Boeing Special Attention Service Bulletin 767-24-0200: Revision 1, text

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Commercial Airplanes 767 Service Bulletin

SPECIAL ATTENTION Number: 767-24-0200 Original Issue: April 14, 2011 Revision 1: September 13, 2012 ATA System: 2431 SUBJECT: ELECTRICAL POWER - Batteries - Battery Charger Enabled In Flight When Standby Power Switch In Battery Position Wiring Change Export of this technology is controlled under the United States Export Administration Regulations (EAR) (15 CFR 300-774). 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:

Treatment of this document and its content is governed by contract with Boeing. Rights to use this document are licensed on a per aircraft basis and such rights may not be transferable. For more information, contact The Boeing Company.

Boeing, the Boeing signature, the Boeing symbol, 707, 717, 727, 737, 747, 757, 767, 777, 787, Dreamliner™, BBJ, DC-8, DC-9, DC-10, KC-10, KDC-10, MD-10, MD-11, MD-80, MD-88, MD-90, P-8A, Poseidon and Boeing liveries 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 is a trademark of Boeing Management Company.

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Table of Contents

Revision Transmittal Sheet7

Summary ..................................................... 1 1

1. PLANNING INFORMATION ........................................ 1 5 A. Effectivity ............................................... 1 5

1. Airplanes ............................................ 1 5

2. Spares Affected ........................................ 2 3 B. Concurrent Requirements ...................................... 2 3 C. Reason ................................................ 2 3 D. Description .............................................. 2 4 E. Compliance .............................................. 2 6 F. Approval ............................................... 2 6 G. Manpower .............................................. 2 6 H. Weight and Balance Changes .................................... 4 5 I. Electrical Load Data ......................................... 4 5 J. References .............................................. 4 5

1. Existing Data: ......................................... 4 5

2. Data Supplied with this Service Bulletin: ........................... 4 5

3. Installation Drawings Used in the Preparation of this Service Bulletin: ........... 4 6 K. Publications Affected ........................................ 4 6 L. Interchangeability and Intermixability of Parts ........................... 4 7 M. Software Accomplishment Summary ................................ 4 7

2. MATERIAL INFORMATION ........................................ 4 9 A. Material - Price and Availability ................................... 4 9 B. Industry Support Information .................................... 5 0 C. Parts Necessary for Each Airplane ................................. 5 0

1. Kits/Parts ............................................ 5 0

2. Parts and Materials Supplied by the Operator ........................ 5 4

3. Parts Modified and Reidentified ................................ 5 4

4. Parts Removed and Not Replaced .............................. 5 4 D. Parts Necessary to Change Spares ................................. 5 4 E. Special Tooling - Price and Availability ............................... 5 4 F. Special Tooling Necessary to do this Service Bulletin ....................... 5 4

3. ACCOMPLISHMENT INSTRUCTIONS .................................. 5 5 A. GENERAL INFORMATION ..................................... 5 5 B. WORK INSTRUCTIONS ....................................... 5 5 FIGURE 1: P33 PANEL - WIRE BUNDLES W0144 AND W0146 - WIRE ROUTING [Group 1-2, 5-6, 8, 11, 13, 15, 17, 19, 23-24] ...................................... 6 6 FIGURE 2: P33 PANEL - WIRE BUNDLES W0144 AND W0146 - WIRE ROUTING [Group 4, 7, 9-10, 12, 16, 18, 25, 28, 37, 39, 41-43] ................................. 7 0 FIGURE 3: P33 PANEL - WIRE BUNDLES W0144 AND W0146 - WIRE ROUTING [Group 14, 20-22, 29-36, 38, 40] .............................................. 7 4 FIGURE 4: P33 PANEL - WIRE BUNDLES W0144 AND W0146 - WIRE ROUTING [Group 3, 26] . . 78 FIGURE 5: P33 PANEL - WIRE BUNDLES W0144 AND W0146 - WIRE ROUTING [Group 27] .... 8 2 FIGURE 6: P33 PANEL - WIRE BUNDLE W0144 - WIRING CHANGE [Group 1, 4, 8, 25] ....... 8 6 FIGURE 7: P33 PANEL - WIRE BUNDLE W0144 - WIRING CHANGE [Group 2-3] ........... 8 8 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.

