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Boeing ASB 767-28A0090: Boeing Commercial Airplane Group – Service Bullentin

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July 03, 2008 767-28A0090 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 1 of 118

ALERT ALERT Commercial Airplane Group 767

ALERTALERT Service Bulletin Number: 767-28A0090 Date: July 03, 2008 ATA System: 2822 2825 2826 2831 SUBJECT: FUEL - Main and Center Tanks - Valve Actuator Inspection and Replacement

BOEING PROPRIETARY, CONFIDENTIAL, AND/OR TRADE SECRET Copyright © 2008 The Boeing Company Unpublished Work - All Rights Reserved Boeing claims copyright in each page of this document only to the extent that the page contains copyrightable subject matter.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, the Boeing signature, the Boeing symbol, 707, 717, 727, 737, 747, 757, 767, 777, BBJ, DC-8, DC-9, DC-10, MD-10, MD-11, MD-80, MD-88, MD-90, and the red-white-and-blue Boeing livery are all trademarks owned by The Boeing Company; and no trademark license is granted in connection with this document unless provided in writing by Boeing.

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BLANK PAGE July 03, 2008 767-28A0090 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 2 of 118 BOEING SERVICE BULLETIN 767-28A0090

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Table of Contents July 03, 2008 767-28A0090 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 3 of 118 BOEING SERVICE BULLETIN 767-28A0090

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Table of Contents Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

1. PLANNING INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 A. Effectivity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

1. Airplanes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

2. Spares Affected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 B. Concurrent Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 C. Reason . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 D. Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 E. Compliance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 F. Approval . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 G. Manpower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 H. Weight and Balance Changes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43 I. Electrical Load Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43 J. References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

1. Existing Data: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

2. Data supplied with this Service Bulletin: . . . . . . . . . . . . . . . . . . . . . . . . . 44

3. Installation Drawings Used in the Preparation of this Service Bulletin: . . . . . . . . . . 44 K. Publications Affected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44 L. Interchangeability and Intermixability of Parts . . . . . . . . . . . . . . . . . . . . . . . . . 44

2. MATERIAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 A. Material - Price and Availability. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 B. Industry Support Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 C. Parts Necessary For Each Airplane . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

1. Kits/Parts: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

2. Parts and Materials Supplied by the Operator: . . . . . . . . . . . . . . . . . . . . . . 47

3. Parts Modified and Reidentified: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

4. Parts Removed and Not Replaced: . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47 D. Parts Necessary to Change Spares . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47 E. Special Tooling - Price and Availability. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47 F. Special Tooling Necessary to do this Service Bulletin . . . . . . . . . . . . . . . . . . . . . 47

3. ACCOMPLISHMENT INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49 A. GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49 B. WORK INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 FIGURE 1: Inspect and Record Defueling MOV Actuator Part Number . . . . . . . . . . . . . . . . . 73 FIGURE 2: Remove and Keep Index Plate. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74 FIGURE 3: Rework Index Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76 FIGURE 4: Measure and Record Electrical Resistance from Adapter Plate to the Airplane Surface . . 77 FIGURE 5: Prepare Adapter Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78 FIGURE 6: Put Index Plate in Position for Installation. . . . . . . . . . . . . . . . . . . . . . . . . . 80 FIGURE 7: Install the MOV actuator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82 FIGURE 8: Clean Adapter Plate and Airplane Surface . . . . . . . . . . . . . . . . . . . . . . . . . 86 FIGURE 9: Inspect and Record Fuel Jettison Transfer MOV Actuator Part Number (left wing) . . . . . 88 FIGURE 10: Inspect and Record Fuel Jettison Transfer MOV Actuator Part Number (right wing) . . . 89 FIGURE 11: Inspect and Record Fuel Jettison Nozzle MOV Actuator Part Number (left wing) . . . . . 90 FIGURE 12: Inspect and Record Fuel Jettison Nozzle MOV Actuator Part Number (right wing) . . . . 92

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FIGURE 13: Inspect and Record APU Shutoff MOV Actuator Part Number . . . . . . . . . . . . . . . 94 FIGURE 14: Inspect and Record APU Isolation MOV Actuator Part Number . . . . . . . . . . . . . . 95 FIGURE 15: Inspect and Record Engine Fuel Shutoff MOV Actuator Part Number (left wing) . . . . . 96 FIGURE 16: Inspect and Record Engine Fuel Shutoff MOV Actuator Part Number (right wing) . . . . . 97 FIGURE 17: Inspect and Record Dual Forward/Aft Engine Fuel Crossfeed MOV Actuator . . . . . . . 98 FIGURE 18: Inspect and Record Single Engine Fuel Crossfeed MOV Actuator Part Number (left wing) .

