# Boeing Alert Service Bulletin 767-28A0094: Revision 1

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- Document: [Boeing Alert Service Bulletin 767-28A0094](https://openairdocs.org/service-documents/boeing/767-28a0094.md)
- Title as filed: Boeing Service Bulletin
- Pages: 76
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## Text

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### Page 1

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Unpublished Work - All Rights Reserved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.
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3.0

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Table of Contents
Revision Transmittal Sheet ............................................ 5
Summary ..................................................... 7
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
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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
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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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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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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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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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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.
Original Issue: November 20, 2007
Revision 1: April 23, 2009  767-28A0094
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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
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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
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GroupVariable Number
1VN292 - VN293
1VN309 - VN314
1VN383 - VN388
1VN421 - VN427
1VN436
1VN498 - VN513
1VN546 - VN547
1VN556 - VN557
1VN561 - VN562
1VN634 - VN638
1VN653 - VN658
1VN676
1VN684 - VN691
1VN732
1VN811 - VN813
1VN921 - VN922
1VN931 - VN936
1VN951 - VN953
1VN966 - VN972
1VR051 - VR060
1VR081
1VR084
1VR201 - VR211
1VR251
1VR256 - VR260
1VR401
1VR421 - VR423
1VR426
1VR441
1VR461
1VR471 - VR472
1VS051 - VS056
1VS061
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GroupVariable Number
1VS066 - VS070
1VS073 - VS078
1VS091 - VS104
1VS111 - VS113
1VS131 - VS133
1VS136 - VS137
1VS176 - VS177
1VS186 - VS187
1VS196 - VS203
1VS206 - VS208
1VS211
1VS216 - VS217
1VS231
1VS246 - VS248
1VS261 - VS263
1VS266 - VS274
1VS291 - VS293
1VS301 - VS303
1VS306 - VS311
1VS316
1VS321 - VS324
1VS331 - VS333
1VS336 - VS337
1VS366 - VS367
1VS381 - VS382
1VS391 - VS392
1VS401
1VS426 - VS428
1VS466 - VS472
1VS486
1VS496 - VS497
1VS506 - VS507
1VS526
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GroupVariable Number
1VS546 - VS549
1VS701 - VS713
4VS714
3VS715
1VS721 - VS732
1VS751 - VS759
1VS821 - VS825
1VS841 - VS844
1VS861
1VS881 - VS883
1VS891
1VS896
3VS901 - VS904
3VS911
1VT501
1VT511 - VT512
3VT513
1VT521
3VT522 - VT523
1VV001
1VW701 - VW721
1VW851
2. Spares Affected
None.
B. Concurrent Requirements
None.
C. Reason
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.
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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".
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 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.
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.
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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.
D. Description
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.
Group 4:
Remove and replace the hot short protector as given in 767 AMM 28-41-24.
Revision 1 - 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.
The work in this service bulletin is done in the maintenance zone(s) given below.
Group 1:
Affected Maintenance Zones
ZoneModel
144, 651767-200, 767-300, 767-300F
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Group 2:
Affected Maintenance Zones
ZoneModel
144, 651767-200
Group 3:
Affected Maintenance Zones
ZoneModel
144, 651767-300, 767-300F
Group 4:
Affected Maintenance Zones
ZoneModel
651767-300
E. 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.
F. Approval
This service bulletin was examined by the Federal Aviation Administration (FAA).The changes specified
in this service bulletin comply with the applicable regulations and are FAA approved, as well as European
Aviation Safety Agency (EASA)/Joint Aviation Authorities (JAA) approved for all EASA/JAA approved
airplanes listed in the service bulletin effectivity. This service bulletin and its approval were based on
the airplane in its original Boeing delivery configuration or as modified by other approved Boeing
changes.
If an airplane has a non-Boeing modification or repair that affects a component or system also affected
by this service bulletin, the operator is responsible for obtaining appropriate regulatory agency approval
before incorporating this service bulletin.
G. Manpower
The table below shows an estimate of the task-hours necessary to do this change for each airplane.
This estimate is for direct labor only, done by an experienced crew. Adjust the estimate with operator
task-hour data if necessary. The estimate does not include lost time. These are some examples of lost
time:
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— Time to adjust to the workplace
— Time to schedule the work
— Time to examine the work
— Time to cure the materials
— Time to make the parts
— Time to find the tools.
Group 1; Group 2, Configuration 1:
Elapsed HoursTask-HoursNumber of Per-
sons
Task
0.751.502Open Access
0.751.502Figure 1
0.750.751Figure 2
2.252.251Figure 3
0.500.501Figure 4
0.500.501Figure 5
0.250.251Figure 6
0.751.502Figure 7
0.751.502Close Access
0.250.251Test
7.5010.50TOTAL FOR EACH AIRPLANE
Group 3:
Elapsed HoursTask-HoursNumber of Per-
sons
Task
0.751.502Open Access
0.751.502Figure 8
0.500.501Figure 9
0.751.502Figure 10
0.751.502Close Access
0.250.251Test
3.756.75TOTAL FOR EACH AIRPLANE
Group 4:
Elapsed HoursTask-Hours
3.004.50TOTAL FOR EACH AIRPLANE
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### Page 20