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FIGURE 8: P33 PANEL - WIRE BUNDLE W0144 - WIRING CHANGE [Group 5, 9-11] ........ 9 0 FIGURE 9: P33 PANEL - WIRE BUNDLE W0144 - WIRING CHANGE [Group 6-7, 21-23, 28-32, 40] . 92 FIGURE 10: P33 PANEL - WIRE BUNDLE W0144 - WIRING CHANGE [Group 12-14, 16-17, 26-27, 33, 41-43] .............................................. 9 4 FIGURE 11: P33 PANEL - WIRE BUNDLE W0144 - WIRING CHANGE [Group 15] ........... 9 6 FIGURE 12: P33 PANEL - WIRE BUNDLE W0144 - WIRING CHANGE [Group 18-20, 35, 37-39] . . . 98 FIGURE 13: P33 PANEL - WIRE BUNDLE W0144 - WIRING CHANGE [Group 24] .......... 1 0 0 FIGURE 14: P33 PANEL - WIRE BUNDLE W0144 - WIRING CHANGE [Group 34] .......... 1 0 2 FIGURE 15: P33 PANEL - WIRE BUNDLE W0144 - WIRING CHANGE [Group 36] .......... 1 0 4 FIGURE 16: P33 PANEL - WIRE BUNDLE W0146 - WIRING CHANGE [Group 1-7, 9, 12-15, 19-24, 26-28, 34, 39] ............................................. 1 0 6 FIGURE 17: WIRE BUNDLE W0146 - WIRING CHANGE [Group 8, 10-11, 17-18, 29-30, 42-43] . . . 107 FIGURE 18: P33 PANEL - WIRE BUNDLE W0146 - WIRING CHANGE [Group 25, 31-33, 35-38] . . 108 FIGURE 19: P36 PANEL - WIRE BUNDLE W0176 - WIRE ROUTING [Group 1-28, 31-43] ...... 1 0 9 FIGURE 20: P36 PANEL - WIRE BUNDLE W0176 - WIRE ROUTING [Group 29-30] ......... 1 1 3 FIGURE 21: P36 PANEL - WIRE BUNDLE W0176 - WIRING CHANGE [Group 1-2, 4-20, 22, 24-27, 31-43] ................................................. 1 1 7 FIGURE 22: P36 PANEL - WIRE BUNDLE W0176 - WIRING CHANGE [Group 21, 23] ........ 1 1 8 FIGURE 23: P36 PANEL - WIRE BUNDLE W0176 - WIRING CHANGE [Group 3, 28] ......... 1 1 9 FIGURE 24: P36 PANEL - WIRE BUNDLE W0176 - WIRING CHANGE [Group 29] .......... 1 2 0 FIGURE 25: P36 PANEL - WIRE BUNDLE W0176 - WIRING CHANGE ................ 1 2 1 FIGURE 26: MAIN EQUIPMENT CENTER - WIRE BUNDLE W0756 - WIRE ROUTING [Group 1, 4-28, 31-43] ................................................. 1 2 2 FIGURE 27: MAIN EQUIPMENT CENTER - WIRE BUNDLE W0756 - WIRE ROUTING [Group 2-3] . 126 FIGURE 28: MAIN EQUIPMENT CENTER - WIRE BUNDLE W0756 - WIRE ROUTING [Group 29-30] . 129 FIGURE 29: MAIN EQUIPMENT CENTER - WIRE BUNDLE W0756 - WIRE ROUTING ........ 1 3 3 FIGURE 30: MAIN EQUIPMENT CENTER - WIRE BUNDLE W0756 - WIRING CHANGE [Group 1, 4, 8, 25] ................................................. 1 3 4 FIGURE 31: MAIN EQUIPMENT CENTER - WIRE BUNDLE W0756 - WIRING CHANGE [Group 2] . 135 FIGURE 32: WIRE BUNDLE W0756 - WIRING CHANGE [Group 5, 9-11] ................ 1 3 6 FIGURE 33: MAIN EQUIPMENT CENTER - WIRE BUNDLE W0756 - WIRING CHANGE [Group 6-7, 22, 31, 40] ............................................... 1 3 7 FIGURE 34: MAIN EQUIPMENT CENTER - WIRE BUNDLE W0756 - WIRING CHANGE [Group 12-14, 16-17, 26-27, 33, 41-43] ................................... 1 3 8 FIGURE 35: MAIN EQUIPMENT CENTER - WIRE BUNDLE W0756 - WIRING CHANGE [Group 15] . 139 FIGURE 36: MAIN EQUIPMENT CENTER - WIRE BUNDLE W0756 - WIRING CHANGE [Group 18-20, 35, 37-39] ............................................. 1 4 0 FIGURE 37: MAIN EQUIPMENT CENTER - WIRE BUNDLE W0756 - WIRING CHANGE [Group 21, 23] ................................................. 1 4 1 FIGURE 38: MAIN EQUIPMENT CENTER - WIRE BUNDLE W0756 - WIRING CHANGE [Group 24] . 142 FIGURE 39: MAIN EQUIPMENT CENTER - WIRE BUNDLE W0756 - WIRING CHANGE [Group 3] . 143 FIGURE 40: MAIN EQUIPMENT CENTER - WIRE BUNDLE W0756 - WIRING CHANGE [Group 28] . 144 FIGURE 41: MAIN EQUIPMENT CENTER - WIRE BUNDLE W0756 - WIRING CHANGE [Group 29] . 145 FIGURE 42: MAIN EQUIPMENT CENTER - WIRE BUNDLE W0756 - WIRING CHANGE [Group 32] . 147 FIGURE 43: MAIN EQUIPMENT CENTER - WIRE BUNDLE W0756 - WIRING CHANGE [Group 34] . 148 FIGURE 44: MAIN EQUIPMENT CENTER - WIRE BUNDLE W0756 - WIRING CHANGE [Group 36] . 149 FIGURE 45: MAIN EQUIPMENT CENTER - WIRE BUNDLE W0756 - WIRING CHANGE ....... 1 5 0 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.

