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Fuel System
Boeing 767-200/300
Fuel System
Training manual
For training purposes only
LEVEL 1
ATA 28
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B767/28/101
Fuel System
Training manual
This publication was created by Sabena technics training department, Brussels-Belgium, following ATA 104 specifications.
The information in this publication is furnished for informational
and training use only, and is subject to change without notice.
Sabena technics training assumes no responsibility for any
errors or inaccuracies that may appear in this publication.
No part of this publication may be reproduced, stored in a retrieval system, or transmitted, in any form or by any means,
electronic, mechanical, photocopying, recording, or otherwise,
without the prior written permission of Sabena technics training.
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TABLE OF CONTENTS
1. INTRODUCTION. ...................................................................................................................6
1.1. General................................................................................................................................6
1.2. Fuel Components - Left Rear Spar. .....................................................................................10
1.3. Fuel Components - Right Rear Spar. ...................................................................................10
2. FUEL TANKS. .......................................................................................................................12
2.1. Construction and Location. ................................................................................................12
3. FUEL VENT SYSTEM............................................................................................................14
3.1. Construction and Components. .........................................................................................14
3.2. Float Valves. .......................................................................................................................14
4. PRESSURE FUELING SYSTEM. ............................................................................................16
4.1. General Configuration. ......................................................................................................16
4.2. Fueling Station. ..................................................................................................................18
4.3. FQIS Load Select Fuel Quantity Indicator. ............................................................................18
4.4. Overwing Fueling Ports. .....................................................................................................20
5. ENGINE FUEL FEED SYSTEM. .............................................................................................22
5.1. General..............................................................................................................................22
5.2. Engine Fuel Feed System Operation....................................................................................22
5.3. Motor-Actuated Valves.......................................................................................................24
5.4. Automatic Sumping Jet Pumps...........................................................................................26
5.5. Transfer Jet Pumps. ............................................................................................................28
6. APU FUEL FEED SYSTEM. ...................................................................................................32
6.1. General..............................................................................................................................32
6.2. Defueling. ..........................................................................................................................36
7. FUEL JETTISON SYSTEM. ....................................................................................................38
7.1. General Description. ..........................................................................................................38
7.2. Fuel Jettison System Operation...........................................................................................38
8. FUEL QUANTITY INDICATING SYSTEM (FQIS)...................................................................40
8.1. Design Features. ................................................................................................................40
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LIST OF ILLUSTRATIONS
APU BOOST PUMP CONTROL AND OPERATION ..................................................................... 34
APU FUEL FEED SYSTEM ........................................................................................................ 33
AUTOMATIC SUMPING JET PUMPS ........................................................................................ 27
DEFUELING SYSTEM............................................................................................................... 37
ENGINE FUEL FEED SYSTEM AND OPERATION ........................................................................ 30
FQIS LOAD SELECT FUEL QUANTITY INDICATOR .................................................................... 19
FUELING STATION .................................................................................................................. 19
FUEL JETTISON SYSTEM AND OPERATION .............................................................................. 39
FUEL QUANTITY INDICATING SYSTEM.................................................................................... 41
FUEL SYSTEM........................................................................................................................... 7
FUEL SYSTEM PANELS .............................................................................................................. 9
FUEL TANKS ........................................................................................................................... 13
FUEL VENT SYSTEM AND FLOAT VALVES ................................................................................ 15
LEFT REAR SPAR - FUEL COMPONENTS .................................................................................. 11
MOTOR ACTUATED VALVES ................................................................................................... 25
OVERWING FUELING PORTS................................................................................................... 21
PRESSURE FUELING SYSTEM .................................................................................................. 17
RIGHT REAR SPAR - FUEL COMPONENTS................................................................................ 11
TRANSFER JET PUMPS ............................................................................................................ 29
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1. INTRODUCTION.
The boeing 767 fuel system includes the fuel tanks, a vent system,
a fueling system, a feed system with automatic sumping, defueling valves,
a fuel jettison system, and a fuel quantity indicating system (FQIS).