H. Weight and Balance Changes
Change in Moment
(Pound-Inches)
Change in Weight
(Pounds)
Airplane Groups
+4197.6 lb-in+4.4 lbsGroup 1 and Group 2
Configuration 1
+3434.4 lb-in+3.6 lbsGroup 3
No ChangeNo ChangeGroup 4
I. Electrical Load Data
Not changed.
J. References
1. Existing Data:
a. Engineering Change Memo PRR B13421-8
b. 767 Aircraft Maintenance Manual (AMM) 20-10-12, 20-10-23, 24-22-00, 28-41-00, 28-41-24,
32-00-15, 32-00-20
c. Boeing Drawing 012W6100
d. 767 Maintenance Planning Data (MPD) Document Section 9
e. Boeing Parts Standards Document D-590
f. Standard Overhaul Practices Manual (SOPM) 20-11-03
g. Standard Wiring Practices Manual (SWPM) 20-10-11, 20-10-12, 20-10-19, 20-20-00
h. 767 Wiring Diagram 28-22-11, 28-22-12, 28-31-11, 28-41-23
2. Data supplied with this Service Bulletin:
None.
3. Installation Drawings Used in the Preparation of this Service Bulletin:
TitleDrawing Number
HOT SHORT PROTECTOR EQUIPMENT INSTALLATION284T3002 Sht 1
WIRE BUNDLE INSTALLATION INBD REAR SPAR AND TRAILING
EDGE RH, BBL 97.42 TO RSS 608.7.
288T1374 Sht 203
WIRE BUNDLE INSTALLATION, WHEELWELL AREA RIGHT,
STA 955 THRU 1065.
288T4570 Sht 201
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### Page 21

These drawings were used to prepare this service bulletin. These drawings are not necessary to
make the specified changes, and are not supplied with this service bulletin. These drawings may
not be applicable to all airplane configurations or operators.
K. Publications Affected
Chapter-SectionPublication
28-22, 28-31, 28-41767 Wiring Diagram Manual
28-41767 Airplane Maintenance Manual
28-41767 Illustrated Parts Catalog
Section 9767 Maintenance Planning Data (MPD) Document
L. Interchangeability and Intermixability of Parts
Accomplishment of this service bulletin does not affect interchangeability or intermixability of parts.
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BLANK PAGE

### Page 23

2.    MATERIAL INFORMATION
A. Material - Price and Availability
Boeing can supply the kits shown in Paragraph 2.C., Parts Necessary For Each Airplane is shown
below. If there is a limit to the quantity (QTY) of available kits, a supply sequence is given by Spares.
More kits become available as shown in the Reorder Lead Time (ROLT). ROLT is calculated from the
date Boeing gets the purchase order.
Group 1; Group 2, Configuration 1:
Unit Price thru
May 31, 2009
QTYDateNameNumber
$14,376.002501/27/2009TOP KIT - Hot Short
Protector Installation -
Center Wing Tank
015T1787-1
2502/24/2009
2503/24/2009
2504/21/2009
2505/17/2009
2506/17/2009
2507/16/2009
2508/13/2009
Group 3:
Unit Price Thru
May 31, 2009
QTYDateNameNumber
$11,377.00208/21/2007TOP KIT - Hot Short
Protector Installation -
Center Wing Tank
015T1787-2
The kits are subject to the terms and conditions of the Boeing standard purchase order acknowledgment.
After the Unit Price date, new price and ROLT data is applicable. Prices are in United States dollars.
Terms: Net 30 days.
Reference this service bulletin and submit your purchase order by one of the methods that
follow:
1. Order on-line via ATA Spec 2000 or Boeing Part Page
2. Fax to (206) 662-7145
3. Spares Customer Support - MC 36-65 Boeing Spares Department P .O. Box 3707 Seattle,
Washington 98124-2207 USA
B. Industry Support Information
Boeing warranty remedies are not available for the configuration changes given in this service bulletin.
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### Page 24

C. Parts Necessary For Each Airplane
1. Kits/Parts:
To get the kits/parts shown below, refer to Paragraph 2.A., Material - Price and Availability.
NOTE: One top kit and the items shown in Paragraph 2.C.2., Parts and Materials Supplied by
the Operator, are necessary for each airplane.
Figure Kit
765432Top Kit
111111015T1787-1
------015T1787-2
Figure Kit
109Top Kit
--015T1787-1
11015T1787-2
Group 1; Group 2, Configuration 1:
KIT 015T1787-1
NOTES
Existing Part
NumberName
Figure
New Part Number
765432
QTY
HOT SHORT PRO-
TECTOR BRACK-
ET ASSEMBL Y
1284T3003U2
BRACKET ASSY1287T0014-463
GROUND BRACK-
ET ASSY
1287T0014-777
BRACKET ASSY1287T0014U379
GROUND STUD
ASSY
1287T0015U522
GROUND STUD
ASSY
1287T0020U559
HOT SHORT PRO-
TECTOR
130283-0201
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### Page 25

Group 1; Group 2, Configuration 1:
KIT 015T1787-1
NOTES
Existing Part
NumberName
Figure
New Part Number
765432
QTY
INSULATION
SLEEVING, HEAT
SHRINKABLE,
YELLOW, IN DIA
1/4", CLASS 1
7829A9003-144
VINYL MARKER1BAC27TEX7059
JUMPER2BACJ40D10-20
NUT15BACN10YR3CD
RIVET, 100 DEG6BACR15CE6AD7
(BACR15CE6DD7
optional)
RIVET, UNIVER-
SAL HD
20BACR15FT5AD6C
RIVET, UNIVER-
SAL HD
20BACR15FT5AD7C
RIVET, UNIVER-
SAL HD
12BACR15FT6AD7C
RIVET, UNIVER-
SAL HD
12BACR15FT6AD8C
BOLT4BACS12HN3-10
BOLT2BACS12HN3-12
SCREW1BACS12HN3-26
BOLT4BACS12HN3-8
CABLE ASSEM-
BL Y , PLUG,
RIGHT CENTER
AUX DENSITOME-
TER, HSP SHIP
SIDE
1CN1156-938
CABLE ASSEM-
BL Y , PLUG,
RIGHT CENTER
AUX DENSITOME-
TER, HSP TANK
SIDE
1CN1156-939
WASHER1110NAS1149D0316H
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### Page 26