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FIGURE 46: MAIN EQUIPMENT CENTER - WIRE BUNDLE W0572 - WIRE ROUTING [Group 2-3] . 151 FIGURE 47: MAIN EQUIPMENT CENTER - WIRE BUNDLE W0572 - WIRING CHANGE [Group 2-3] . 153 FIGURE 48: MAIN EQUIPMENT CENTER - WIRE BUNDLE W0264 - WIRE ROUTING [Group 1-28, 30-40, 42-43] ............................................. 1 5 5 FIGURE 49: MAIN EQUIPMENT CENTER - WIRE BUNDLE W0264 - WIRE ROUTING [Group 29] . 163 FIGURE 50: MAIN EQUIPMENT CENTER - WIRE BUNDLE W0264 - WIRE ROUTING ........ 1 7 5 FIGURE 51: MAIN EQUIPMENT CENTER - WIRE BUNDLE W0264 - WIRING CHANGE [Group 1-7, 9, 12-15, 19-24, 26-28, 34, 39] ................................. 1 7 6 FIGURE 52: MAIN EQUIPMENT CENTER - WIRE BUNDLE W0264 - WIRING CHANGE [Group 25, 32, 36-38] ............................................. 1 7 7 FIGURE 53: MAIN EQUIPMENT CENTER - WIRE BUNDLE W0264 - WIRING CHANGE [Group 8, 10-11, 17-18] ............................................. 1 7 8 FIGURE 54: MAIN EQUIPMENT CENTER - WIRE BUNDLE W0264 - WIRING CHANGE [Group 29-30] . 179 FIGURE 55: MAIN EQUIPMENT CENTER - WIRE BUNDLE W0264 - WIRING CHANGE [Group 31, 33, 35] ................................................. 1 8 1 FIGURE 56: MAIN EQUIPMENT CENTER - WIRE BUNDLE W0264 - WIRING CHANGE ....... 1 8 2 FIGURE 57: MAIN EQUIPMENT CENTER - WIRE BUNDLE W2264 - WIRE ROUTING ........ 1 8 3 FIGURE 58: MAIN EQUIPMENT CENTER - WIRE BUNDLE W2264 - WIRING CHANGE ....... 1 8 4 FIGURE 59: FLIGHT COMPARTMENT - WIRE BUNDLE W0070 - WIRE ROUTING .......... 1 8 5 FIGURE 60: FLIGHT COMPARTMENT - WIRE BUNDLE W0070 - WIRING CHANGE [Group 1-24, 26-28, 31, 33-35, 39-43] ....................................... 1 8 9 FIGURE 61: FLIGHT COMPARTMENT - WIRE BUNDLE W0070 - WIRING CHANGE [Group 25, 29-30, 32, 36-38] ............................................. 1 9 1 FIGURE 62: FLIGHT COMPARTMENT - WIRE BUNDLE W0070 - WIRING CHANGE ......... 1 9 3 FIGURE 63: P33 PANEL - RELAY K10719 - INSTALLATION [Group 1, 4-43] ............. 1 9 4 FIGURE 64: P33 PANEL - RELAY K10719 - INSTALLATION ...................... 1 9 8 FIGURE 65: P33 PANEL - RELAY K10719 - INSTALLATION [Group 2-3] ................ 1 9 9 FIGURE 66: WIRE BUNDLE W0146 - WIRING CHANGE [Group 16] .................. 2 0 2 FIGURE 67: WIRE BUNDLE W0146 - WIRING CHANGE [Group 41] .................. 2 0 3 FIGURE 68: P33 PANEL - WIRE BUNDLE W0146 - WIRING CHANGE [Group 40] .......... 2 0 4 FIGURE 69: MAIN EQUIPMENT CENTER - WIRE BUNDLE W0264 - WIRING CHANGE [Group 16] . 205 FIGURE 70: MAIN EQUIPMENT CENTER - WIRE BUNDLE W0264 - WIRE ROUTING [Group 41] . 206 FIGURE 71: MAIN EQUIPMENT CENTER / FLIGHT COMPARTMENT - WIRE BUNDLE W0264 - WIRING CHANGE [Group 41] ..................................... 2 1 4 FIGURE 72: MAIN EQUIPMENT CENTER - WIRE BUNDLE W0264 - WIRING CHANGE [Group 42] . 216 FIGURE 73: MAIN EQUIPMENT CENTER - WIRE BUNDLE W0264 - WIRING CHANGE [Group 43] . 217 FIGURE 74: MAIN EQUIPMENT CENTER - WIRE BUNDLE W0264 - WIRING CHANGE [Group 40] . 218 FIGURE 75: MAIN EQUIPMENT CENTER - WIRE BUNDLE W0756 - WIRING CHANGE [Group 30] . 219 FIGURE 76: P36 PANEL - WIRE BUNDLE W0176 - WIRING CHANGE [Group 30] .......... 2 2 0 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.

