Boeing ASB 767-28A0084: Revision 1, text

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Commercial Airplane Group 767 Service Bulletin Number: 767-28A0084 Date: May 03, 2006 Revision 1: April 26, 2007 ATA System: 2822 2842 SUBJECT: FUEL SYSTEM - Engine Fuel Feed System - Fuel Pump Inlet Protection - Auxiliary Fuel Tank Pump Automatic Shut Off Installation

BOEING PROPRIETARY, CONFIDENTIAL, AND/OR TRADE SECRET Copyright © 2006 The Boeing Company Unpublished Work - All Rights Reserved Boeing claims copyright in each page of this document only to the extent that the page contains copyrightable subject matter.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.

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Table of Contents Revision Transmittal Sheet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

1. PLANNING INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 A. Effectivity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

1. Airplanes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

2. Spares Affected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 B. Concurrent Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 C. Reason . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 D. Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 E. Compliance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 F. Approval . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 G. Manpower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 H. Weight and Balance Changes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 I. Electrical Load Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 J. References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

1. Existing Data: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

2. Data supplied with this Service Bulletin: . . . . . . . . . . . . . . . . . . . . . . . . . 14

3. Installation Drawings Used in the Preparation of this Service Bulletin: . . . . . . . . . . 14 K. Publications Affected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 L. Interchangeability and Intermixability of Parts . . . . . . . . . . . . . . . . . . . . . . . . . 15

2. MATERIAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 A. Material - Price and Availability. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 B. Industry Support Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 C. Parts Necessary For Each Airplane . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

1. Kits/Parts: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

2. Parts and Materials Supplied by the Operator: . . . . . . . . . . . . . . . . . . . . . . 21

3. Parts Modified and Reidentified: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

4. Parts Removed and Not Replaced: . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 D. Parts Necessary to Change Spares . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 E. Special Tooling - Price and Availability. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 F. Special Tooling Necessary to do this Service Bulletin . . . . . . . . . . . . . . . . . . . . . 21

3. ACCOMPLISHMENT INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 A. GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 B. WORK INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 FIGURE 1: Relay Bracket Installation P36 PANEL, Group 1 Airplanes . . . . . . . . . . . . . . . . . 25 FIGURE 2: Relay Bracket Installation P37 Panel, Group 1 Airplanes . . . . . . . . . . . . . . . . . . 28 FIGURE 3: Wire Bundle W0176 Changes P36 Panel, Group 1 Airplanes. . . . . . . . . . . . . . . . 31 FIGURE 4: Wire Bundle W0184 Changes P36 Panel, Group 1 Airplanes. . . . . . . . . . . . . . . . 33 FIGURE 5: Relay Installation P36 Panel, Groups 1 Airplanes . . . . . . . . . . . . . . . . . . . . . . 34 FIGURE 6: Wire Bundle W0192 Changes P37 Panel, Group 1 Airplanes. . . . . . . . . . . . . . . . 36 FIGURE 7: Wire Bundle W0188 Changes P37 Panel, Group 1 Airplanes. . . . . . . . . . . . . . . . 38 FIGURE 8: Relay Installation P37 Panel, Groups 1 Airplanes . . . . . . . . . . . . . . . . . . . . . . 39 FIGURE 9: Wire Bundle W0942 Changes P36 Panel to P37 Panel, Group 1 Airplanes . . . . . . . . 41 FIGURE 10: Wire Bundle W0942 routing, P36 panel to P37 panel . . . . . . . . . . . . . . . . . . . 42 FIGURE 11: Wire Bundle W1118 Changes P37 Panel, Group 1 Airplanes . . . . . . . . . . . . . . . 44

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Commercial Airplane Group 767 Service Bulletin Number: 767-28A0084 Revision Transmittal Sheet Date: May 03, 2006 Revision 1: April 26, 2007 ATA System: 2822 2842 SUBJECT: FUEL SYSTEM - Engine Fuel Feed System - Fuel Pump Inlet Protection - Auxiliary Fuel Tank Pump Automatic Shut Off 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.

REASON FOR REVISION This revision is sent to address the comments received from operators since the initial release of the service bulletin and incorporate differences identified during the the validation of the service bulletin.

As a part of a service bulletin validation program, this change was completed on airplane VQ076 by initial release of Service Bulletin 767-28A0084 and before the release of Revision 1 of this service bulletin. The change was completed on airplane VQ076 by Service Bulletin 767-28A0084 is equivalent to the Revision 1 of this service bulletin. Airplane VQ076 has the configuration of a Group 1 airplane.

The following sections of the service bulletin are changed:

— Weight and Balance table Section1.H, to show new information.

— Material Section 2.A, to show new availability and pricing.

— Accomplishment Instructions Section 3. added Airplane Maintenance Manual (AMM) for Functional Test Requirements.

— Figures 1 and 2 removed the bonding requirement for the relay mounting bracket.

— Figures 5 and 8 to clarify the relay location.