100 FIGURE 19: Install the MOV actuator (directly to the motor operated valve). . . . . . . . . . . . . . 101 FIGURE 20: Remove Bracket and Install new Bracket on Engine Fuel Shutoff MOV Actuator Deflector (left wing) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105 FIGURE 21: Remove Bracket and Install new Bracket on Engine Fuel Shutoff MOV Actuator Deflector (right wing) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108 FIGURE 22: Install the Shim and Forward Engine Fuel Crossfeed MOV Actuator. . . . . . . . . . . 111 FIGURE 23: Install the Shim and Aft Engine Fuel Crossfeed MOV Actuator. . . . . . . . . . . . . . 115

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July 03, 2008 767-28A0090 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 5 of 118

ALERT ALERT Commercial Airplane Group 767

ALERTALERT Service Bulletin Number: 767-28A0090 Summary Date: July 03, 2008 ATA System: 2822 2825 2826 2831 SUBJECT: FUEL - Main and Center Tanks - Valve Actuator Inspection and Replacement

THIS BULLETIN IS SENT TO THE OPERATORS OF RECORD OF THE AIRPLANES SHOWN IN PARAGRAPH 1.A., EFFECTIVITY. IF AN AIRPLANE HAS BEEN LEASED OR SOLD, SEND THIS SERVICE BULLETIN TO THE NEW OPERATOR. IF APPLICABLE SPARES HAVE BEEN SOLD, SEND THIS SERVICE BULLETIN TO THE NEW OWNER.

CONCURRENT REQUIREMENTS None.

BACKGROUND This service bulletin gives instructions to inspect all the motor operated valve (MOV) actuators and to install new MOV actuators where necessary. The MOV actuators are installed at each fuel system. The new MOV actuator will prevent electrical current flow through the actuator into the fuel tank. If this service bulletin is not done it is possible that a flow of electricity into the fuel tank will supply an ignition source for the fuel fumes in the tank.

The Boeing system safety assessment necessary for Special Federal Aviation Regulation (SFAR) 88, showed that under specific conditions it was possible for electrical current to flow through certain MOV actuators into the fuel tank. A new MOV actuator is available to replace the existing MOV actuator with this condition. The new MOV actuator includes an internal electrical isolator to give the MOV actuator protection against electrical energy from lightning, 115 VAC hot shorts, and 28 VDC internal shorts. The new MOV actuator will prevent the flow of an electrical current into the fuel tank and increase the reliability of the fuel system.

This service bulletin replaces the MOV actuator part number MA20A1001-1 with the new MOV actuator part number MA30A1001. The MOV actuator part number MA20A1001-1 is the only installed MOV actuator part number that is affected by this service bulletin.

This service bulletin gives instruction on how to measure the electrical resistance of bonds at the installed MOV actuator locations, how to prepare a Faying surface for the install of the new MOV actuator, how to prepare affected airplane parts, and how to install the new MOV actuator.

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

Section 9 of the 767 Maintenance Planning Data (MPD) Document was change.

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ACTION (PRR B13421-6) — Gain access to each MOV actuator.

— Inspect each MOV actuator part number. If the MOV actuator part number is MA20A1001-1, remove, discard, and replace with the MOV actuator part number MA30A1001. The MA20A1001-1 is the only installed MOV actuator part number that is affected by this service bulletin.

— If you are required to install the MA30A1001, you must do an electrical resistance check at each location.

If the measured resistance is not acceptable, you must rework the Faying bond and the airplane parts. This may require rework of the index plate and the adapter plate. This may require a tank entry to rework the interface between the adapter plate and the airplane structure.

— If you are required to install the MA30A1001 at the dual foward/aft engine fuel crossfeed valve actuator location, you must inspect for the "SWEENEY ENGR CORP" marking on the adapter plate. If found, you must install the shim kit.

— Some airplane models have a deflector installed at the left and right engine fuel shutoff MOV actuator location, where an installed wire support assembly can potentially interfere with the new MOV actuator. If you are required to install the MA30A1001 at these locations, you must also install the new wire support assembly on the deflector. The new wire support assembly will prevent part interference.

— Close access to each MOV actuator.

EFFECTIVITY 767 -200 /-300 /-300F /-400ER airplanes. Refer to this service bulletin Paragraph 1.A.1 for effectivity.