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Commercial Airplanes 767 Service Bulletin

SPECIAL ATTENTION Revision Transmittal SheetNumber: 767-24-0200Original Issue: April 14, 2011 Revision 1: September 13, 2012 ATA System: 2431 SUBJECT: ELECTRICAL POWER - Batteries - Battery Charger Enabled In Flight When Standby Power Switch In Battery Position Wiring Change This revision includes all pages of the service bulletin.

COMPLIANCE INFORMATION RELATED TO THIS REVISION More work is necessary on the airplanes changed in accordance with the original issue of this service bulletin.

The functional test of the battery charger system in accordance with the original issue of this service bulletin was incorrect. Do the new functional test of the battery charger system.

REASON FOR REVISION This revision is sent to correct discrepancies found by operators during the accomplishment of this service bulletin. The wire routing data for wire bundle W0756 is changed to give a shorter route to install the new wire from the P33 panel to the P36 panel. The functional test of the battery charger system is changed. Also, a new top kit 015T1848-4 and a new wire kit 289T1166-109 is added for airplanes VN191 and VN192 which includes the necessary parts to install a new wire to wire bundle W0264.

Airplane VV001 has been removed from this service bulletin effectivity. Airplanes VR421-VR423, VR471-VR472 have moved from Group 33 to Group 14. Airplanes VR401, VR426, VR441, VR461 have moved from Group 31 to Group 40. Airplanes VN191-VN192 have moved from Group 16 to a new Group 41. Airplanes VK081-VK102 have moved from Group 16 to a new Group 42. Airplanes VK103-VK113 have moved from Group 16 to a new Group 43.

These sections were changed:

1. In Summary:

a. Action, changed the text and the applicability.

b. Changed the summary illustration.

2. In Paragraph 1.D., Description:

a. Changed the text and the applicability.

b. Changed the Affected Maintenance Zones data.

3. In Paragraph 1.G., Manpower:

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a. Changed the task hour data.

b. Added new Manpower tables.

4. In Paragraph 1.H., Weight and Balance Changes, changed the applicability.

5. In Paragraph 1.K., Publications Affected, changed the publications data.

6. In Paragraph 2.A., Material - Price and Availability:

a. Changed the kit pricing data.

b. Removed the top kit 015T1848-2.

c. Added the top kit 015T1848-4 pricing data.

7. In Paragraph 2.C.2., Parts and Materials Supplied by the Operator:

a. Changed the strap part numbers.

b. Added an optional part number for the identification tape.

8. In Paragraph 3.B., Work Instructions:

a. Condition 1, added new steps for Groups 40 thru 43.

b. Condition 1, changed some FIGURE references and the applicability.

c. Condition 1, changed the functional test data.

d. Added Condition 2 for the more work necessary data.

9. Deleted Figures 25, 29, 45, 50, 56 thru 58, 62 and 64.

10. In Figures 1 thru 5, 19, 20, 26 thru 28, 46, 48 thru 49 and 59, step table, changed the note(s).

11. In Figures 2, 3, 6, 9, 10, 17 thru 21, 24, 26, 33, 34, 41, 48, 53, 60 and 63, changed the applicability.

12. In Figures 21 thru 24, changed the Wiring Diagram Manual (WDM) reference.

13. In Figures 26 thru 28:

a. Changed the wire routing data.

b. Step table, added new notes.