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: May 03, 2006 Revision 1: April 26, 2007

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Commercial Airplane Group 767 Service Bulletin Number: 767-28A0084 Summary Date: May 03, 2006 Revision 1: April 26, 2007 ATA System: 2822 2842 SUBJECT: FUEL SYSTEM - Engine Fuel Feed System - Fuel Pump Inlet Protection - Auxiliary Fuel Tank Pump Automatic Shut Off Installation

CONCURRENT REQUIREMENTS None.

BACKGROUND This service bulletin is the result of the safety assessments conducted by Boeing under SFAR 88, "Fuel Tank System Fault Tolerance Evaluation Requirements".

Initial results from the Fuel System Safety Analysis show that fuel pumps that run dry could cause an overheat condition external of the pump explosion resistance area that is open to the pump inlet. An overheat condition in this area could possibly cause an unwanted ignition source for the fuel vapors in the fuel tank. Ignition of flammable fuel vapors could cause a fire or explosion which could put the airplane in an unsafe condition.

Installation of the automatic shut off system adds fuel pump inlet protection against sparks caused by friction overheat damage in the fuel tanks.

This service bulletin gives the instructions and a kit of parts to install an automatic shut off system for the center wing tank override boost pumps. Installation of the automatic system will prevent a potential ignition source in the tank by making sure the pumps do not run for an extended period of time when the fuel level is below pump inlet or the pump has failed.

Currently the flight crew turns off the pumps when a pump low pressure message is displayed on EICAS. The automatic shut off system installed by this service bulletin will make sure that the pumps will not run for more than 15 seconds with continuous low fuel pressure if the flight crew does not respond to the EICAS message sooner. The flight crew remains in primary control, with this automatic shut off system as a backup, to turn the pumps off after continuous low pressure indication.

This change affects Section 9 of the Maintenance Planning Data (MPD) Document. New Airworthiness Limitations (AWL) "28-AWL-20" will be added to Section 9 of the MPD to include a functional check of the center tank fuel boost pump automatic shut off system. This change also affects Section 1 and 3.1 of the FAA Approved Airplane Flight Manual.

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ACTION (PRR B13421-4) In the P36 panel, install a new relay bracket and two new relays. In the P37 panel, install a new relay bracket and two new relays. Change the wiring in the P36 panel and P37 panel. Install wiring between the P36 panel and P37 panel. Do a functional test.

EFFECTIVITY All 767-400ER Airplanes. See Service Bulletin Paragraph 1.A.1 for effectivity.

COMPLIANCE Boeing warranty recommends that the operators incorporate this service bulletin within 36 months after the release date on this service bulletin.

INDUSTRY SUPPORT INFORMATION Boeing warranty remedies are not available for the configuration changes given in this service bulletin.

MANPOWER

MATERIAL INFORMATION Boeing Supplied Kits/Parts.

Refer to Paragraph 2.A., Material - Price and Availability.

Airplanes Total Task Hours Elapsed Hours Group 1 27 13.5

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CHANGE THE PANEL WIRING.

RELAY BRACKET AND TWO RELAYS.

IN THE P37 PANEL, INSTALL A NEW CHANGE THE PANEL WIRING.

RELAY BRACKET AND TWO RELAYS.

IN THE P36 PANEL, INSTALL A NEW

MAIN EQUIPMENT CENTER FWD 498795

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1. PLANNING INFORMATION A. Effectivity

1. Airplanes Refer to Service Bulletin Index Document D624T001 Part 3 for Airplane Variable Number, Line Number, and Serial Number data.

This service bulletin is for the airplanes shown below. An equivalent change is on subsequent production airplanes. Refer to PRR B13421-4 for data about this change.

Airplane models:

767-400ER

IDENTIFICATION BY CUSTOMER, CUSTOMER CODE, GROUP AND VARIABLE NUMBER

CONTINENTAL AIRLINES (CAL) 1 VQ071–VQ086

DELTA AIR LINES (DAL) 1 VQ001–VQ021

IDENTIFICATION BY VARIABLE NUMBER

GROUP CONFIGURATION DESCRIPTION 1 - VQ001-VQ021, VQ071-VQ086 airplanes Variable Group VQ001–VQ021 1 VQ071–VQ086 1

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2. Spares Affected None.

B. Concurrent Requirements None.

C. Reason This service bulletin is the result of the safety assessments conducted by Boeing under SFAR 88, "Fuel Tank System Fault Tolerance Evaluation Requirements".

Revision 1 is sent to address the comments received from operators since the initial release of the service bulletin and incorporate differences identified during the the validation of the service bulletin.

The following sections of the service bulletin are changed:

— Weight and Balance table Section1.H, to show new information.

— Material Section 2.A, to show new availability and pricing.

— Accomplishment Instructions Section 3. added Airplane Maintenance Manual (AMM) for Functional Test Requirements.

— Figures 1 and 2 removed the bonding requirement for the relay mounting bracket.

— Figures 5 and 8 to clarify the relay location.

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