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Commercial Airplanes 767 Service Bulletin Number: 767-28A0094 Original Issue: November 20, 2007 Revision 1: April 23, 2009 ATA System: 2841 SUBJECT: FUEL - Indicating - Fuel Quantity Indicating System - Center Wing Tank - Hot Short Protector Change Export of this technology is controlled under the United States Export Administration Regulations (EAR) (15 CFR 730-774). An export license may be required before it is used for development, production or use by foreign persons from specific countries. The controller of this data has the individual responsibility to abide by all export laws.
9E991ECCN:
BOEING PROPRIETARY, CONFIDENTIAL, AND/OR TRADE SECRET Copyright © 2007 The Boeing Company Unpublished Work - All Rights Reserved Boeing claims copyright in each page of this document only to the extent that the page contains copyrightable subject matter.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, 787, Dreamliner, BBJ, DC-8, DC-9, DC-10, MD-10, MD-11, MD-80, MD-88, MD-90, P-8A, Poseidon and the 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.
BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: November 20, 2007 767-28A0094Revision 1: April 23, 2009 1 of 76
3.0
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Original Issue: November 20, 2007 767-28A0094Revision 1: April 23, 2009 2 of 76 BOEING SERVICE BULLETIN 767-28A0094
BLANK PAGE
Table of Contents
Revision Transmittal Sheet5
Summary7
1. PLANNING INFORMATION ........................................ 1 1 A. Effectivity ............................................... 1 1
1. Airplanes ............................................ 1 1
2. Spares Affected ........................................ 1 5 B. Concurrent Requirements ...................................... 1 5 C. Reason ................................................ 1 5 D. Description .............................................. 1 7 E. Compliance .............................................. 1 8 F . Approval ............................................... 1 8 G. Manpower .............................................. 1 8 H. Weight and Balance Changes .................................... 2 0 I. Electrical Load Data ......................................... 2 0 J. References .............................................. 2 0
1. Existing Data: .......................................... 2 0
2. Data supplied with this Service Bulletin: ........................... 2 0
3. Installation Drawings Used in the Preparation of this Service Bulletin: ........... 2 0 K. Publications Affected ......................................... 2 1 L. Interchangeability and Intermixability of Parts ........................... 2 1
2. MATERIAL INFORMATION ........................................ 2 3 A. Material - Price and Availability ................................... 2 3 B. Industry Support Information .................................... 2 3 C. Parts Necessary For Each Airplane ................................. 2 4
1. Kits/Parts: ............................................ 2 4
2. Parts and Materials Supplied by the Operator: ........................ 2 7
3. Parts Modified and Reidentified: ................................ 2 7
4. Parts Removed and Not Replaced: .............................. 2 7 D. Parts Necessary to Change Spares ................................. 2 7 E. Special Tooling - Price and Availability ............................... 2 7 F . Special Tooling Necessary to do this Service Bulletin ....................... 2 7
3. ACCOMPLISHMENT INSTRUCTIONS .................................. 2 9 A. GENERAL INFORMATION ..................................... 2 9 B. WORK INSTRUCTIONS ....................................... 2 9 FIGURE 1: REMOVE WIRE BUNDLE CN1156-135 OR -935 [Group 1; Group 2, Configuration 1] . . . 34 FIGURE 2: DISCONNECT GROUND WIRES AND GROUND BRACKETS REMOVAL [Group 1; Group 2, Configuration 1] ......................................... 3 8 FIGURE 3: INSTALL HOT SHORT PROTECTOR MOUNTING AND GROUNDING BRACKETS [Group 1;
Group 2, Configuration 1] ................................... 4 1 FIGURE 4: INSTALL HOT SHORT PROTECTOR AND BONDING JUMPERS [Group 1; Group 2, Configuration 1] ......................................... 4 7 FIGURE 5: WIRE BUNDLE IDENTIFICATION AND WIRING CHANGES [Group 1; Group 2, Configuration 1 ] ................................................ 5 1 FIGURE 6: INSTALL WIRING [Group 1; Group 2, Configuration 1] .................... 5 4 FIGURE 7: INSTALL WIRE BUNDLES CN1156-938 AND CN1156-939 [Group 1; Group 2, Configuration 1 ] ................................................ 5 8 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: November 20, 2007 767-28A0094Revision 1: April 23, 2009 3 of 76 BOEING SERVICE BULLETIN 767-28A0094
FIGURE 8: REMOVE WIRE BUNDLE CN1156-135 OR -935 [Group 3] ................. 6 4 FIGURE 9: INSTALL HOT SHORT PROTECTOR AND BONDING JUMPER [Group 3] ......... 6 7 FIGURE 10: INSTALL WIRE BUNDLES CN1156-938 AND CN1156-939 [Group 3] ........... 7 1 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: November 20, 2007 767-28A0094Revision 1: April 23, 2009 4 of 76 BOEING SERVICE BULLETIN 767-28A0094
Commercial Airplanes 767 Service Bulletin Revision Transmittal SheetNumber: 767-28A0094Original Issue: November 20, 2007 Revision 1: April 23, 2009 ATA System: 2841 SUBJECT: FUEL - Indicating - Fuel Quantity Indicating System - Center Wing Tank - Hot Short Protector Change 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 original issue of this service bulletin. Boeing has determined that the changes given in this revision do not require any rework to airplanes which have successfully incorporated original issue of this service bulletin. If operators had reworked the supplied wire bundle to reflect the connector pins numbers as shown in Figures 7, sheet 4 or Figure 10, Sheet 4 of the original issue of this service bulletin, then the functional test would have failed making the system inoperable. Boeing has released IN 01 which gives the correct connector pin numbers.
