Boeing 767 Series Aeroplanes

AIRWORTHINESS DIRECTIVE

For the reasons set out in the background section, the CASA delegate whose signature appears below issues the following Airworthiness Directive (AD) under subregulation 39.1 (1) of CAR 1998. The AD requires that the action set out in the requirement section (being action that the delegate considers necessary to correct the unsafe condition) be taken in relation to the aircraft or aeronautical product mentioned in the applicability section: (a) in the circumstances mentioned in the requirement section; and (b) in accordance with the instructions set out in the requirement section; and (c) at the time mentioned in the compliance section.

AD/B767/123  Fuel Tank Boost Pump and Override/Jettison Pump Wiring

Applicability: All Model 767 series aeroplanes.

8/2000

TX

Requirement: 1. Perform a detailed visual inspection to detect discrepancies, including the presence of splices, cuts, splits, holes, worn areas, and lacing ties installed on the outside of the sleeves (except at the sleeve ends); of the Teflon sleeves surrounding the wiring of the fuel tank boost pumps and override/jettison pumps, in accordance with Boeing Service Bulletin (SB) 767-28A0053, Revision 1, dated 5 August 1999.

Note 1: For the purposes of this Directive, a detailed visual inspection is defined as: "An intensive visual examination of a specific structural area, system, installation, or assembly to detect damage, failure, or irregularity. Available lighting is normally supplemented with a direct source of good lighting at intensity deemed appropriate by the inspector. Inspection aids such as mirror, magnifying lenses, etc. may be used. Surface cleaning and elaborate access procedures may be required."

2.        If any discrepancy is detected during any inspection accomplished in accordance with Requirement 1 remove the Teflon sleeves and perform a detailed visual inspection to detect damage of the wiring, in accordance with paragraph D. of the Accomplishment Instructions of SB 767-28A0053, Revision 1.

3.        If damage to the wiring is not detected during the Requirement 2 inspection, install new Teflon sleeves in accordance with the SB 767-28A0053 Revision 1.

4.        If any damage to the wiring is detected during any inspection accomplished in accordance with Requirement 2, perform a detailed visual inspection to determine if the wiring damage was caused by arcing, in accordance with paragraph D. of the Accomplishment Instructions of SB 767-28A0053 Revision 1.

5.        If the wire damage was not caused by arcing, repair any damaged wires or replace the wires with new or serviceable wires, as applicable, and install new Teflon sleeves; in accordance with SB 767-28A0053 Revision 1.

6.        If any damage caused by arcing is found, perform an inspection for signs of fuel inside the conduit or on the wires, in accordance with SB 767-28A0053 Revision 1.

7.         If no sign of fuel is found during the Requirement 6 inspection;

1. Repair the wires or replace the wires with new or serviceable wires, as applicable, in accordance with SB 767-28A0053 Revision 1 and

b.    Install new Teflon sleeves, in accordance with SB 767-28A0053 Revision 1.

8.        If any fuel is found inside the conduit during any inspection accomplished in accordance with Requirement 6, replace the conduit with a new or serviceable conduit in accordance with SB 767-28A0053 Revision 1. Conduit replacement constitutes terminating action for the Requirement 6 repetitive fuel inspections.

9.        Replace the conduit with a new or serviceable conduit, in accordance with SB 767-28A0053 Revision 1. Conduit replacement constitutes terminating action for the Requirement 6 repetitive fuel inspections.

10.    If any wire bundle was removed and reinstalled during any inspection required by this Directive, retest the fuel pump in accordance with paragraph G., H., I., or J., as applicable, of the Accomplishment Instructions, of SB767-28A0053 Revision 1.

11.    Submit a report of positive inspection findings (findings of discrepancies only), along with any damaged wiring and sleeves, to the

Federal Aviation Administration

Seattle Manufacturing Inspection District Office 2500 East Valley Road, Suite C-2

RENTON WA 98055-4056 USA

Facsimile 0015 1 425 227-1159

with an information copy of the report to Section Head - Systems

Certification Standards Branch Civil Aviation Safety Authority GPO Box 2005

CANBERRA ACT 2601

Facsimile (02) 6217 1914

The report must include the aeroplane serial number; the number of total flight hours and flight cycles on the aeroplane; the location of the electrical cable on the aeroplane; and a statement indicating, if known, whether any wire has ever been removed and inspected during maintenance, along with the date (if known) of any such inspection.

Note 2: FAA AD 2000-11-06 Amdt 39-11754 refers.

Compliance: For Requirement 1 - Initially either:

1. Prior to the accumulation of 50,000 total hours time in service, or within 90 days after the effective date of this Directive, whichever occurs later; or

b.    Within 18 months after the effective date of this Directive;

and thereafter, repeat the inspection at intervals not to exceed 60,000 hours time in service or 30,000 flight cycles, whichever occurs first.

Note 3: If the Requirement 1 inspection was accomplished before the effective date of this Directive, the compliance interval (either hours time in service or flight cycle count) for the repetitive inspection commences when the initial inspection was performed.

For Requirement 2 - Before further flight. For Requirement 3 - Before further flight. For Requirement 4 - Before further flight. For Requirement 5 - Before further flight.

For Requirement 6 - Before further flight and thereafter at intervals not to exceed 500 flight hours, until the conduit has been replaced in accordance with either Requirement 8 or 9.

For Requirement 7 - Before further flight. For Requirement 8 - Before further flight.

For Requirement 9 - Within 6,000 hours time in service or 18 months after the initial fuel inspection specified by Requirement 6, whichever occurs first.

For Requirement 10 - Before further flight after the reinstallation.

For Requirement 11 -

For aeroplanes on which the initial inspection required by Requirement 1 is accomplished after the effective date of this Directive - Within 10 days after performing the initial inspection.

For aeroplanes on which the initial inspection required by Requirement 1 has been accomplished prior to the effective date of this Directive - Within 10 days after the effective date of this Directive.

This Airworthiness Directive becomes effective on 5 July 2000.

Background:  This Directive requires repetitive inspections to detect discrepancies with the fuel tank boost pumps and override/jettison pumps wiring and surrounding Teflon sleeves; replacement of the sleeves with new sleeves in some instances; and repair or replacement of the wiring and sleeves with new parts.

The Federal Aviation Administration (FAA) and the aircraft manufacturer have received reports of chafing of Teflon sleeves that surround and protect electrical wires inside conduits installed in the fuel tanks. This Directive is intended to ensure adequate protection to the fuel pump wire insulation. Chafing of the wire insulation could eventually result in exposure of electrical conductor, permit arcing from the wire to the conduit, and create a potential for a fuel tank fire or explosion.

The Directive has been issued as a Telex to align the effective date with that of the FAA airworthiness directive. This will assist the FAA to more accurately assess the scope of wire chafing on Boeing 767 aeroplanes.

Eugene Paul Holzapfel

Delegate of the Civil Aviation Safety Authority 29 June 2000

The above AD is notified in the Commonwealth of Australia Gazette on 5 July 2000.