Airworthiness Directive · Amendment 39-15108 · Boeing Model 747-400, 747-400D, and 747-400F Series Airplanes
Boeing Model 747-400, 747-400D, and 747-400F Series Airplanes
This AD applies to airplanes identified in Table 2 of this AD, certificated in any category.
| Boeing model— | As identified in Boeing Alert Service Bulletin— |
|---|---|
| (1) 747-400, 747-400D, and 747-400F series airplanes | 747-31A2351, Revision 1, dated March 17, 2005. |
| (2) 747-400 and 747-400F series airplanes | 747-31A2350, Revision 1, dated March 17, 2005. |
| (3) 747-400 and 747-400F series airplanes | 747-31A2352, Revision 1, dated March 17, 2005. |
The FAA is superseding an existing airworthiness directive (AD), which applies to all Boeing Model 747-400, -400D, and -400F series airplanes. That AD currently requires revising the airplane flight manual (AFM) to require the flightcrew to maintain certain minimum fuel levels in the center fuel tanks, and to prohibit the use of the horizontal stabilizer fuel tank. This new AD requires installing new integrated display system (IDS) software; and also requires revising the AFM to include procedures to prevent dry operation of the center wing and horizontal stabilizer fuel tanks, for maintaining minimum fuel levels, and for de-fueling fuel tanks. For certain airplanes, this new AD also requires removing certain program pin ground wires of the IDS. This AD results from fuel system reviews conducted by the manufacturer. We are issuing this AD to reduce the potential for ignition sources inside fuel tanks, which, in combination with flammable fuel vapors, could result in fuel tank explosions and consequent loss of the airplane.
You are responsible for having the actions required by this AD performed within the compliance times specified, unless the actions have already been done.
Within 4 days after receipt of emergency AD 2002-24-51, instead of complying with the requirements of paragraph (d) of AD 2002-24-51, revise the Limitations section of the AFM to include the following (this may be accomplished by inserting a copy of this AD into the AFM):
Fueling and use of the horizontal stabilizer tank (if installed) is prohibited.
The center wing tank (CWT) must contain a minimum of 17,000 pounds (7,700 kilograms) prior to engine start, if the CWT override/jettison pumps are to be selected ON during flight.
The CWT fuel quantity indication system must be operative to dispatch with CWT mission fuel.
Both CWT override/jettison pump switches must be selected OFF at or before CWT fuel quantity reaches 7,000 pounds (3,200 kilograms), if CWT fuel quantity is less than 50,000 pounds (22,700 kilograms) prior to engine start. The CWT override pumps may be selected ON during stabilized cruise conditions. Both CWT override/jettison pump switches must be selected OFF at or before the CWT fuel quantity reaches 3,000 pounds (1,400 kilograms).
With CWT override/jettison pumps selected OFF and CWT fuel quantity greater than 6,000 pounds (2,800 kilograms), the FUEL OVRD CTR L & R EICAS messages will be displayed. Do not accomplish the associated non-normal procedure.
Both CWT override/jettison pump switches must be selected OFF at or before CWT fuel quantity reaches 3,000 pounds (1,400 kilograms), if CWT fuel quantity is greater than or equal to 50,000 pounds (22,700 kilograms) prior to engine start.
Both CWT override/jettison pumps must be selected OFF when either CWT override/jettison fuel pump low pressure light illuminates.
Do not reset a tripped fuel pump circuit breaker.
Do not cycle CWT override/jettison pump switches from ON to OFF to ON with any continuous low pressure indication present.
The center wing tank may be emptied normally during an emergency fuel jettison.
In a low fuel situation, both CWT override/jettison pumps may be selected ON and all CWT fuel may be used.
If a center wing tank pump fails with fuel in the center tank, accomplish the FUEL OVRD CTR L, R non-normal procedure.
If the main tanks are not full, the zero fuel gross weight of the airplane plus the weight of CWT tank fuel may exceed the maximum zero fuel gross weight by up to 7,000 pounds (3,200 kilograms) for takeoff, climb, cruise, descent, and landing, provided that the effects of balance (CG) have been considered.
When defueling any fuel tanks, the Fuel Pump Low Pressure indication lights must be monitored and the fuel pumps positioned to OFF at the first indication of fuel pump low pressure. Defueling with passengers on board is prohibited.
The limitations contained in this AD supersede any conflicting basic airplane flight manual limitations.”
(g) If an operator has already complied with AD 2002-24-51, it can comply with paragraph (f) of this AD by deleting the phrase “if a placard prohibiting its use is installed” from the first paragraph of the AFM revision required by paragraph (d) of AD 2002-24-51.
Within 6 months after the effective date of this AD, install new IDS-504 software in the integrated display units and electronic flight instrument system/engine indication and crew alerting system interface units of the flight deck, in accordance with the Accomplishment Instructions of the applicable service bulletin identified in Table 3 of this AD.
| For model— | Boeing alert service bulletin— |
|---|---|
| (1) 747-400, 747-400D, and 747-400F series airplanes | 747-31A2351, Revision 1, dated March 17, 2005. |
| (2) 747-400 and 747-400F series airplanes | 747-31A2350, Revision 1, dated March 17, 2005. |
| (3) 747-400 and 747-400F series airplanes | 747-31A2352, Revision 1, dated March 17, 2005. |
Note 1: Each service bulletin identified in Table 3 of this AD refers to Rockwell Collins Service Bulletin IDS-7000-31-49, IDS-7000-31-50, or IDS-7000-31-51; all dated June 28, 2004; as applicable; as an additional source of service information for installing the new IDS software.