Group 1; Group 2, Configuration 1:
KIT 015T1787-1
NOTES
Existing Part
NumberName
Figure
New Part Number
765432
QTY
WASHER, PLAIN4NAS1149D0332H
SPACERS FOR
RIVETS
1NAS42DD6-64FC
Group 3:
KIT 015T1787-2
NOTES
Existing Part
NumberName
Figure
New Part Number
109
QTY
HOT SHORT PRO-
TECTOR
130283-0201
VINYL MARKER1BAC27TEX7059
JUMPER2BACJ40D10-20
NUT1BACN10YR3CD
BOLT4BACS12HN3-10
BOLT2BACS12HN3-12
SCREW1BACS12HN3-26
CABLE ASSEM-
BL Y , PLUG,
RIGHT CENTER
AUX DENSITOME-
TER, HSP SHIP
SIDE
1CN1156-938
CABLE ASSEM-
BL Y , PLUG,
RIGHT CENTER
AUX DENSITOME-
TER, HSP TANK
SIDE
1CN1156-939
WASHER210NAS1149D0316H
WASHER, PLAIN4NAS1149D0332H
SPACERS FOR
RIVETS
1NAS42DD6-64FC
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2. Parts and Materials Supplied by the Operator:
NotesNameQTYPart Number/ Specification
(a)PRIMER1 ptBMS 10-11, TYPE1
(a)SEALANT1 ptBMS 5-95
(a)LOCK WIRE8 ftMS20995C32
(a) See the Qualified Products List at the end of the Boeing Material Specification (BMS) for
supplier data.
Group 4:
NotesExisting Part Num-
ber
NameQTYPart Number/Speci-
fication
(a) (b)30283-0101HOT SHORT PRO-
TECTOR
130283-0201
(a) This part is used in production.
(b) Discard the existing part.
3. Parts Modified and Reidentified:
None.
4. Parts Removed and Not Replaced:
None.
D. Parts Necessary to Change Spares
None.
E. Special Tooling - Price and Availability
None.
F. Special Tooling Necessary to do this Service Bulletin
No special tools or equipment are necessary to do the change in this service bulletin. But, maintenance
and overhaul tools in the manuals given in Paragraph 1.J., References, can be necessary. Examine
operator tool supply to make sure all necessary tools are available.
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BLANK PAGE