1.1. General.
Fuel Tanks.
All fuel for the engines and APU is stored within the wing. The three tanks,
left main, right main, and center auxiliary are of wet wing construction.
Baffle ribs in the main tanks control outboard flow. Outboard of both main
tanks is a surge tank. The surge tanks contain overflow and prevent fuel spills.
The surge tanks drain into the center auxiliary tank and are normally empty.
Vent System.
The vent system maintains near ambient atmospheric pressure within the
tanks. A vent scoop in each wing creates a slightly positive pressure during
flight to its associated surge tank.
Vent channels connect each surge tank to the main and auxiliary fuel tanks.
A flame arrester is mounted in both vent scoop tubes. Backup pressure relief
valves are provided.
Fueling System.
The fueling system includes a manifold with six fueling valves inside the tanks
and a fueling station on the left wing leading edge. The fueling valves are
controlled by the fuel quantity indicating system (FQIS) to allow versatility in
fueling operations. An overfill sensor in each surge tank terminates fueling
operations should the tanks overfill. An overwing fill port is located on the
upper wing surface for both main tanks. Pump priming and FQIS component
washing is also accomplished during fueling.
Feed System.
The fuel feed system supplies fuel to the two main engines and the APU.
Two AC boost pumps are installed in each main tank. Two AC override pumps
are installed, one per side, in the center auxiliary tank. A bypass valve in each
main tank allows suction flow from the main tanks. A DC pump pressure feeds
the APU automatically when the AC pumps are not operating. Dual crossfeed
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valves interconnect the normally isolated left and right feed manifolds.
This allows any tank to feed either engine if desired. Automatic jet pumps
prevent water and contaminates from accumulating in tank low points and
transfer remaining fuel into the main tanks from the center auxiliary tank after
the main tanks are depleted to approximately one-half full.
Defueling.
The defueling valves interconnect the feed system and the fueling system.
This allows defueling and fuel transfer operations on the ground only.
Fuel Jettison.
A fuel jettison system is installed to rapidly reduce the gross weight of the
aircraft. Two jettison pumps operate along with the center override pumps,
to jettison center auxiliary tank fuel overboard.
Controls for the system are located on the flight deck.
Fuel Quantity Indicating System (FQIS).
The FQIS is a microprocessor controlled capacitance type fuel quantity
measuring system.
The FQIS requires only 28V DC power for operation.
A direct digital display of fuel weight is provided in the flight compartment
and at the fueling station.
Tank units and compensators provide volume measurement.
Densitometers, one in each tank, provide fuel density signals.
The FQIS also controls the fueling valves to allow overfill protection and
automatic fueling termination at preselected quantity levels.
Measuring Sticks.
Magnetic dripless type measuring sticks are mounted in the lower wing
surfaces of each tank to provide an alternate method of determining fuel
quantity.
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The following fuel system components are located on the left rear spar :
The following fuel system components are located on the right rear spar :
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2. FUEL TANKS.
2.1. Construction and Location.
All three fuel tanks are constructed by sealing the primary wing structure with
sealant. The tanks are formed by the front and rear spars, the top and bottom
wing skins, and by selected wing ribs.
Main Tanks.
The left and right main tanks are located between rib 3 and rib 31 in both
wings. Dry bays are located in both wing leading edges over the engine hot
sections to prevent fuel leakage from contacting the engine. Rib 5 and rib
18 are sealed, and have free-swinging check valves in the bottom to allow
inboard fuel flow while preventing outboard fuel flow. These fuel dams control
flow to prevent uncovering the pump inlet ports, and to prevent fuel weight
shifts. The main tanks may be fueled by use of an overwing port near the
leading edge between rib 23 and rib 24.
Center Auxiliary Tanks.
The center auxiliary tank is between ribs 3 in the wing and through the
fuselage. There is no dry bay in this tank.
Surge Tanks.
The surge tanks are located between rib 31 and rib 34 in both wings.