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 validation of the service bulletin.
As a part of a service bulletin validation program, this change was completed on Airplane VR051 by initial release of Service Bulletin 767-28A0094 and before the release of Revision 1 of this service bulletin. The change completed on airplane VR051 by Service Bulletin 767-28A0094 is equivalent to Revision 1 of this service bulletin.
Airplane VR051 has the configuration of a Group 1 airplane.
Airplanes VR089 and VR107 have been removed from this service bulletin. These airplanes have an upgraded FQIS system and do not require the installation of the Hot Short Protector (HSP).
These sections were changed:
1. Accomplishment Instructions Section 3, Revised circuit breaker C01045 label from FUEL QTY REFUEL to read FUEL QTY in steps 4, 6 and 14 for Group 1; Group 2, Configuration 1 and in steps 4, 6 and 11 for Group 3 airplanes.
2. Figure 1, sheet 2, Step 2, added additional wire clamp to be removed and revised More Data to read:
Remove and keep all clamps and hardware necessary for wire bundle removal.
3. Figure 3, sheet 2, revised the Hole symbol legend, the legend was reversed for New Holes and Existing Holes and the symbols for some existing holes and new holes were incorrectly shown in View C.
4. Figure 3, sheet 3, revised the Hole symbol legend, the legend was reversed for New Holes and Existing Holes.
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Original Issue: November 20, 2007 767-28A0094Revision 1: April 23, 2009 5 of 76
5. Figure 3, sheet 4, step table, revised parts installed in steps 1-4 to use unpiloted parts to improve bracket installation.
6. Figure 4, sheet 2, revised view D to show the typical bonding jumper installation.
7. Figure 7, sheet 4, revised connector D4538J pins to show pins 1-7, not pins 1-3 and 6-9. The wiring shown in Figure 10, sheet 4 is for reference with wire termination information.
8. Figure 8, sheet 2, Step 2, added additional wire clamp to be removed and revised, More Data to read:
Remove and keep all clamps and hardware necessary for wire bundle removal.
9. Figure 9, sheet 2, revised view D to show the typical bonding jumper installation.
10. Figure 10, sheet 4, revised connector D4538J pins to show pins 1-7, not pins 1-3 and 6-9.The wiring shown in Figure 10, sheet 4 is for reference with wire termination information.
The data given in Information Notice 767-28A0094 IN 01 is included in this revision.
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 November 20, 2007Original Issue:
April 23, 2009Revision 1:
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Original Issue: November 20, 2007 767-28A0094Revision 1: April 23, 2009 6 of 76 BOEING SERVICE BULLETIN 767-28A0094
Commercial Airplanes 767 Service Bulletin SummaryNumber: 767-28A0094Original Issue: November 20, 2007 Revision 1: April 23, 2009 ATA System: 2841 SUBJECT: FUEL - Indicating - Fuel Quantity Indicating System - Center Wing Tank - Hot Short Protector Change
CONCURRENT REQUIREMENTS None.
BACKGROUND This service bulletin gives instructions to install a Hot Short Protector and related wire bundles. The accomplishment of this service bulletin will prevent the center wing tank Fuel Quantity Indicating System (FQIS) densitometer from becoming an ignition source. If this service bulletin is not done, a potential 115 VAC hot short could cause the center wing tank FQIS densitometer resistors to fail. When the fuel level in the center wing tank is low such a densitometer failure could ignite fuel vapors in the center wing tank.
As part of the Special Federal Aviation Regulations (SFAR) 88 system safety analysis, Boeing found that an electrical short from a source outside the FQIS to the densitometer wiring could result in an ignition event if the densitometer resistors failed while not covered by fuel. A hot short protector will be installed to protect the fuel densitometer for the center wing tank from exposure to unsafe energy levels.
This change affects Section 9 of the Maintenance Planning Data (MPD) Document. New Airworthiness LImitations (AWL) "28-AWL-22" will be added to Section 9 of the MPD to include verifying the bonding requirements during the replacement of the HSP .