COMPLIANCE The Federal Aviation Administration (FAA) will possibly release an Airworthiness Directive related to this service bulletin. The Airworthiness Directive will make the compliance tasks and times given in this service bulletin mandatory.

Boeing recommends that this service bulletin be incorporated within 60 months after the date on this service bulletin.

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

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MANPOWER

MATERIAL INFORMATION Operator Supplied Parts.

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

Airplanes Total Task Hours Elapsed Hours Group 1.0 401.00 (a) (b) 175.00 (a) (b) Group 2.0 401.00 (a) (b) 175.00 (a) (b) Group 3.0 237.15 (a) (b) 107.65 (a) (b) Group 4.0 237.15 (a) (b) 107.65 (a) (b) Group 5.1 405.60 (a) (b) 178.10 (a) (b) Group 5.2 394.85 (a) (b) 169.35 (a) (b) Group 6.1 241.75 (a) (b) 110.75 (a) (b) Group 6.2 231.00 (a) (b) 102.00 (a) (b) Group 7.1 405.60 (a) (b) 178.10 (a) (b) Group 7.2 405.60 (a) (b) 178.10 (a) (b) Group 7.3 394.85 (a) (b) 169.35 (a) (b) Group 7.4 394.85 (a) (b) 169.35 (a) (b) Group 8.1 241.75 (a) (b) 110.75 (a) (b) Group 8.2 231.00 (a) (b) 102.00 (a) (b) Group 9.0 447.45 (a) (b) 193.95 (a) (b)

(a) Entry into the fuel tank should not be frequent.

(b) If entry into the fuel tank is not necessary, the time needed to do the work is much less.

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ENGINE FUEL

CROSS FEED

MOV ACTUATOR

APU FUEL SHUTOFF

MOV ACTUATOR

APU FUEL

ISOLATION MOV

ACTUATOR

FUEL JETTISON

NOZZLE MOV

ACTUATOR

DEFUELING MOV

ACTUATOR

ENGINE FUEL

SHUTOFF MOV

ACTUATOR

FUEL JETTISON

TRANSFER MOV

ACTUATOR

FUEL JETTISON

NOZZLE MOV

ACTUATOR

DEFUELING MOV

ACTUATOR INSPECT THE MOV ACTUATORS AT THE ABOVE LOCATIONS.

- IF THE MOV ACTUATOR HAS AN UNACCEPTABLE PART NUMBER, REPLACE THE MOV ACTUATOR.

- PREPARE AN ELECTRICAL BOND.

REAR SPAR

INDEX PLATE

TYPICAL MOV ACTURATOR

INSTALLATION WITHOUT INDEX PLATE

TYPICAL MOV ACTUATOR

INSTALLATION WITH INDEX PLATE

REAR SPAR

FWD FWD

ADAPTER PLATE

FUEL JETTISON

TRANSFER MOV

ACTUATOR U31989

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July 03, 2008 767-28A0090 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 9 of 118

ALERT ALERT Commercial Airplane Group 767

ALERTALERT Service Bulletin Number: 767-28A0090 Date: July 03, 2008 ATA System: 2822 2825 2826 2831 SUBJECT: FUEL - Main and Center Tanks - Valve Actuator Inspection and Replacement

THIS BULLETIN IS SENT TO THE OPERATORS OF RECORD OF THE AIRPLANES SHOWN IN PARAGRAPH 1.A., EFFECTIVITY. IF AN AIRPLANE HAS BEEN LEASED OR SOLD, SEND THIS SERVICE BULLETIN TO THE NEW OPERATOR. IF APPLICABLE SPARES HAVE BEEN SOLD, SEND THIS SERVICE BULLETIN TO THE NEW OWNER.

1. PLANNING INFORMATION A. Effectivity

1. Airplanes This service bulletin is for the airplanes shown below. An equivalent change is on subsequent production airplanes. Refer to PRR B13421-6 for data about this change.

GROUP CONFIGURATION DESCRIPTION 1 - 767-200/300/300F airplanes with the production dual crossfeed installation and the production fuel jettison installation.

2 - 767-200/300/300F airplanes with the production dual crossfeed installation and the production fuel jettison installation. And requires an inspection to determine if the Sweeney adapter plates were installed in production.

3 - 767-200/300/300F airplanes with the production dual crossfeed installation, but without fuel jettison installation.

4 - 767-200/300/300F airplanes with the production dual crossfeed installation, but without fuel jettison installation. And requires an inspection to determine if the Sweeney adapter plates were installed in production.

