 2004 Revision 1: October 12, 2006 767-51A0027 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 6 of 62 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