These normally empty tanks are designed to contain overflow to prevent fuel
spillage.
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Access.
Access to all tanks and the dry bays is through oval cutouts in the lower wing
surface. In selected cases (ribs 1, 2, 4, 5 and 9), openings in the rib allow
access to adjoining rib sections. A cover panel is installed over the opening in
rib 5, to prevent fuel slosh through the opening. The panel must be removed
to gain access to the inboard tank area. The cutouts vary in size, with the
smaller ones outboard. Other components, such as measuring sticks and
pressure relief valves are installed on selected access doors. The center section
has one access door in the lower right corner, located just forward of the right
air conditioning bay area.
Sump drains.
Identical sump drain valves are located in the low point of both main tanks,
both surge tanks, and in each side of the center auxiliary tank outboard of
the S.O.B . rib. In addition, a sump drain valve with a tube attached is located
inboard of each S.O.B. rib.
These are accessed by use of a door in the wing root fairing. There are a total
of eight drain valves. These allow fuel sampling, and draining of residual fuel.
In addition, the dry bay for the engine hot section has two drain holes with
flame arresters.
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Fueling Capabilities.
Normal fueling is accomplished from the fueling station with 28V DC power.
The fuel quantity indicating system (FQIS) interfaces with the fueling system to
allow automatic fueling shutdown at preselected quantities or when the tanks
are full by volume.
Backup overfill protection is supplied by a separate card located in the P50
card file and a sensor in each surge tank.
The fueling manifold is located near the rear spar inside the tank. It includes
six fueling valves, a manifold vacuum valve, two manifold drain valves,
a pressure relief valve and two defuel valves.
Fueling check valves prevent backflow.
Pressure Fueling Valves.
There are two fueling valves for each tank. These valves are fuel pressure
actuated, solenoid controlled valves. The solenoid is controlled by the FQIS
microprocessor through a switch on the P28 panel. A knurled knob on the
valve allows the valves to be manually opened without solenoid power.
Fuel Manifold Draining.
The two manifold drain valves drain the manifold into the center auxiliary tank
after fueling. These close during fueling to prevent undesired fueling flows.
The single manifold vacuum valve vents air into the manifold. It closes during
defueling to prevent sucking air into the manifold.
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Open the fueling station door by pushing the two guide release fasteners.
Inside are two fueling adapters, the fueling control panel, a panel light for
illumination and power indication, an interphone jack, and two grounding
jacks.
The load select and fuel quantity indicators are mounted on the fueling control
panel in the fueling station. There is one indicator for each of the three tanks.
Fueling adapter caps cover the fueling adapters on aircraft equipped with fuel
jettison. The caps supply a secondary seal to the fueling manifold.
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FUELING STATION
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The fuel feed system is designed to supply fuel to the engines and APU.
This system is also utilized to transfer fuel from tank-to-tank on the ground.
Automatic sumping jet pumps are powered by the feed system to prevent
water and contamination buildup in the tanks. Transfer jet pumps are
also powered by the feed system to transfer the last remaining fuel in the
center auxiliary tank into the main tank when the main tank is less then
approximately one-half full.
Configuration.
The feed manifold and most system components are located within the tanks.
The left and right manifolds are interconnected by dual crossfeed valves.
There are two AC boost pumps in a common dry bay housing on the lower
surface of each main tank.
There is one AC override pump and one fuel jettison pump in a dry bay
housing in the lower wing surface on each side of the center auxiliary tank.
A bypass valve allows suction flow from both main tanks. A fuel shutoff valve
shuts off fuel to the engine.
The crossfeed valves, engine fuel shutoff valves, defuel valves, jettison valves,
and APU fuel shutoff valve are dc motor actuated. They are all mounted on
the rear spar.
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Actuator Replacement.
The actuator is replaceable without defueling. It mounts to an adapter plate
with 4 screws. It should be installed in the valve closed position.
Do not loosen the three adjustment screws, because the valve closed
alignment marks on the valve body are not visible outside of the tank.