14. In Figure 48, sheet 7, Figure 49, sheet 11 and Figure 57, sheet 9, changed the wire routing data.

15. Added new Figures 66 thru 75.

Vertical lines are put on the left edge of each page, except in Paragraph 1.A., Effectivity, to show the location of important changes.

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Pages with no vertical lines have no important changes.

REVISION HISTORY April 14, 2011Original Issue:

September 13, 2012Revision 1:

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Commercial Airplanes 767 Service Bulletin

SPECIAL ATTENTION SummaryNumber: 767-24-0200Original Issue: April 14, 2011 Revision 1: September 13, 2012 ATA System: 2431 SUBJECT: ELECTRICAL POWER - Batteries - Battery Charger Enabled In Flight When Standby Power Switch In Battery Position Wiring Change BOEING RECOMMENDS THAT EACH OPERATOR EXAMINE THIS SERVICE BULLETIN IMMEDIATELY.

CONCURRENT REQUIREMENTS None.

BACKGROUND Accomplishment of this service bulletin will let the main battery charger stay powered when the right main AC bus is powered, and when the standby power switch is set to the BAT position during flight. This will prevent discharge of the main battery. If this service bulletin is not done, the battery will discharge and could cause the airplane to lose battery power. This would result in the loss of airplane systems connected to the standby buses, and could affect flight and landing operations.

During the flight of a 757 airplane, the standby power OFF indication came on. The flight crew set the standby power switch to the BAT position, and continued with the flight. The flight continued beyond the battery's capability to supply power to the standby loads, and a number of system annunciations came on. The hot battery bus, battery bus, DC standby bus, and the AC standby bus had lost power. The pilots found that the horizontal stabilizer trim was not available, and that the lateral control was affected. During landing, the inboard tires blew due to lack of inboard anti-skid. When the airplane stopped, the engines could not be powered off until the standby power switch was set back to the AUTO position, and main generators were switched on to put back power to the battery charger, battery and the fuel shutoff valves. Some of these conditions would also be found on 767 airplanes.

This service bulletin gives instructions to add a new air/ground relay to the battery charger system. This change will keep the main battery charger powered, when right main AC power is available through the ground service bus, and when the standby power switch is in the BAT position during flight. This will prevent discharge of the main battery.

Boeing Service Related Problem 767-SRP-24-135 is related to this service bulletin.

Fleet Team Digest 767 FTD 24-08002 is related to this service bulletin.

ACTION (PRR B12901-96S) CONDITION 1: Airplanes not changed in accordance with the original issue of this service bulletin.

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Group 1, 4-40, 42-43:

In the main equipment center, in the P33 panel, install a new relay and change wire bundles W0144 and W0146.

In the P36 panel, change wire bundle W0176. Between the P33 panel and the P36 panel, change wire bundle W0756. Between the P33 panel and the P61 panel, change wire bundle W0264. In the flight compartment, between the P61 panel and the P5 panel, change wire bundle W0070. Do a functional test of the battery charger system.

Group 2-3:

In the main equipment center, in the P33 panel, install a new relay and change wire bundles W0144 and W0146.

In the P36 panel, change wire bundle W0176. Between the P33 panel and the P36 panel, change wire bundles W0572 and W0756. Between the P33 panel and the P61 panel, change wire bundle W0264. In the flight compartment, between the P61 panel and the P5 panel, change wire bundle W0070. Do a functional test of the battery charger system.

Group 41:

In the main equipment center, in the P33 panel, install a new relay and change wire bundles W0144 and W0146.

In the P36 panel, change wire bundle W0176. Between the P33 panel and the P36 panel, change wire bundle W0756. Between the P33 panel, P87 panel and the P61 panel, change wire bundle W0264. In the flight compartment, between the P61 panel and the P5 panel, change wire bundle W0070. Do a functional test of the battery charger system.

CONDITION 2: Airplanes changed in accordance with the original issue of this service bulletin.

More work is necessary. Do a functional test of the battery charger system.

Accomplishment of this service bulletin changes the flight deck and/or operations of the airplane. Refer to Paragraph 1.K., Publications Affected, for affected publications.

EFFECTIVITY 767-200, 767-300, 767-300F, 767-400ER Airplanes. Refer to Paragraph 1.A.1., Airplanes, for the list of affected airplanes.

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 the change given in this service bulletin be done within 60 months after the original issue date of this service bulletin.

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

MANPOWER Refer to Paragraph 1.G., Manpower.

MATERIAL INFORMATION Boeing Supplied Kits/Parts.

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