### Page 29

3.    ACCOMPLISHMENT INSTRUCTIONS
A. GENERAL INFORMATION
CAUTION: KEEP THE WORK AREA, WIRES AND ELECTRICAL BUNDLES CLEAN OF METAL
PARTICLES OR CONTAMINATION WHEN YOU USE TOOLS. UNWANTED MATERIAL,
METAL PARTICLES OR CONTAMINATION CAUGHT IN WIRE BUNDLES CAN CAUSE
DAMAGE TO THE BUNDLES. DAMAGED WIRE BUNDLES CAN CAUSE SPARKS OR
OTHER ELECTRICAL DAMAGE.
NOTE: 1. Manual titles are referred to by acronyms. Refer to Paragraph 1.J., References, for
definition of the acronyms.
2. Obey all of the warnings and cautions given in the specified manual sections.
3. Unless shown differently, these dimensions and tolerances are used:
— Linear dimensions are in inches
— Tolerance on linear dimensions, other than rivet and bolt edge margins, is plus
or minus 0.03 inch.
— Tolerance on rivet and bolt edge margin is plus or minus 0.05 inch
— Hole dimensions for standard solid rivets are given in 767 Structural Repair
Manual, Chapter 51
— Torque limits to tighten nuts and bolts are given in 767 Structural Repair Manual,
Chapter 51.
4. For approved fastener and process material substitutions, refer to 767 Structural
Repair Manual, Chapter 51, Alternate fasteners are given in 767 Structural Repair
Manual Chapter 51 and Boeing Drawing 012W6100
5. Refer to the Boeing Standard Wiring Practices Manuals, SWPM 20-10-11, SWPM
20-10-12 and SWPM 20-10-19 for the wire installation procedures.
6. If the length of fasteners specified in this service bulletin do not meet the installation
standards, fasteners of the same specification, or an approved substitute, one grip
length longer or shorter may be used.
7. These work instructions refer to procedures included on other Boeing documents.
When the words "refer to" are used and the operator has an accepted alternative
procedure, the accepted alternative procedure can be used. When the words "as
given in" are included in the instruction, the procedure in the Boeing document must
be used.
B. WORK INSTRUCTIONS
Group 1; Group 2, Configuration 1:
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1. Make sure the down locks are installed in the nose and main landing gear. Refer to 767 AMM
32-00-20 as an accepted procedure.
2. Make sure the door locks are installed on the landing gear doors. Refer to 767 AMM 32-00-15 as
an accepted procedure.
3. Make sure electrical power is applied to the airplane. Refer to 767 AMM 24-22-00 as an accepted
procedure.
4. Make sure the following circuit breakers are Closed and Remove "DO NOT CLOSE" safety tags
(if installed):
TitleCircuit BreakerPanel
FUEL QTY 1C01048P11
FUEL QTY 2C01053P11
FUEL QTYC01045P6
FUEL QTY REFUELC01040P34
5. Do the Fuel Quantity BITE Procedure as given in 767 AMM 28-41-00 to verify that the densitometer
passes before installation of the hot short protector in the system.
a. If the Fuel Quantity BITE Procedure, "Self Test" passed, then proceed with the hot short
protector installation.
b. Do not close the Electrical/Electronic access door in Step 6 of the Fuel Quantity BITE Procedure
at this time.
6. Make sure the following circuit breakers are Open and Install "DO NOT CLOSE" safety tags:
TitleCircuit BreakerPanel
FUEL QTY 1C01048P11
FUEL QTY 2C01053P11
FUEL QTYC01045P6
FUEL QTY REFUELC01040P34
7. Gain access to right rear spar of the center wing tank through the right wheel well and the inner
rear spar to install the Hot Short Protector and supporting hardware at station.
8. Disconnect Cinch wire bundle at the marker labeled "RIGHT CTR AUX DENSITOMETER" and
the disconnect panel in the right well wheel. Remove clamping and disconnect any bonding grounds
to remove Cinch wire bundle from the airplane as given in Figure 1.
CAUTION: WHEN REMOVING THE WIRE BUNDLE CONNECTOR AT THE "RIGHT CTR AUX
DENSITOMETER" DO NOT TURN MOUNTING NUT AS THIS MAY BREAK THE
SEALANT INTERNAL TO THE FUEL TANK.
9. Disconnect existing ground wires and remove existing grounding brackets as given in Figure 2.
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10. Install new hot short protector support bracket, grounding brackets and identify grounding studs
as given in Figure 3.
11. Install Hot Short Protector and bonding straps as given in Figure 4.
12. Identify new ground numbers using identification tape and install wires as given in Figure 5 and
Figure 6.
13. Install new Cinch wire bundle CN1156-938 and CN1156-939 as given in Figure 7.
14. Make sure the following circuit breakers are Closed and Remove "DO NOT CLOSE" safety tags:
TitleCircuit BreakerPanel
FUEL QTY 1C01048P11
FUEL QTY 2C01053P11
FUEL QTYC01045P6
FUEL QTY REFUELC01040P34
15. Do the Fuel Quantity BITE Procedure as given in 767 AMM 28-41-00 to verify system operation.
16. Close access.
17. Remove electrical power from the airplane if required. Refer to 767 AMM 24-22-00 as an accepted
procedure.
18. Remove landing gear doorlocks if they were installed in Step 2. Refer to 767 AMM 32-00-15 as
an accepted procedure.
19. Remove landing gear downlocks if they were installed in Step 1. Refer to 767 AMM 32-00-20 as
an accepted procedure.
20. Return the airplane to serviceable condition.
Group 2, Configuration 2:
1. 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:
1. Make sure the down locks are installed in the nose and main landing gear. Refer to 767 AMM
32-00-20 as an accepted procedure.
2. Make sure the door locks are installed on the landing gear doors. Refer to 767 AMM 32-00-15 as
an accepted procedure.
3. Make sure electrical power is applied to the airplane. Refer to 767 AMM 24-22-00 as an accepted
procedure.
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4. Make sure the following circuit breakers are Closed and Remove "DO NOT CLOSE" safety tags
(if installed):
TitleCircuit BreakerPanel
FUEL QTY 1C01048P11
FUEL QTY 2C01053P11
FUEL QTYC01045P6
FUEL QTY REFUELC01040P34
5. Do the Fuel Quantity BITE Procedure as given in 767 AMM 28-41-00 to verify that the densitometer
passes before installation of the hot short protector in the system.
a. If the Fuel Quantity BITE Procedure, "Self Test" passed, then proceed with the hot short
protector installation.
b. Do not close the Electrical/Electronic access door in Step 6 of the Fuel Quantity BITE Procedure
at this time.
6. Make sure the following circuit breakers are Open and Install "DO NOT CLOSE" safety tags:
TitleCircuit BreakerPanel
FUEL QTY 1C01048P11
FUEL QTY 2C01053P11
FUEL QTYC01045P6
FUEL QTY REFUELC01040P34
7. Gain access to right rear spar of the center wing tank through the right wheel well and the inner
rear spar to install the Hot Short Protector and two new Cinch wire bundles.
8. Disconnect Cinch wire bundle at the marker labeled "RIGHT CTR AUX DENSITOMETER" and
the disconnect panel in the right well wheel. Remove clamping and disconnect any bonding grounds
to remove Cinch wire bundle from the airplane as given in Figure 8.
CAUTION: WHEN REMOVING THE WIRE BUNDLE CONNECTOR AT THE "RIGHT CTR AUX
DENSITOMETER" DO NOT TURN MOUNTING NUT AS THIS MAY BREAK THE
SEALANT INTERNAL TO THE FUEL TANK.
9. Install Hot Short Protector and bonding straps as given in Figure 9.
10. Install two new Cinch wire bundle CN1156-938 and CN1156-939 as given in Figure 10.
11. Make sure the following circuit breakers are Closed and Remove "DO NOT CLOSE" safety tags:
TitleCircuit BreakerPanel
FUEL QTY 1C01048P11
FUEL QTY 2C01053P11
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TitleCircuit BreakerPanel
FUEL QTYC01045P6
FUEL QTY REFUELC01040P34
12. Do the Fuel Quantity BITE Procedure as given in 767 AMM 28-41-00 to verify system operation.
13. Close access.
14. Remove electrical power from the airplane if required. Refer to 767 AMM 24-22-00 as an accepted
procedure.
15. Remove landing gear doorlocks if they were installed in Step 2. Refer to 767 AMM 32-00-15 as
an accepted procedure.
16. Remove landing gear downlocks if they were installed in Step 1. Refer to 767 AMM 32-00-20 as
an accepted procedure.
17. Return the airplane to serviceable condition.
Group 4:
1. Remove hot short protector part number 30283-0101 as given in 767 AMM 28-41-24.
2. Install new hot short protector part number 30283-0201 as given in 767 AMM 28-41-24.
3. Return the airplane to serviceable condition.
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BOEING SERVICE BULLETIN 767-28A0094
This Figure applies only to: Group 1; Group 2, Configuration 1.
STA
999
SEE A
SEE B
CN1156-135/-935
UP
AL 1002
INBD  • FWD
CN1156-135/-935
GD4098S
GD3946S
AL1010
FWD C
CN1156-135/-935  U33174
FIGURE 1: REMOVE WIRE BUNDLE CN1156-135 OR -935
(SHEET 1 OF 4)
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### Page 35 (OCR)

