[Federal Register Volume 61, Number 156 (Monday, August 12, 1996)]
[Rules and Regulations]
[Pages 41733-41735]
From the Federal Register Online via the Government Publishing Office [www.gpo.gov]
[FR Doc No: 96-20307]


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DEPARTMENT OF TRANSPORTATION

Federal Aviation Administration

14 CFR Part 39

[Docket No. 96-NM-157-AD; Amendment 39-9708; AD 96-16-08]
RIN 2120-AA64


Airworthiness Directives; Boeing Model 727-100 and -200 Series 
Airplanes With a Main Deck Cargo Door Installed in Accordance With 
Supplemental Type Certificate (STC) SA1797SO

AGENCY: Federal Aviation Administration, DOT.

ACTION: Final rule; request for comments.

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SUMMARY: This amendment adopts a new airworthiness directive (AD) that 
is applicable to certain Boeing Model 727-100 and -200 series 
airplanes. This action requires an inspection to detect discrepancies 
of internal wires and electrical components of the control box of the 
main deck cargo door; modification of the wiring and components of the 
control box of the main deck cargo door; and a revision of the Airplane 
Flight Manual to impose an operational limitation of the motor pump 
power relay and pump motor. This amendment is prompted by results of an 
engineering review of the wiring diagram of the main deck cargo door 
installations, which revealed potential failures of the control box and 
hydraulic pump assembly installed in accordance with the STC. The 
actions specified in this AD are intended to prevent such failures, 
which could result in an inadvertent opening of the main deck cargo 
door during flight, with resultant major structural damage and possible 
reduced controllability of the airplane.

DATES: Effective August 27, 1996.
    -The incorporation by reference of certain publications listed in 
the regulations is approved by the Director of the Federal Register as 
of August 27, 1996.
    -Comments for inclusion in the Rules Docket must be received on or 
before October 11, 1996.

ADDRESSES: Submit comments in triplicate to the Federal Aviation 
Administration (FAA), Transport Airplane Directorate, ANM-103, 
Attention: Rules Docket No. 96-NM-157-AD, 1601 Lind Avenue, SW., 
Renton, Washington 98055-4056.
    -The Boeing Manufacturing Drawing D65446 referenced in this AD may 
be obtained from Boeing Commercial Airplane Group, P.O. Box 3707, 
Seattle, Washington 98124-2207. FAA Advisory Circular (AC) 4313-1A, 
referenced in this AD, may be obtained from the Superintendent of 
Documents, U.S. Government Printing Office, Washington, DC 20402. Both 
of these documents may be examined at the FAA, Transport Airplane 
Directorate, 1601 Lind Avenue, SW., Renton, Washington; or at the FAA, 
Atlanta Aircraft Certification Office, Small Airplane Directorate, 
Campus Building, 1701 Columbia Avenue, Suite 2-160, College Park, 
Georgia 30337-2748; or at the Office of the Federal Register, 800 North 
Capitol Street, NW., suite 700, Washington, DC.

FOR FURTHER INFORMATION CONTACT: Randy Avera, Systems Engineer, ACE-
116A, FAA, Atlanta Aircraft Certification Office, Small Airplane 
Directorate, Campus Building, 1701 Columbia Avenue, Suite 2-160, 
College Park, Georgia 30337-2748; telephone (404) 305-7381; fax (404) 
305-7348.

SUPPLEMENTARY INFORMATION: The FAA recently conducted an engineering 
review of the wiring diagram of the main deck cargo door installations 
on Boeing Model 727-100 and -200 series airplanes that have been 
modified in accordance with Supplemental Type Certificate (STC) 
SA1797SO. The results of this review revealed the existence of two 
unsafe conditions related to the control box and hydraulic pump 
assembly installed on these airplanes:
    -1. Due to the close proximity to the relays, a 28-volt wire could 
become chafed as a result of vibration and, consequently, could short 
to power a single DC relay (AN 3311-2). This short to power could 
energize the DC relay and simultaneously apply electrical power to the 
hydraulic pump motor and to the control valve of the main deck cargo 
door.
    -2. Failure of an electrical relay on the 115-volt AC power circuit 
could cause the hydraulic pump motor to become energized and, 
consequently, produce full hydraulic pressure in the pump. Such 
available pressure could unlock the main deck cargo door.
    -These conditions, if not corrected, could result in an inadvertent 
opening of the main deck cargo door during flight, which could result 
in major structural damage and possible reduced controllability of the 
airplane.

