Airworthiness Directive · Amendment 39-15344 · Boeing Model 747-400, -400D, and -400F Series Airplanes; Boeing Model 757 Airplanes; and Boeing Model 767 Airplanes
Boeing Model 747-400, -400D, and -400F Series Airplanes; Boeing Model 757 Airplanes; and Boeing Model 767 Airplanes
This AD applies to Boeing airplanes listed in Table 1 of this AD, certificated in any category.
| Model— | As identified in Boeing Alert Service Bulletin— |
|---|---|
| 747-400, -400D, and -400F series airplanes | 747-33A2280, Revision 1, dated September 25, 2003. |
| 757-200, -200CB, and -200PF series airplanes | 757-33A0044, Revision 1, dated September 25, 2003. |
| 757-300 series airplanes | 757-33A0045, Revision 1, dated September 25, 2003. |
| 767-200, -300, and -300F series airplanes | 767-33A0087, Revision 1, dated September 25, 2003. |
| 767-400ER series airplanes | 767-33A0088, including Appendix A, dated December 19, 2001. |
The FAA is adopting a new airworthiness directive (AD) for certain Boeing airplanes listed above. This AD requires an inspection of certain lighted pushbutton switches in the flight compartment for configuration `D' master modules and part numbers and corrective action if necessary. This AD also provides an option to inspect panel assemblies for part numbers. This AD results from a report indicating that the integrated drive generator failed in flight due to a possible switch malfunction. We are issuing this AD to ensure that certain lighted pushbutton switches in the flight compartment do not malfunction and cause the flightcrew to be unable to control critical airplane systems and continue safe airplane operation.
You are responsible for having the actions required by this AD performed within the compliance times specified, unless the actions have already been done.
The term “the service bulletin,” as used in this AD, means the Accomplishment Instructions of the service bulletins listed in Table 1 of this AD, as applicable.
Note 1: The Boeing service bulletins refer to Korry Service Bulletin 433-33-05, dated July 23, 2001, as an additional source of service information for finding configuration ‘D' switches, for replacing the switch master module with a configuration ‘D' master module, and for doing various operational tests after the replacement.
The Boeing service bulletins listed in Table 1 of this AD refer to the Boeing component service bulletins specified in Table 2 of this AD as additional sources of service information for replacing the switch or switch master module at critical locations, for doing operational tests after the replacement, and for identifying new panel part numbers.
| Boeing Component Service Bulletin— | Date— | Model— | Critical location— |
|---|---|---|---|
| 233N3203-21-01, Revision 1 | September 25, 2003 | 757 airplanes | Equipment Cooling Panel. |
| 233N3204-30-02, Revision 1 | September 25, 2003 | 757 airplanes | Anti-ice Panel. |
| 233N3206-28-02, Revision 1 | September 25, 2003 | 757-200, -200CB, and -200PF series airplanes | Fuel Control Panel. |
| 233N3209-24-03, Revision 1 | September 25, 2003 | 757 airplanes and 767-200, -300, and -300F series airplanes | Electrical Systems Panel. |
| 233N3211-24-02, Revision 1 | September 25, 2003 | 757 airplanes and 767 airplanes | Battery/Standby Power Panel. |
| 233N3215-36-01, Revision 1 | September 25, 2003 | 757 airplanes | Bleed Air Panel Assembly. |
| 233N3216-22-01, Revision 1 | September 25, 2003 | 757 airplanes and 767 airplanes | Yaw Damper Panel Assembly. |
| 233N3219-33-01, including Appendix A | December 19, 2001 | 757-200, -200CB, and -200PF series airplanes | Emergency Lights/Passenger Oxygen Panel. |
| 233N3223-31-03, Revision 1 | September 25, 2003 | 757 airplanes | Engine Start/Ram Air Turbine Panel Assembly. |
| 233N3224-73-01, Revision 1 | September 25, 2003 | 757-200, -200CB, and -200PF series airplanes | Electronic Engine Control Power Panel Assembly. |
| 233N6203-26-10, Revision 1 | September 25, 2003 | 757 airplanes and 767-200, -300, and -300F series airplanes | Auxiliary Power Unit/Cargo Fire Control Panel Assembly. |
| 233T3210-33-01, Revision 1 | September 25, 2003 | 757 airplanes and 767 airplanes | Emergency Lights Panel. |
| 233T3215-24-01, including Appendix A | December 19, 2001 | 767-400ER series airplanes | Electrical Control Module Assembly. |