BOEING SERVICE BULLETIN 767-28A0094
CN1156-135/-935
SEE ©  INBD <
FWD  RSS
254
U33175
FIGURE 1: REMOVE WIRE BUNDLE CN1156-135 OR -935
(SHEET 2 OF 4)
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### Page 36 (OCR)

BOEING SERVICE BULLETIN 767-28A0094
M1952
CN1156-135/-935
INBD
FWD
1336735
FIGURE 1: REMOVE WIRE BUNDLE CN1156-135 OR -935
(SHEET 3 OF 4)
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### Page 37

The step numbers shown below agree with the numbers shown in the circle symbols in the figure. The QTY
numbers shown below are the number of parts necessary for this figure.
MORE DATAQTYIDENTIFICATIONNAMETASKSTEP
CAUTION: DO NOT REMOVE MOUNTING NUT AS THIS MAY BREAK THE SEALANT INTERNAL TO
THE FUEL TANK.
Disconnect wire
bundle in the right
wheel well at connec-
tor D4538P .
1CN1156-135 OR -935FQIS WIRE BUNDLEDisconnect1
2-PIGTAILDisconnect
Remove and keep
all clamps necessary
for wire bundle re-
moval.
--CLAMPRemove / Keep2
For lock wire re-
moval refer to 767
AMM 20-10-23 as
an accepted proce-
dure.
--LOCK WIRERemove3
At the RIGHT CTR
AUX DENSITOME-
TER.
1CN1156-135 OR -935FQIS WIRE BUNDLEDisconnect
Remove bonding
jumper from ground
stud GD5976-S,
1-BONDING JUMPERRemove4
1-LOCK NUTRemove
2-WASHERRemove
1CN1156-135 OR -935FQIS WIRE BUNDLERemove5
FIGURE 1: REMOVE WIRE BUNDLE CN1156-135 OR -935
(SHEET 4 OF 4)
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### Page 38 (OCR)

BOEING SERVICE BULLETIN 767-28A0094
This Figure applies only to: Group 1; Group 2, Configuration 1.
SEE A
INBD
FWD
SEE B  U34160
FIGURE 2: DISCONNECT GROUND WIRES AND GROUND BRACKETS REMOVAL
(SHEET 1 OF 3)
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### Page 39 (OCR)

BOEING SERVICE BULLETIN 767-28A0094
• SEE
INBD
FWD<
RSS
254
INBD
FIGURE 2: DISCONNECT GROUND WIRES AND GROUND BRACKETS REMOVAL
(SHEET 2 OF 3)
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### Page 40

The step numbers shown below agree with the numbers shown in the circle symbols in the figure. The QTY
numbers shown below are the number of parts necessary for this figure.
MORE DATAQTYIDENTIFICATIONNAMETASKSTEP
To be reinstalled on
new ground studs.
--GROUND WIRESDisconnect1
--LOCK NUTRemove
--WASHERRemove / Keep
2-CLAMPRemove / Keep2
2-BOLTRemove
2-WASHERRemove
4-BRACKETRemove3
Fill open holes flush
for mounting support
brackets. Quantity
shown includes ex-
tra parts.
6BACR15CE6AD7
(BACR15CE6DD7 op-
tional)
RIVET, 100 DEGInstall (New)4
FIGURE 2: DISCONNECT GROUND WIRES AND GROUND BRACKETS REMOVAL
(SHEET 3 OF 3)
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### Page 41 (OCR)

BOEING SERVICE BULLETIN 767-28A0094
This Figure applies only to: Group 1; Group 2, Configuration 1.
SEE A
INBD <
FWD
SEE  U34305
FIGURE 3: INSTALL HOT SHORT PROTECTOR MOUNTING AND GROUNDING BRACKETS
(SHEET 1 OF 6)
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### Page 42 (OCR)

BOEING SERVICE BULLETIN 767-28A0094
• SEE  0.43  $0.43  0.58
SEE
SEE
- SEE ©
SEE
0.95
FWD •  0.43  2.01
-0.43
INBD  UP  † NEW HOLES
* EXISTING HOLES
FWD <
FIGURE 3: INSTALL HOT SHORT PROTECTOR MOUNTING AND GROUNDING BRACKETS
(SHEET 2 OF 6)
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### Page 43 (OCR)

BOEING SERVICE BULLETIN 767-28A0094
-1.98 →
- 1.00
0.32
BON OR BON
0.87
A 5N OR A 5N  B 6N OR B 6N
0.77
0.37  0.87  A 5N OR AT 0.32
3 LOCATIONS\
1.18
- BON OR BON
0.35
0.75
A 5 OR 415M  2.02
12.81
AN OR 45N  2.00
3 LOCATIONS-
1.53
0.95 1
0.37
10.  0.37
AN OR 45N
0.32
3 LOCATIONS
_ 18
0.75
5.86  -2.02-
0.32
2.01
FWD  NEW HOLES  FWDC
D  EXISTING HOLES
FIGURE 3: INSTALL HOT SHORT PROTECTOR MOUNTING AND GROUNDING BRACKETS
(SHEET 3 OF 6)
Original Issue: November 20, 2007
Revision 1 April 23, 2009  767-28A0094
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### Page 44

