AD/B767/237 Korry Pushbutton Switches (Cth)

AIRWORTHINESS DIRECTIVE

For the reasons set out in the background section, the CASA delegate whose signature appears below issues the following Airworthiness Directive (AD) under subregulation 39.001(1) of CASR 1998.  The AD requires that the action set out in the requirement section (being action that the delegate considers necessary to correct the unsafe condition) be taken in relation to the aircraft or aeronautical product mentioned in the applicability section: (a) in the circumstances mentioned in the requirement section; and (b) in accordance with the instructions set out in the requirement section; and (c) at the time mentioned in the compliance section.

Boeing 767 Series Aeroplanes

AD/B767/237 Korry Pushbutton Switches 4/2008

Applicability:	Model 767-200, -300, -300F and -400ER series aeroplanes as identified in the Boeing Alert Service Bulletins listed at Table 1.
Table 1
Aeroplane Model	Boeing ASB
767-200, -300 and -300F series 767-400ER series	767-33A0087, Revision 1, dated 25 September 2003 767-33A0088, including Appendix A, dated 19 December 2001
Requirement:	1.    Either:
a.   Carry out a general visual inspection of the switches identified for the panel assemblies specified below to identify configuration `D' master modules and the part number (P/N) of the switch as follows:
(i)      For Model 767-200, -300 and -300F series aeroplanes - Switches identified in step 1 of Figure 1 of ASB 767-33A0087, Revision 1.
(ii)     For Model 767-400ER series aeroplanes - Switches identified in step 1 of Figure 1 of ASB 767-33A0088.
(iii)    For all aeroplanes - Switches identified for the panel assemblies specified in the applicable service bulletin.
or,
b.   Inspect the panel assemblies identified below to determine the part number (P/N).  If the P/N is identified as a new P/N in paragraph 2.E. “Existing Parts Accountability” or Appendix B of the applicable service bulletin, no further action is required.
(i)      P3-1 and P10 panel assemblies, as applicable:
(a)     For Model 767-200, -300 and -300F series aeroplanes - Switches identified in step 1 of Figure 1 of ASB 767-33A0087, Revision 1.

(b)     For Model 767-400ER series aeroplanes - Switches identified in step 1 of Figure 1 of ASB 767-33A0088.

(ii)     For all aeroplanes - Switches identified for the panel assemblies specified in the applicable service bulletin.

Note 1:  For the purposes of this Directive, a general visual inspection is "A visual examination of an 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.''

Note 2:  ASB 767-33A0087, Revision 1 and ASB 767-33A0088 refer to Korry Service Bulletin (SB) 433-33-05, dated 23 July 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.

2.    If, as a result of the Requirement 1.b. inspection, the P/N is not identified as a new P/N, the inspection required by Requirement 1.a. must be accomplished.

3.    If, during any Requirement 1.a. inspection, any switch is found that does not have a configuration `D' switch master module and the switch P/N is not specified Table 1, carry out either Requirement 3.a. or 3.b. as follows and do the part number revision in accordance with Requirement 3.c:

a.   Replace the switch with a switch specified in Table 2, in accordance with the applicable ASB as listed in Table 1, except as provided by Requirement 4.

b.   Replace the switch master module with a new configuration `D' master module in accordance with the applicable ASB as listed in Table 1.

c.   If all switches on a panel assembly have a configuration `D' master module or have a switch P/N specified Table 1 revise the P/N of the panel assembly in accordance with the applicable ASB as listed in Table 1.

Table 2

Boeing P/N S231T290-4201 through -4325 inclusive,
Korry P/N 4336731004-4201 through -4325 inclusive, or
switches that have a configuration `D' master module.

Note 3:  One-to-one switch correlation between the existing switches and the new part number switches can be found in Korry SB 433-33-06, dated 7 November 2001.

4.    If, during any Requirement 1.a. inspection, a configuration `D' switch master module is found, or the switch P/N is specified in Table 2 on all switches for a panel assembly, revise the part number of the panel assembly, in accordance with the applicable ASB as listed in Table 1.
5.    If any panel assembly, switch or master module is replaced during any action required by this Directive, carry out all applicable operational tests in accordance with the applicable ASB as listed in Table 1.
Note 4:  The Boeing ASBs listed in Table 1 refer to the Boeing component service bulletins specified in Table 3 of this Directive 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.
Table 3
Boeing Component Service Bulletin	Date	Aeroplane Model/Series	Critical Location
233N3209-24-03, Revision 1	25 September 2003	767-200, -300 and -300F	Electrical Systems Panel
233N3211-24-02, Revision 1	25 September 2003	767	Battery/Standby Power Panel
233N3216-22-01, Revision 1	25 September 2003	767	Yaw Damper Panel Assembly
233N6203-26-10, Revision 1	25 September 2003	767-200, -300 and -300F	Auxiliary Power Unit/Cargo Fire Control Panel Assembly
233T3210-33-01, Revision 1	25 September 2003	767	Emergency Lights Panel
233T3215-24-01, including Appendix A	19 December 2001	767-400ER	Electrical Control Module Assembly
233T3235-28-05, Revision 1	25 September 2003	767-200, -300 and -300F	Fuel Management Panel Assembly
233T3236-21-05, Revision 1	25 September 2003	767	Temperature Control Panel

233T3237-36-04, Revision 1	25 September 2003	767	Bleed Air Control Panel
233T3241-30-03, Revision 1	25 September 2003	767-200, -300 and -300F	Wing and Engine Anti-ice Control Panel
233T3242-73-02, Revision 1	25 September 2003	767-200, -300 and -300F	Electronic Engine Control Panel
233T3244-74-03, Revision 1	25 September 2003	767	Engine Ignition and Start Control Panel
233T6211-26-01, including Appendix A	19 December 2001	767-400ER	Auxiliary Power Unit and Cargo Fire Control Module Assembly
Actions accomplished before the effective date of this Directive in accordance with Boeing ASB 767-33A0087, dated 19 December 2001, are considered acceptable for compliance with the corresponding action specified in this Directive, provided that the actions specified in this Directive are done on the switches for the additional panel assemblies specified in Revision 1 of the service bulletin.
Later revisions of Boeing ASB 767-33A0087 or 767-33A0088, approved by the United States Federal Aviation Administration (FAA) as an Alternate Method of Compliance (AMOC) to FAA AD 2008-02-14, are considered acceptable for compliance with the equivalent Requirements of this Directive.
Note 5:  FAA AD 2008-02-14 Amdt 39-15344 refers.
Compliance:	For Requirements 1 and 2 - Within 60 months after the effective date of this Directive.
For Requirement 3, 4 and 5 - Before further flight after the Requirement 1.a. inspection.
This Airworthiness Directive becomes effective on 10 April 2008.
Background:	The FAA has received a report indicating that the integrated drive generator failed in flight due to a possible switch malfunction.  This Directive is issued to ensure that certain lighted pushbutton switches in the flight compartment do not malfunction and cause the flightcrew to be unable to control critical systems and continue safe operation of the aeroplane.

The Directive requires an inspection of certain lighted pushbutton switches in the flight compartment for configuration `D' master modules and part numbers together with any necessary corrective action.  The Directive also provides an option to inspect panel assemblies for part numbers.

David Punshon
Delegate of the Civil Aviation Safety Authority

28 February 2008