(i) Installing new IDS-504 software before the effective date of this AD, in accordance with the applicable service bulletin identified in Table 4 of this AD or during production of the airplane, is acceptable for compliance with the requirements of paragraph (h) of this AD.
| For model— | Boeing alert service bulletin— |
|---|---|
| (1) 747-400, 747-400D, and 747-400F series airplanes | 747-31A2351, dated September 3, 2004. |
| (2) 747-400 and 747-400F series airplanes | 747-31A2350, dated September 3, 2004. |
| (3) 747-400 and 747-400F series airplanes | 747-31A2352, dated September 3, 2004. |
(j) For airplanes not equipped with an HST: Installing IDS-503 software before the effective date of this AD, in accordance with the applicable service bulletin identified in Table 5 of this AD, is acceptable for compliance with the requirements of paragraph (h) of this AD.
| For model— | Boeing alert service bulletin— |
|---|---|
| (1) 747-400, -400D, and -400F series airplanes | 747-31A2340, Revision 1, dated November 20, 2003. |
| (2) 747-400 and -400F series airplanes | 747-31A2341, Revision 1, dated November 20, 2003. |
| (3) 747-400 and -400F series airplanes | 747-31A2342, Revision 1, dated November 20, 2003. |
Note 2: Each service bulletin identified in Table 5 of this AD refers to Rockwell Collins Service Bulletin IDS-7000-31-46, IDS-7000-31-47, or IDS-7000-31-48; all dated April 22, 2003; as applicable; as an additional source of service information for installing the IDS-503 software.
(k) Installing IDS-505 or IDS-506 software during production of the airplane is acceptable for compliance with the requirements of paragraph (h) of this AD. Also, installing IDS-506 software as a retrofit in accordance with the applicable service bulletin identified in Table 6 of this AD, is acceptable for compliance with the requirements of paragraph (h) of this AD.
| For model— | Boeing service bulletin— |
|---|---|
| (1) 747-400, -400D, and -400F series airplanes | 747-31-2376, dated September 5, 2006. |
| (2) 747-400 and -400F series airplanes | 747-31-2377, dated September 5, 2006. |
| (3) 747-400 and -400F series airplanes | 747-31-2378, dated September 5, 2006. |
Note 3: Each service bulletin identified in Table 6 of this AD refers to Rockwell Collins Service Bulletin IDS-7000-31-52, IDS-7000-31-53, or IDS-7000-31-54; all dated August 30, 2006; as applicable; as an additional source of service information for installing the IDS-506 software.
For airplanes on which FR-HiTEMP fuel pumps have been installed in accordance with Boeing Service Bulletin 747-28-2258, dated December 19, 2003, or Revision 1, dated August 11, 2005; or in production: After installing the new IDS-504 software required by paragraph (h) of this AD and within 6 months after the effective date of this AD, remove the ground wire of the wire integration unit that corresponds to the connector and pin locations in Table 7 of this AD, in accordance with a method approved by the Manager, Seattle Aircraft Certification Office (ACO), FAA. Chapter 20-41-03 of the Boeing 747-400 Aircraft Maintenance Manual is one approved method.
| Connector | Pin |
|---|---|
| L-EIU DM7353CA | G13 |
| C-EIU DM7352CA | G13 |
| R-EIU DM7351CA | G13 |
Except as specified in paragraph (n) of this AD, concurrently with the requirements of paragraph (h) of this AD, revise the Limitations section of the AFM to include the following (this may be done by inserting a copy of this AD into the AFM):
Center Wing Tank (CWT):
The CWT fuel quantity indication system must be operative to dispatch with CWT mission fuel.
If the FUEL LO CTR L or R message is displayed both CWT override/jettison pumps must be selected OFF.
If the FUEL PRESS CTR L or R message is displayed, the corresponding CWT override/jettison pump must be selected OFF.
Note: In a low fuel situation, both CWT override/jettison pumps may be selected ON and all CWT fuel may be used.
Horizontal Stabilizer Tank (HST):
The following additional limitations must be followed if the HST is fueled and used:
The HST fuel quantity indication system must be operative to dispatch with HST mission fuel.
If the FUEL PMP STB L or R message is displayed while on the ground both HST pumps must be selected OFF.
If the FUEL LO STAB L or R message is displayed in flight the corresponding HST pump must be selected OFF.
If the FUEL PRESS STAB L or R message is displayed the corresponding HST pump must be selected OFF.
The remaining fuel in the HST must be considered unusable, and the effects of that unusable fuel on balance (CG) must be considered.
Note: In a low fuel situation, both HST transfer pumps may be selected ON and all HST fuel may be used.
Do not cycle CWT and HST pump switches from ON to OFF to ON with any continuous low pressure indication present.
Do not reset a tripped fuel pump circuit breaker.
Defueling:
Prior to defueling any fuel tanks, perform a lamp test of the respective Fuel Pump Low Pressure indication lights. When defueling, the Fuel Pump Low Pressure indication lights must be monitored and the fuel pumps positioned to OFF at the first indication of fuel pump low pressure. When defueling with passengers on board, fuel pump switches must be selected OFF at or above approximately 7,000 pounds (3,200 kilograms) for the CWT, 3,000 pounds (1,400 kilograms) for main tanks, and 2,100 pounds (1,000 kilograms) for the HST.
The above requirements apply for defueling or transferring between tanks.”
(n) For airplanes on which FR-HiTEMP fuel pumps have been installed in accordance with Boeing Service Bulletin 747-28-2258, dated December 19, 2003, or Revision 1, dated August 11, 2005; or in production: Concurrently with the requirements of paragraph (l) of this AD, revise the Limitations section of the AFM in accordance with paragraph (m) of this AD.