The step numbers shown below agree with the numbers shown in the circle symbols in the figure. The QTY
numbers shown below are the number of parts necessary for this figure. Use parts in Top Kit 015T1787-1.
MORE DATAQTYIDENTIFICATIONNAMETASKSTEP
1284T3003U2HOT SHORT PROTEC-
TOR BRACKET AS-
SEMBL Y
Install (New)1
Refer to fastener
code table below.
Install rivets for a
driven rivet bond.
Refer to SOPM 20-
11-03 as an accept-
ed procedure.
--FASTENERInstall (New)
1287T0020U559GROUND STUD ASSYInstall (New)2
Refer to fastener
code table below.
Install rivets for a
driven rivet bond.
Refer to SOPM 20-
11-03 as an accept-
ed procedure.
--FASTENERInstall (New)
1287T0015U522GROUND STUD ASSYInstall (New)3
Refer to fastener
code table below.
Install rivets for a
driven rivet bond.
Refer to SOPM 20-
11-03 as an accept-
ed procedure.
--FASTENERInstall (New)
1287T0014U379BRACKET ASSYInstall (New)4
Refer to fastener
code table below.
Install rivets for a
driven rivet bond.
Refer to SOPM 20-
11-03 as an accept-
ed procedure.
--FASTENERInstall (New)
FIGURE 3: INSTALL HOT SHORT PROTECTOR MOUNTING AND GROUNDING BRACKETS
(SHEET 4 OF 6)
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Original Issue: November 20, 2007
767-28A0094Revision 1 April 23, 2009
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BOEING SERVICE BULLETIN 767-28A0094

### Page 45

MORE DATAQTYIDENTIFICATIONNAMETASKSTEP
1287T0014-777GROUND BRACKET
ASSY
Install (New)5
Refer to fastener
code table below.
Install rivets for a
driven rivet bond.
Refer to SOPM 20-
11-03 as an accept-
ed procedure.
--FASTENERInstall (New)
1287T0014-463BRACKET ASSYInstall (New)6
Refer to fastener
code table below.
Install rivets for a
driven rivet bond.
Refer to SOPM 20-
11-03 as an accept-
ed procedure.
--FASTENERInstall (New)
(a) (b)--RESISTANCEMeasure7
Touch-up all bare
metal surfaces, in-
cluding brackets and
top coat to match
area color.
-BMS 10-11, TYPE1PRIMERApply8
Use permanent
marker as an accept-
ed procedure, identi-
fy GD11672 at loca-
tion shown.
1GD11672GROUND STUDIdentify9
Use permanent
marker as an accept-
ed procedure, identi-
fy GD11674 at loca-
tion shown.
1GD11674GROUND STUDIdentify10
Use permanent
marker as an accept-
ed procedure, identi-
fy GD10393S at loca-
tion shown.
1GD10393SGROUND STUDIdentify11
Use permanent
marker as an accept-
ed procedure, identi-
fy GD3438S at loca-
tion shown.
1GD3438SGROUND STUDIdentify12
FIGURE 3: INSTALL HOT SHORT PROTECTOR MOUNTING AND GROUNDING BRACKETS
(SHEET 5 OF 6)
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45 of 76
BOEING SERVICE BULLETIN 767-28A0094

### Page 46

MORE DATAQTYIDENTIFICATIONNAMETASKSTEP
(a) (a) Use Bonding Meter as given in SWPM 20-20-00. Maximum resistance between grounding bracket
and primary structure for a driven rivet bond is 0.0005 ohms.
(b) b) If maximum resistance is exceeded, disassemble bracket assembly and reassemble using the procedures
as given in SOPM 20-11-03.
The codes shown below agree with the letter shown in the upper left corner of the fastener symbols in the figure.
A number in the lower right corner gives the grip length of the fastener. The QTY numbers shown below are in
excess for this figure.
If the grip length shown is not available at Boeing, fasteners supplied in kits may be one grip length longer than
indicated. Also, if any of the fastener part numbers are not available or have been superseded, substitute
fasteners may be supplied in Boeing kits, Boeing Document D-590 and Boeing drawing 012W6100 are used to
determine the part numbers used as substitutes.
MORE DATAHOLE DIAQTYIDENTIFICATIONNAMECODE
-20BACR15FT5AD6CRIVET, UNIVERSAL
HD
A
BACR15FT5D7C is option-
al if a longer grip length is
required.
-20BACR15FT5AD7CRIVET, UNIVERSAL
HD
-12BACR15FT6AD7CRIVET, UNIVERSAL
HD
B
BACR15FT6AD8C is op-
tional if a longer grip
length is required.
-12BACR15FT6AD8CRIVET, UNIVERSAL
HD
FIGURE 3: INSTALL HOT SHORT PROTECTOR MOUNTING AND GROUNDING BRACKETS
(SHEET 6 OF 6)
BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: November 20, 2007
767-28A0094Revision 1 April 23, 2009
46 of 76
BOEING SERVICE BULLETIN 767-28A0094

### Page 47 (OCR)

BOEING SERVICE BULLETIN 767-28A0094
This Figure applies only to: Group 1; Group 2, Configuration 1.
SEE A
INBD <
FWD '
SEE
U34643
FIGURE 4: INSTALL HOT SHORT PROTECTOR AND BONDING JUMPERS
(SHEET 1 OF 4)
Original Issue: November 20, 2007
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### Page 48 (OCR)

BOEING SERVICE BULLETIN 767-28A0094
5 2 LOCATIONS
SEE O
SEE
F&PU SIDE
26
2 LOCATIONS
2 LOCATIONS 5
INBD
BOLT
WASHER
BOTH SIDES OF
GROUND STRAP
INBD <  B  SEE C  WASHER  GROUND STRAP
TYPICAL BONDING JUMPER
INSTALLATION
U34672
FIGURE 4: INSTALL HOT SHORT PROTECTOR AND BONDING JUMPERS
(SHEET 2 OF 4)
Original Issue: November 20, 2007
Revision 1 April 23, 2009  767-28A0094
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### Page 49