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Airplane models:

767-200 767-300 767-300F 767-400ER 5 - 767-200/300/300F airplanes effected by Boeing service bulletin 767-28-0034 to install the dual crossfeed, and with the production jettison installation.

1 Made changes as given in Boeing service bulletin 767-28-0034.

2 Did not make changes as given in Boeing service bulletin 767-28-0034.

6 - 767-200/300/300F airplanes effected by Boeing service bulletin 767-28-0034 to install the dual crossfeed, but without the production jettison installation.

1 Made changes as given in Boeing service bulletin 767-28-0034.

2 Did not make changes as given in Boeing service bulletin 767-28-0034.

7 - 767-200/300/300F airplanes effected by Boeing service bulletin 767-28-0034 to install the dual crossfeed, and effected by Boeing service bulletin 767-28-0027 to install the fuel jettison.

1 Made changes as given in Boeing service bulletin 767-28-0034, and made changes as given in Boeing service bulletin 767-28-0027.

2 Made changes as given in Boeing service bulletin 767-28-0034, but did not make changes as given in Boeing service bulletin 767-28-0027.

3 Did not make changes as given in Boeing service bulletin 767-28-0034, but made changes as given in Boeing service bulletin 767-28-0027.

4 Did not make changes as given in Boeing service bulletin 767-28-0034, and did not make changes as given in Boeing service bulletin 767- 28-0027.

8 - 767-200/300/300F airplanes effected only by Boeing service bulletin 767-28-0034 to install the dual crossfeed. No Jettison Installed.

1 Made changes as given in Boeing service bulletin 767-28-0034.

2 Did not make changes as given in Boeing service bulletin 767-28-0034.

9 - 767-400ER airplanes with an inspection to determine if the Sweeney adapter plates were installed in production.

GROUP CONFIGURATION DESCRIPTION

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IDENTIFICATION BY CUSTOMER, CUSTOMER CODE, GROUP AND VARIABLE NUMBER 767-200ER TANKER-JAPAN (YTD) 1 VR106 AA 767 LLC (SVX) 8V E 0 6 7

ABX AIR (ABX) 7V B 1 2 5 8 VA301 VA304–VA305 VA309–VA313 VA315 VA803 VA807–VA809 VB101–VB123 VB302

AEROFLOT (ARO) 1 VL896–VL897 2 VS216–VS217 VS321–VS324 VS392 5 VN471–VN472

AEROMEXICO (AMX) 1V F 1 6 2 2V S 2 1 1 5V F 0 7 1 V F 0 9 3

AEROSVIT (UKA) 5 VN157 7 VN155

AEROTURBINE (AUB) 8 VB051 VB054–VB055 VB321–VB322

AIR ALGERIE (ALG) 6 VK131–VK133

AIR ASTANA (AKZ) 1 VL899

AIR CANADA (ACN) 1 VN546–VN547 VN811–VN812 VS546–VS549 2 VS381–VS382 3 VN931–VN936 5 VN059–VN062 VN531 VN536 VN541–VN542 VN751–VN752 7 VA713–VA719 VN051–VN054 VN056–VN058 8 VA701–VA709 VA711–VA712 VB001–VB002 VB201–VB202

AIR CHINA (BEJ) 1 VN388 2 VS206 VS208 VS274 VS307 3 VK162–VK164 6V K 1 6 1 7 VE085–VE086 8 VE064 VE083–VE084

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AIR DO (HIA) 2 VS176–VS177

AIR EUROPA (ARE) 1 VN638 VS292–VS293 2 VS291

AIR ITALY (RIT) 1 VL913

AIR MADAGASCAR (MAD) 5V N 1 6 7 V N 7 3 1

AIR NEW ZEALAND (ANZ) 1 VN653 VN655–VN658 2 VS113

AIR NIUGINI (NIU) 5V N 6 5 1

AIR PACIFIC (APC) 1V N 6 7 6

AIR SAHARA (SAQ) 5V N 4 9 5

AIR SEYCHELLES (ASY) 1 VL941 VS526

AIR TRANSPORT INTERNATIONAL (TIN) 8 VA509–VA513

AIR ZIMBABWE (ZMB) 5V F 0 6 2 7V F 0 6 1

ALITALIA (ALI) 1 VL701–VL702 VN422–VN427 VN732 VN813 2 VS366–VS367 VS401

ALL NIPPON AIRWAYS (ANA) 1 VN194–VN198 VS721–VS732 VT501 VT521 3 VK100–VK113 4V R 4 0 1 5V N 1 9 3 6 VK094–VK099 7 VK081–VK093 VN191–VN192

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