Explanation of Relevant Service Information

    -The FAA has issued Advisory Circular (AC) 43.13-1A, Change 3, 
dated 1988, which contains the following sections of Chapter 11 
(``Electrical Systems''):
    -1. Section 1 (``Care of Electrical Systems''),
    -2. Section 3 (``Electrical Wire''),
    -3. Section 5 (``Connectors''), and
    -4. Section 7 (``Routing, Tying, Lacing, and Clamping'').
    -The FAA also has reviewed and approved Chapter 20, ``Standard 
Wiring Practices'', of Boeing Wiring Diagram Manual Document D6-54446, 
Revision 21, dated June 1, 1994.
    -These documents describe procedures for verifying that the wire 
and wire bundles are properly installed and restrained, and for 
reinstalling and restraining any wire or component that has been 
altered.

Explanation of the Requirements of the Rule

    -Since an unsafe condition has been identified that is likely to 
exist or develop on other Boeing Model 727-100 and -200 series 
airplanes of the same type design, equipped with a main deck cargo door 
installed in accordance with STC SA1797SO, this AD is being issued to 
prevent an inadvertent opening of the main deck cargo door during 
flight, which can result in major structural damage and possible 
reduced controllability of the airplane. This AD requires the following 
actions:
    -1. Performing a one-time visual inspection of the internal wires 
and electrical components of the control box of the main deck cargo 
door to detect discrepancies, and repair, if necessary.

[[Page 41734]]

(These discrepancies include chafed, crimped, crushed, or damaged 
electrical wires or wire bundles inside the control box of the cargo 
door; loose electrical wire connections; abnormally pulled or twisted 
individual wires or wire bundles; any removal of insulation from the 
conductor in the control box; and any damaged protective grommets.)
    -2. Verifying that the wire and wire bundles are properly installed 
and restrained; and reinstalling and restraining any wire or component 
that has been altered.
    -3. Submitting a report of the inspection results (both positive 
and negative findings) to the FAA.
    -4. Revising the Limitations Section of the FAA-approved Airplane 
Flight Manual (AFM) to impose an operational limitation of the motor 
pump power relay and pump motor. This limitation requires the flight 
crew to verify that certain circuit breakers supplying electrical power 
to the hydraulic pump motor are pulled prior to taxi. It also requires 
that, prior to each taxi and takeoff after closing the cargo door, 
these circuit breakers are set to the open condition, tagged, and 
secured for flight.
    -5. Modifying the wiring and components of the control box of the 
main deck cargo door to preclude the identified problems. Aeronautical 
Engineers, Inc. (AEI), which is the holder of the subject STC, 
currently is developing a change to the wiring diagram that will 
address this.
    Certain of the actions are required to be accomplished in 
accordance with the documents described previously. Certain other 
actions are required to be accomplished in accordance with a method 
approved by the FAA.

Determination of Rule's Effective Date

    -Since a situation exists that requires the immediate adoption of 
this regulation, it is found that notice and opportunity for prior 
public comment hereon are impracticable, and that good cause exists for 
making this amendment effective in less than 30 days.