The step numbers shown below agree with the numbers shown in the circle symbols in the figure. The QTY
numbers shown below are the number of parts necessary for installation of the Hot Short Protector. Use parts
in Top Kit 015T1787-1.
MORE DATAQTYIDENTIFICATIONNAMETASKSTEP
130283-0201
HOT SHORT PROTEC-
TORInstall (New)
1
Clean surface of Hot
Short Protector in lo-
cation shown. Refer
to SWPM 20-20-00,
Cleaning Procedure
1, 2, or 3 as an ac-
cepted procedure.--SURFACEPrepare
Refer to SWPM 20-
20-00 "Electrical and
Bonds and Ground-
ing" for Jumper
bonding and ground
stud installation as
an accepted proce-
dure.2BACJ40D10-20JUMPERInstall (New)
Install each bolt us-
ing two washers,
one washer on each
side of jumper.
2BACS12HN3-12BOLTInstall (New)
4NAS1149D0316HWASHERInstall (New)
Install each bolt us-
ing two washers,
one washer on each
side of jumper.
2BACS12HN3-10BOLTInstall (New)
2 4NAS1149D0316HWASHERInstall (New)
1BACS12HN3-10BOLTInstall (New)
3 1NAS1149D0316HWASHERInstall (New)
Do not tighten until
wire bundle is in-
stalled.1BACS12HN3-26SCREWInstall (New)
4
1NAS1149D0316HWASHERInstall (New)
1NAS42DD6-64FC
SPACERS FOR RIV-
ETSInstall (New)
Extra washer, use
where required for
correct grip length.4NAS1149D0332HWASHER, PLAINInstall (New)
(a) (b)--RESISTANCEMeasure5
FIGURE 4: INSTALL HOT SHORT PROTECTOR AND BONDING JUMPERS
(SHEET 3 OF 4)
BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: November 20, 2007
767-28A0094Revision 1 April 23, 2009
49 of 76
BOEING SERVICE BULLETIN 767-28A0094

### Page 50

MORE DATAQTYIDENTIFICATIONNAMETASKSTEP
Refer to SWPM 20-
20-00 as an accept-
ed procedure "Seal
of a Ground Stud
Assembly".-BMS 5-95SEALANTApply6
For Vinyl Marker in-
stallation, refer to
767 AMM 20-10-12
as an accepted pro-
cedure.1BAC27TEX7059VINYL MARKERInstall (New)7
(a) Use Bonding Meter as given in SWPM 20-20-00. Maximum resistance between bonding jumper and
bracket or between bonding jumper and Hot Short Protector is 0.0025 ohms.
(b) If Maximum resistance is exceeded, disassemble bonding jumper buildup and clean all mating surfaces
and reassemble, refer to SWPM 20-20-00 as an accepted procedure.
The parts shown in the table below are provided as extra parts for this figure.
MORE DATAQTYIDENTIFICATIONNAME
1BACS12HN3-10Bolt
FIGURE 4: INSTALL HOT SHORT PROTECTOR AND BONDING JUMPERS
(SHEET 4 OF 4)
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BOEING SERVICE BULLETIN 767-28A0094

### Page 51 (OCR)

BOEING SERVICE BULLETIN 767-28A0094
This Figure applies only to: Group 1; Group 2, Configuration 1.
PRESSURE
SEAL
AL 1002
3  W452-302Y-20
5  W452-302B-20  2
2  W452-302R-20  3
Q11 GD3438-S GD4044-S110
D8376P
W452-027-18-  17Q11 GD3334-DC 11
QI' GD11672 14
W452-028-18  H/QII GD3336-S 11
(JI)  D12182  QI: GD11674 1 4
V160 VALVE ACTUATOR R JETTISON
TRANSFER
REFERENCE: 767 WIRE DIAGRAM 28-31-11
FIGURE 5: WIRE BUNDLE IDENTIFICATION AND WIRING CHANGES
(SHEET 1 OF 3)
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### Page 52 (OCR)

BOEING SERVICE BULLETIN 767-28A0094
AL1004  PRESSURE
SEAL
R
W478-302B-18  1
R
W478-302R-18  2
R
6  W478-302Y-18  3
QI: GD4042-S  GD4040-S110
R
3  W478-002-18  Q11 GD3438-S 14
(J1)  D1540  D4410J
M335 RIGHT AFT
FUEL BOOST PUMP
REFERENCE: 767 WIRE DIAGRAM 28-22-11
AL1004  PRESSURE
SEAL
R
W478-301B-14  1
R
W478-301R-14  2
R
6  W478-301Y-14  3
1  QII GD4042-S  GD4040-S110
R
3  W478-001-14  QI' GD3438-S 14
(J1)  D2804  P  D5508J
M637 RIGHT AUX
TANK FUEL BOOST
OVERRIDE PUMP
REFERENCE: 767 WIRE DIAGRAM 28-22-12
FIGURE 5: WIRE BUNDLE IDENTIFICATION AND WIRING CHANGES
(SHEET 2 OF 3)
Original Issue: November 20, 2007
Revision 1 April 23, 2009  767-28A0094
BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.  52 of 76