| 233T3235-28-05, Revision 1 | September 25, 2003 | 767-200, -300, and -300F series airplanes | Fuel Management Panel Assembly. |
| 233T3236-21-05, Revision 1 | September 25, 2003 | 767 airplanes | Temperature Control Panel. |
| 233T3237-36-04, Revision 1 | September 25, 2003 | 767 airplanes | Bleed Air Control Panel. |
| 233T3241-30-03, Revision 1 | September 25, 2003 | 757-200, -200CB, and -200PF series airplanes, and 767-200, -300, and -300F series airplanes | Wing and Engine Anti-ice Control Panel. |
| 233T3242-73-02, Revision 1 | September 25, 2003 | 757 airplanes and 767-200, -300, and -300F series airplanes | Electronic Engine Control Panel. |
| 233T3244-74-03, Revision 1 | September 25, 2003 | 767 airplanes | Engine Ignition and Start Control Panel. |
| 233T6211-26-01, including Appendix A | December 19, 2001 | 767-400ER series airplanes | Auxiliary Power Unit and Cargo Fire Control Module Assembly. |
| 233U3201-30-04, Revision 1 | September 25, 2003 | 747-400, -400D, and -400F series airplanes | Rain Removal/Anti-ice Module. |
| 233U3202-24-02, Revision 1 | September 25, 2003 | 747-400, -400D, and -400F series airplanes | Electrical and Standby Power/Auxiliary Power Unit Start Module. |
| 233U3203-36-01, Revision 1 | September 25, 2003 | 747-400, -400D, and -400F series airplanes | Bleed Air Control Module. |
| 233U3206-28-01, Revision 1 | September 25, 2003 | 747-400, -400D, and -400F series airplanes | Engine Ignition Control/Fuel Jettison Module. |
| 233U3208-22-02, Revision 1 | September 25, 2003 | 747-400, -400D, and -400F series airplanes | Passenger Oxygen and Yaw Damper Module. |
| 233U3214-26-06, Revision 1 | September 25, 2003 | 747-400, -400D, and -400F series airplanes | Fire Control Module. |
| 257U0002-32-04, including Appendix A | December 19, 2001 | 747-400, -400D, and -400F series airplanes | Landing Gear Actuator Control Lever Module Assembly. |
Within 60 months after the effective date of this AD: Do a general visual inspection of the switches specified in paragraphs (h)(1), (h)(2), (h)(3), (h)(4), and (h)(5) of this AD, as applicable, to identify configuration ‘D' master modules and the part number (P/N) of the switch, in accordance with the applicable service bulletin, except as provided by paragraph (i) of this AD.
Note 2: For the purposes of this AD, a general visual inspection is “A visual examination of a interior or exterior area, installation or assembly to detect obvious damage, failure or irregularity. This level of inspection is made from within touching distance unless otherwise specified. A mirror may be necessary to ensure visual access to all surfaces in the inspection area. This level of inspection is made under normal available lighting conditions such as daylight, hangar lighting, flashlight or drop-light and may require removal or opening of access panels or doors. Stands, ladders or platforms may be required to gain proximity to the area being checked.”
(1) For Model 757-200, -200CB, and -200PF series airplanes: Switches identified in step 1 and step 3 of Figure 1 of Boeing Alert Service Bulletin 757-33A0044, Revision 1, dated September 25, 2003.
(2) For Model 757-300 series airplanes: Switches identified in step 1 of Figure 1 of Boeing Alert Service Bulletin 757-33A0045, Revision 1, dated September 25, 2003.
(3) For Model 767-200, -300, and -300F series airplanes: Switches identified in step 1 of Figure 1 of Boeing Alert Service Bulletin 767-33A0087, Revision 1, dated September 25, 2003.
(4) For Model 767-400ER series airplanes: Switches identified in step 1 of Figure 1 of Boeing Alert Service Bulletin 767-33A0088, dated December 19, 2001.
(5) For all airplanes: Switches identified for the panel assemblies specified in the applicable service bulletin.
(i) Instead of doing the inspection required by paragraph (h) of this AD, operators may inspect the part number of the panel assemblies specified in paragraphs (i)(1) and (i)(2) of this AD, as applicable, at the time specified in paragraph (h) of this AD. If the part number is identified as a new part number in paragraph 2.E. “Existing Parts Accountability” or Appendix B of the applicable service bulletin, no further action is required. If the part number is not identified as a new part number, the inspection required by paragraph (h) of this AD must be done at the specified time.