Comments Invited

    -Although this action is in the form of a final rule that involves 
requirements affecting flight safety and, thus, was not preceded by 
notice and an opportunity for public comment, comments are invited on 
this rule. Interested persons are invited to comment on this rule by 
submitting such written data, views, or arguments as they may desire. 
Communications shall identify the Rules Docket number and be submitted 
in triplicate to the address specified under the caption ADDRESSES. All 
communications received on or before the closing date for comments will 
be considered, and this rule may be amended in light of the comments 
received. Factual information that supports the commenter's ideas and 
suggestions is extremely helpful in evaluating the effectiveness of the 
AD action and determining whether additional rulemaking action would be 
needed.
    -Comments are specifically invited on the overall regulatory, 
economic, environmental, and energy aspects of the rule that might 
suggest a need to modify the rule. All comments submitted will be 
available, both before and after the closing date for comments, in the 
Rules Docket for examination by interested persons. A report that 
summarizes each FAA-public contact concerned with the substance of this 
AD will be filed in the Rules Docket.
    -Commenters wishing the FAA to acknowledge receipt of their 
comments submitted in response to this rule must submit a self-
addressed, stamped postcard on which the following statement is made: 
``Comments to Docket Number 96-NM-157-AD.'' The postcard will be date 
stamped and returned to the commenter.

Regulatory Impact

    -The regulations adopted herein will not have substantial direct 
effects on the States, on the relationship between the national 
government and the States, or on the distribution of power and 
responsibilities among the various levels of government. Therefore, in 
accordance with Executive Order 12612, it is determined that this final 
rule does not have sufficient federalism implications to warrant the 
preparation of a Federalism Assessment.
    -The FAA has determined that this regulation is an emergency 
regulation that must be issued immediately to correct an unsafe 
condition in aircraft, and that it is not a ``significant regulatory 
action'' under Executive Order 12866. It has been determined further 
that this action involves an emergency regulation under DOT Regulatory 
Policies and Procedures (44 FR 11034, February 26, 1979). If it is 
determined that this emergency regulation otherwise would be 
significant under DOT Regulatory Policies and Procedures, a final 
regulatory evaluation will be prepared and placed in the Rules Docket. 
A copy of it, if filed, may be obtained from the Rules Docket at the 
location provided under the caption ADDRESSES.

List of Subjects in 14 CFR Part 39

    -Air transportation, Aircraft, Aviation safety, Incorporation by 
reference, Safety.

Adoption of the Amendment

    -Accordingly, pursuant to the authority delegated to me by the 
Administrator, the Federal Aviation Administration amends part 39 of 
the Federal Aviation Regulations (14 CFR part 39) as follows:

PART 39--AIRWORTHINESS DIRECTIVES

    -1. The authority citation for part 39 continues to read as 
follows:

    Authority: 49 U.S.C. 106(g), 40113, 44701.


Sec. 39.13  [Amended]

    -2. Section 39.13 is amended by adding the following new 
airworthiness directive:

96-16-08 BOEING: Amendment 39-9708. Docket 96-NM-157-AD.

    Applicability: Model 727-100 and -200 series airplanes that have 
been modified in accordance with Supplemental Type Certificate (STC) 
SA1797SO, certificated in any category.

    Note 1: This AD applies to each airplane identified in the 
preceding applicability provision, regardless of whether it has been 
otherwise modified, altered, or repaired in the area subject to the 
requirements of this AD. For airplanes that have been modified, 
altered, or repaired so that the performance of the requirements of 
this AD is affected, the owner/operator must request approval for an 
alternative method of compliance in accordance with paragraph (d) of 
this AD. The request should include an assessment of the effect of 
the modification, alteration, or repair on the unsafe condition 
addressed by this AD; and, if the unsafe condition has not been 
eliminated, the request should include specific proposed actions to 
address it.
    Compliance: Required as indicated, unless accomplished 
previously.
    -To prevent the inadvertent opening of the main deck cargo door 
during flight, which could result in major structural damage and 
possible reduced controllability of the airplane, accomplish the 
following:
    -(a) Accomplish the actions specified in paragraphs (a)(1), 
(a)(2), (a)(3), and (a)(4) of this AD at the time specified in each 
of those paragraphs:
    -(1) Within 3 days after the effective date of this AD, perform 
a visual inspection of internal wires and electrical components of 
the control box of the main deck cargo door to detect the following 
discrepancies:
    -(i) chafed, crimped, crushed, or damaged electrical wires or 
wire bundles inside the control box of the cargo door;
    -(ii) loose electrical wire connections;
    -(iii) abnormally pulled or twisted individual wires or wire 
bundles;
    -(iv) any removal of insulation from the conductor in the 
control box; or
    -(v) any damaged protective grommets.