### Page 53

The flag note numbers shown below agree with the numbers shown in the flag symbols in the figure. Use parts
in Top Kit 015T1787-1.
MORE DATAQTYIDENTIFICATIONNAME
FLAG
NOTE
Remove existing ground identifica-
tion tape.
1W452-027-18Wire1
Install new ground identification
tape and identify with GD11672.
Refer to SWPM 20-10-11 as an
accepted procedure.
1829A9003-144INSULATION SLEEVING,
HEAT SHRINKABLE, YEL-
LOW, IN DIA 1/4", CLASS
1
2
Remove existing ground identifica-
tion tape.
1W452-028-18Wire3
Install new ground identification
tape and identify with GD11674.
Refer to SWPM 20-10-11 as an
accepted procedure.
1829A9003-144INSULATION SLEEVING,
HEAT SHRINKABLE, YEL-
LOW, IN DIA 1/4", CLASS
1
4
Reinstall existing wires on
GD3438-S ground. (a), (b)
-W478Wire5
(a) Use Bonding Meter as given in SWPM 20-20-00 Procedure "Bonding Test of a Current Return Ground".
Maximum resistance between ground lug and bracket for 10-32 stud is 0.001 ohms.
(b) If maximum resistance is exceeded disassemble ground stud buildup and clean, reassembly as given in
SWPM 20-20-00.
The parts shown in the table below are provided as extra parts for this figure.
MORE DATAQTYIDENTIFICATIONNAME
5829A9003-144INSULATION SLEEV-
ING, HEAT SHRINK-
ABLE, YELLOW, IN
DIA 1/4", CLASS 1
FIGURE 5: WIRE BUNDLE IDENTIFICATION AND WIRING CHANGES
(SHEET 3 OF 3)
BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: November 20, 2007
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BOEING SERVICE BULLETIN 767-28A0094

### Page 54 (OCR)

BOEING SERVICE BULLETIN 767-28A0094
This Figure applies only to: Group 1; Group 2, Configuration 1.
SEE M
INBD
FWD
SEE ®  U33163
FIGURE 6: INSTALL WIRING
(SHEET 1 OF 4)
Original Issue: November 20, 2007
Revision 1 April 23, 2009
BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.

### Page 55 (OCR)

BOEING SERVICE BULLETIN 767-28A0094
6X7
INBD <
FWD
INBD <
FWD '  B  U34867
FIGURE 6: INSTALL WIRING
(SHEET 2 OF 4)
Original Issue: November 20, 2007
Revision 1 April 23, 2009  767-28A0094
BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.  55 of 76

### Page 56

The step numbers shown below agree with the numbers shown in the circle symbols in the figure. The QTY
numbers shown below are the number of parts necessary to install the existing wire bundles. Use parts in Top
Kit 015T1787-1.
MORE DATAQTYIDENTIFICATIONNAMETASKSTEP
--GROUND WIRESRoute1
Route wire bundle
thru clamp and tight-
en screw.--ClampInstall (Kept)2
Install ground wires.
Refer to SWPM 20-
20-00 as an accept-
ed procedure for
torque values.4BACN10YR3CDNUTInstall (New)
3 4NAS1149D0316HWASHERInstall (Kept)
Install clamp (kept)
in location shown.1-ClampInstall (Kept)
4
1BACS12HN3-8BOLTInstall (New)
1NAS1149D0316HWASHERInstall (New)
Install wire bundle
clamps at locations
shown, refer to SW-
PM 20-10-12 as an
accepted procedure.2-CLAMPInstall (Kept)
5
2-BOLTInstall (Kept)
2-WASHERInstall (Kept)
(a) (b)--RESISTANCEMeasure6
Refer to SWPM 20-
20-00 as accepted
procedure "Seal of a
Ground Stud Assem-
bly".-BMS 5-95SEALANTApply7
(a) Use Bonding Meter as given in SWPM 20-20-00 Procedure "Bonding Test of a Current Return Ground".
Maximum resistance between ground lug and bracket for 10-32 stud is 0.001 ohms.
(b) If maximum resistance is exceeded disassemble ground stud buildup and clean, reassembly as given in
SWPM 20-20-00.
The parts shown in the table below are provided as extra parts for this figure.
MORE DATAQTYIDENTIFICATIONNAME
1BACN10YR3CDNut
FIGURE 6: INSTALL WIRING
(SHEET 3 OF 4)
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Original Issue: November 20, 2007
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56 of 76
BOEING SERVICE BULLETIN 767-28A0094

### Page 57

MORE DATAQTYIDENTIFICATIONNAME
3BACS12HN3-8Bolt
FIGURE 6: INSTALL WIRING
(SHEET 4 OF 4)
BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: November 20, 2007
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57 of 76
BOEING SERVICE BULLETIN 767-28A0094

### Page 58 (OCR)

BOEING SERVICE BULLETIN 767-28A0094
This Figure applies only to: Group 1; Group 2, Configuration 1.
STA
999
SEE
SEE B
AL1002
UP
INBD *  • FWD
CN1156-938
GD4098S
GD3946S
AL1010
FWDE
CN1156-938  U35395
FIGURE 7: INSTALL WIRE BUNDLES CN1156-938 AND CN1156-939
(SHEET 1 OF 6)
Original Issue: November 20, 2007
Revision 1 April 23, 2009  767-28A0094
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### Page 59 (OCR)

BOEING SERVICE BULLETIN 767-28A0094
CN1156-938
SEE C
CN1156-939
INBD <
FWD *  U35933
FIGURE 7: INSTALL WIRE BUNDLES CN1156-938 AND CN1156-939
(SHEET 2 OF 6)
Original Issue: November 20, 2007
Revision 1 April 23, 2009  767-28A0094
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### Page 60 (OCR)

BOEING SERVICE BULLETIN 767-28A0094
INBD
FWD *
FIGURE 7: INSTALL WIRE BUNDLES CN1156-938 AND CN1156-939
(SHEET 3 OF 6)
Original Issue: November 20, 2007
Revision 1 April 23, 2009  767-28A0094
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