This service bulletin is the result of the safety assessments conducted by Boeing under Special Federal Aviation Regulation (SFAR) 88, "Fuel Tank System Fault Tolerance Evaluation Requirements".
ACTION (PRR B13421-8) Group 1; Group 2, Configuration 1:
Get access to the rear spar of the right center wing tank. Remove the existing wire bundle from the densitometer connector and back to the right wheel well disconnect. Install mounting hardware, hot short protector and two new wire bundles. Do system test.
Group 2, Configuration 2:
Airplanes which have not incorporated service bulletin 767-28-0043 will have Honeywell densitometer installed and therefore do not require the installation of the hot short protector.
Group 3:
Get access to the rear spar of the right center wing tank. Remove the existing wire bundle from the densitometer connector and back to the right wheel well disconnect. Install hot short protector and two new wire bundles. Do system test.
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Original Issue: November 20, 2007 767-28A0094Revision 1: April 23, 2009 7 of 76
Group 4:
Remove and replace the hot short protector as given in 767 AMM 28-41-24.
EFFECTIVITY 767-200, 767-300 and 767-300F airplanes. See 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 this change be made within five years from the date on the service bulletin.
INDUSTRY SUPPORT INFORMATION Boeing warranty remedies are not available for the configuration changes, and/or repair procedures given in this service bulletin.
MANPOWER Elapsed HoursTotal Task HoursAirplanes
7.5010.50Groups 1 and Group 2 Configuration 1
3.756.75Group 3
3.004.50Group 4
MATERIAL INFORMATION Boeing Supplied Kits/Parts.
Refer to Paragraph 2.A., Material - Price and Availability.
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Original Issue: November 20, 2007 767-28A0094Revision 1: April 23, 2009 8 of 76 BOEING SERVICE BULLETIN 767-28A0094
BOEING SERVICE BULLETIN 767-28A0094 INBD GROUP 1 AND 2, CONFIGURATION 1 AIRPLANES:
INSTALL MOUNTING HARDWARE, HOT SHORT PROTECTOR FWD * AND TWO NEW WIRE BUNDLES. DO A SYSTEM TEST.
GROUP 2, CONFIGURATION 2 AIRPLANES:
NO WORK IS REQUIRED.
GROUP 3 AIRPLANES:
INSTALL HOT SHORT PROTECTOR AND TWO NEW WIRE BUNDLES.
DO A SYSTEM TEST.
GROUP 4 AIRPLANES:
REMOVE HOT SHORT PROTECTOR AND INSTALL NEW HOT J95793 SHORT PROTECTOR. DO A SYSTEM TEST.
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Commercial Airplanes 767 Service Bulletin Number: 767-28A0094 Original Issue: November 20, 2007 Revision 1: April 23, 2009 ATA System: 2841 SUBJECT: FUEL - Indicating - Fuel Quantity Indicating System - Center Wing Tank - Hot Short Protector Change
1. PLANNING INFORMATION A. Effectivity
1. Airplanes Refer to Service Bulletin Index Document D6-30300 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 13421-8 for data about this change.
DESCRIPTIONCONFIGURATIONGROUP 767 airplanes with right center aux fuel tank and Simmonds or Goodrich densitometer installed.
-1 767 airplanes affected by service bulletin 767-28-0043.-2 767 airplanes that were changed by service bulletin 767-28-0043 which installs Simmonds or Goodrich densitometers and will require hot short protector installation.
1 767 airplanes that were not changed by service bulletin 767-28-0043 and have Honeywell densitometers installed, no rework will be required.
2 767 airplanes with mounting hardware installed during production but require the installation of Hot Short Protector and new wire bundles.
-3 767 airplanes with Simmonds or Goodrich densitometer installed but require existing Hot Short Protector removed and new Hot Short Protector installed.
-4 Airplane Models:
767-200, 767-300, 767-300F BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: November 20, 2007 767-28A0094Revision 1: April 23, 2009 11 of 76
GroupVariable Number 2VA509 - VA525 2VA527 - VA530 1VB441 - VB444 1VF162 1VF171 - VF172 1VF180 - VF184 1VF251 1VK012 - VK016 1VK055 - VK056 1VK101 - VK113 1VK143 - VK148 1VK162 - VK164 1VK171 1VK181 1VK186 1VL701 - VL703 1VL751 - VL755 1VL806 - VL807 1VL871 - VL873 1VL891 - VL900 1VL911 - VL914 1VL931 - VL932 1VL941 1VN021 - VN041 1VN094 - VN099 1VN125 - VN127 1VN133 - VN137 1VN174 1VN195 - VN198 1VN225 1VN242 - VN243 1VN261 - VN276 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: November 20, 2007 767-28A0094Revision 1: April 23, 2009 12 of 76 BOEING SERVICE BULLETIN 767-28A0094