[[Page 41735]]

    (2) If any discrepancy is detected during the inspection 
required by paragraph (a)(1) of this AD, prior to further flight, 
repair it in accordance with a method approved by the Manager, FAA, 
Atlanta Aircraft Certification Office (ACO), Small Airplane 
Directorate.
    (3) Following accomplishment of paragraphs (a)(1) and, if 
applicable, (a)(2) of this AD, verify that the wire and wire bundles 
are properly installed and restrained, and reinstall and restrain 
any wire or component that has been altered, in accordance with the 
document identified in either paragraph (a)(3)(i) or (a)(3)(ii) of 
this AD.
    (i) Section 1 (``Care of Electrical System''); Section 3 
(``Electric Wire''); Section 5 (``Connectors''); and Section 7 
(``Routing, Tying, Lacing, and Clamping); of Chapter 11 
(``Electrical Systems'') of FAA Advisory Circular AC 4313-1A, Change 
3, dated 1988; or
    (ii) Chapter 20 (``Standard Wiring Practices'') of Boeing Wiring 
Diagram Manual Document D6-54446, Revision 21, dated June 1, 1994.
    (4) Within 10 days after accomplishing the inspection required 
by paragraph (a)(1) of this AD, submit a report of the inspection 
results (both positive and negative findings) to the Manager, FAA, 
Atlanta Aircraft Certification Office, Small Airplane Directorate, 
Campus Building, 1701 Columbia Avenue, Suite 2-160, College Park, 
Georgia 30337-2748; telephone (404) 305-7381; fax (404) 305-7348. 
Information collection requirements contained in this regulation 
have been approved by the Office of Management and Budget (OMB) 
under the provisions of the Paperwork Reduction Act of 1980 (44 
U.S.C. 3501 et seq.) and have been assigned OMB Control Number 2120-
0056.
    (b) Within 3 days after the effective date of this AD, revise 
the Limitations Section of the FAA-approved Airplane Flight Manual 
(AFM) to include the following statement. This may be accomplished 
by inserting a copy of this AD in the AFM.

``Operational Restriction

    Prior to taxi, verify that the alternating current (AC) or 
direct current (DC) circuit breakers that supply electrical power to 
the hydraulic pump motor are PULLED to interrupt power to the motor 
pump power relay and pump motor.

    Note 1: The 28VDC circuit breaker is located in the electrical 
equipment compartment on the J9 battery shield panel next to the 
auxiliary power unit (APU) starter circuit breaker. The 115VAC 
circuit breakers are located on the P6 breaker panel to the right of 
the Flight Engineers station. These circuit breakers are identified 
as ``Cargo Door Hydraulic Pump''.

    Prior to each taxi and take-off after closing the cargo door, 
set these circuit breakers to an open condition. Tag and secure the 
circuit breakers for flight.
    After landing and taxiing to the ramp, the circuit breakers may 
be RESET to facilitate cargo door opening.''
    (c) Within 90 days after the effective date of this AD, modify 
the wiring and components of the control box of the main deck cargo 
door, in accordance with a method approved by the Manager, FAA, 
Atlanta Aircraft Certification Office (ACO), Small Airplane 
Directorate.
    (d) An alternative method of compliance or adjustment of the 
compliance time that provides an acceptable level of safety may be 
used if approved by the Manager, FAA, Atlanta Aircraft Certification 
Office (ACO), Small Airplane Directorate. Operators shall submit 
their requests through an appropriate FAA Principal Maintenance 
Inspector, who may add comments and then send it to the Manager, 
Atlanta ACO.