(1) For switches identified in paragraphs (h)(1), (h)(2), (h)(3), and (h)(4) of this AD: P3-1 and P10 panel assemblies, as applicable.
(2) For switches identified in paragraph (h)(5) of this AD: The panel assemblies identified in the applicable service bulletin.
If during any inspection required by paragraph (h) of this AD, any switch is found that does not have a configuration ‘D' switch master module and no switch part number specified in paragraph (j)(1)(i) or (j)(1)(ii) of this AD is found: Before further flight, do the actions specified in either paragraph (j)(1) or (j)(2) of this AD and do the part number revision, as applicable, specified in paragraph (j)(3) of this AD.
(1) Replace the switch with a switch specified in paragraph (j)(1)(i), (j)(1)(ii), or (j)(1)(iii) of this AD, in accordance with the applicable service bulletin, except as provided by paragraph (k) of this AD.
(i) Switches having Boeing P/N S231T290-4201 through -4325 inclusive.
(ii) Switches having Korry P/N 4336731004-4201 through -4325 inclusive.
Note 3: One-to-one switch correlation between the existing switches and the new part number switches can be found in Korry Service Bulletin 433-33-06, dated November 7, 2001.
(iii) Switches that have a configuration ‘D' master module.
(2) Replace the switch master module with a new configuration ‘D' master module in accordance with the applicable service bulletin.
(3) If all switches on a panel assembly have a configuration ‘D' master module or have a switch part number specified in paragraph (j)(1)(i) or (j)(1)(ii) of this AD: Revise the part number of the panel assembly in accordance with the applicable service bulletin.
(k) If during any inspection required by paragraph (h) of this AD, a configuration ‘D' switch master module is found or the switch part number is specified in paragraph (j)(1)(i) or (j)(1)(ii) of this AD on all switches for a panel assembly: Before further flight, revise the part number of the panel assembly, in accordance with the applicable service bulletin.
If the applicable service bulletin specifies removal or installation of certain parts and does not specify removal or installation instructions: Before further flight, remove or install those parts according to a method approved by the Manager, Seattle Aircraft Certification Office (ACO), FAA, or by doing the actions specified in paragraph (l)(1) of this AD for removal or paragraph (l)(2) of this AD for installation, as applicable.
(1) Remove the module/panel assembly by doing the actions specified in paragraphs (l)(1)(i), (l)(1)(ii), and (l)(1)(iii) of this AD.
(i) Hold the module/panel assembly in position and loosen the quick-release screws.
(ii) Carefully lower the module/panel assembly from the overhead panel.
(iii) Remove the electrical connectors attached to the rear of the module/panel assembly.
(2) Install the module/panel assembly by doing the actions specified in paragraphs (l)(2)(i) and (l)(2)(ii) of this AD.
(i) Make sure that the module/panel assembly is correctly aligned, and connect the electrical connectors to the rear of the unit.
(ii) Carefully lift the module/panel assembly into position and install it with the quick-release screws.
If any panel assemblies, switches, or master modules are replaced during any action required by this AD: Before further flight, do all applicable operational tests in accordance with the applicable service bulletin, except as provided by paragraph (n) of this AD.
(n) Where paragraph 3.B.14.b.(3) of the Accomplishment Instructions of Boeing Alert Service Bulletin 747-33A2280, Revision 1, dated September 25, 2003, specifies procedures to do a test of the engine ignition control/fuel jettison module assembly, this AD requires that operators dry-motor the engine to remove the fuel from the tailpipe before doing the procedures in paragraph 3.B.14.b.(3). All fuel must be removed from the engine tailpipe before performing the test, because during the test the engine igniter will be energized.
Actions accomplished before the effective date of this AD in accordance with Boeing Alert Service Bulletin 747-33A2280, 757-33A0044, 757-33A0045, or 767-33A0087, all dated December 19, 2001, are considered acceptable for compliance with the corresponding action specified in this AD, provided that the actions specified in this AD are done on the switches for the additional panel assemblies specified in Revision 1 of the service bulletin.
The aircraft, engines and makers this AD names, by the model designations in its text. A model listed here may still be outside the AD's serial ranges.
Aircraft