    Note 2: Information concerning the existence of approved 
alternative methods of compliance with this AD, if any, may be 
obtained from the Atlanta ACO.

    (e) Special flight permits may be issued in accordance with 
21.197 and 21.199 of the Federal Aviation Regulations (14 CFR 21.197 
and 21.199) to operate the airplane to a location where the 
requirements of this AD can be accomplished.
    (f) Certain actions shall be done either in accordance with 
Sections 1, 3, 5, and 7 of Chapter 11 (``Electrical Systems'') of 
FAA Advisory Circular (AC) 4313-1A, Change 3, dated 1988; or in 
accordance with Chapter 20 (``Standard Wiring Practices'') of Boeing 
Wiring Diagram Manual Document D6-54446, Revision 21, dated June 1, 
1994. Sections 1, 3, 5, and 7 of Chapter 11 of FAA Advisory Circular 
AC 4313-1A contain the following list of effective pages:

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                                                                                                  Date shown on 
          Section referenced-                 Page number-         Change level shown on page-         page     
----------------------------------------------------------------------------------------------------------------
Section 1, ``Care of Electrical         173-174-................  Original-....................            1972 
 Systems''.                                                                                                     
Section 3, ``Electric ``Wire''---.....  179, 180, 180-1,180-2,    3............................            1988 
                                         181, 181-1, 181-2, 182,                                                
                                         182-1, 182-2, 183-185,                                                 
                                         185-1, 185-2, 186, 188,                                                
                                         188-1, 188-2.                                                          
                                        187, 189-193-...........  Original-....................            1972 
Section 5, ``Connectors''-............  196,200-................  3-...........................            1988 
                                        197-199.................  Original.....................            1972 
Section 7, ``Routing,Tying, Lacing,     203, 204, 206-209-......  Original.....................            1972 
 and Clamping''-.                                                                                               
  -                                     205, 205-1, 205-2.......  3-...........................            1988 
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    -Chapter 20 of Boeing Wiring Diagram Manual Document D6-54446 
contains the following list of effective pages:

------------------------------------------------------------------------
        Page title and number                  Date shown on page       
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Title Page-..........................  December 1, 1991.                
Revision Transmittal Pages 1-6.......  June 1, 1994.                    
Revision Record Pages 1, 2-..........  December 1, 1991.                
Temporary Revision Record Pages 1, 2 - December 1, 1991.                
 .                                                                      
List of Effective Pages 1-30.........  June 1, 1994.                    
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    This incorporation by reference was approved by the Director of 
the Federal Register in accordance with 5 U.S.C. 552(a) and 1 CFR 
part 51. Copies of Boeing Manufacturing Drawing D65446 may be 
obtained from Boeing Commercial Airplane Group, P.O. Box 3707, 
Seattle, Washington 98124-2207. Copies of FAA Advisory Circular (AC) 
4313-1A may be obtained from Superintendent of Documents, U.S. 
Government Printing Office, Washington, DC 20402. Copies of all of 
these documents may be inspected at the FAA, Transport Airplane 
Directorate, 1601 Lind Avenue, SW., Renton, Washington; or at FAA, 
Atlanta Aircraft Certification Office, Small Airplane Directorate, 
Campus Building, 1701 Columbia Avenue, Suite 2-160, College Park, 
Georgia 30337-2748; or at the Office of the Federal Register, 800 
North Capitol Street, NW., suite 700, Washington, DC.
    (g) This amendment becomes effective on August 27, 1996.

    Issued in Renton, Washington, on August 2, 1996.
Gary L. Killion,
Acting Manager, Transport Airplane Directorate, Aircraft Certification 
Service.
[FR Doc. 96-20307 Filed 8-9-96; 8:45 am]
BILLING CODE 4910-13-U