Realignment requires tank access.
Valve Body.
The valve bodies are mounted in-line on the engine manifold, inside the tanks,
using two couplings. The body has a 4 hole mounting flange, a thermal relief,
and a splined operating shaft with a universal joint. One spline is missing to
assure proper indexing on installation. The thermal relief valve is threaded to
allow installation of a plug for pressure testing. Alignment marks indicate that
the valve is closed, because the valve does not hard stop either open or closed.
Adapter and Shaft Assembly.
The adapter and shaft assembly is custom-fit to each installation. The assembly
includes a mount plate, an adapter plate, and a shaft with a universal joint.
The actuator and adapter have two splines omitted to assure proper indexing.
Loosening three adjustment screws allows the adapter plate to be rotated
in slots with respect to the mount plate. During the original installation of
the adapter and shaft assembly, the adapter plate can be rotated with the
actuator installed, and in the valve closed position, to align the marks on the
valve body. Three screws on the adapter plate can be loosened to allow the
alignment.
Motor Actuator.
All motor actuator on the fuel system are mounted in the wheel wells on the
rear spar, are interchangeable, and are powered by 28V DC.
A manual override lever allows the actuator to be operated without electrical
power. This lever also indicates valve position. Cycle time between limits is
approximately 2 to 3 seconds.
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L. AFT
PRESS. SW.
L. FWD.
PRESS. SW.
L. CENTER
PRESS. SW.
FIRE
HOT BATT. BUS
M
M
DC BOOST
PUMP
LOW PRESS.
ENGINE
BOOST PUMP
L. FWD.
L. AFT
L. CNTR.
DC BOOST
PUMP RELAY
K191
APU ON
APU FUEL
VALVE
DISAGREE
RELAY
K192
6 sec.
FAULT
NO PWR.
IF DISAGREE
OR TRANSIT
1 = CL.
P > 3 psi
DC FUEL PUMP ON
(M)
EICAS COMPUTER
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6.2. Defueling.
Defueling and tank to tank fuel transfer operations are performed on the
ground only.
Two 28V DC permanent magnet motor actuated defuel valves, one in each
main tank, connect the engine fuel feed manifold to the fueling manifold
allowing defuel or transfer.
The defuel valves are controlled by guarded switches at the fueling station.
Defuel Valve.
The defuel valve is identical to the engine fuel shutoff valve and crossfeed
valve.
The actuators and valve bodies are the same part number. The adapter and
shaft is customized for each installation.
A manual override on lever the actuator allows mechanical opening and
closing of the valve and also indicates valve position.
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Tank-to-tank transfer.
Tank-to-tank fuel transfer is the same procedure as pressure defueling.
The appropriate boost or override pumps must be operating to provide
sufficient pressure to actuate the fueling valve diaphragms. Open the fueling
valves for the tank to receive the fuel and turn on the boost or override
pumps for the tanks to be defueled. Monitor the quantity gages to determine
progress. It is not necessary to connect fueling nozzles, or to turn the adapter
cams to the DEFUEL position.
Defuel valve position indication.
A blue press-to-test light for each defuel valve indicates valve position.
The light comes on when the valve is fully open, and remains on until the valve
is fully closed.
Pressure defueling.
Press-to-test the blue defuel valve lights after the fueling station has been
powered.
Turn the adapter cams to the DEFUEL position and connect the nozzles.
Open the defuel valves.
Turn on the appropriate boost or override pumps for the tank(s) to be
defueled using the switchlights in the flight compartment.
Suction defueling.
Suction defueling of the main tanks is the same as pressure defueling of
the tanks except the boost pumps are not used. Suction supplied from the
defueling vehicle allows fuel flow through the bypass valves and defuel valves
to the vehicle.
Suction defueling of the center auxiliary tank is not possible.
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The fuel jettison outlet tube assembly consists of an aluminum tube with a
shroud (bond assembly) made of titanium. The assemblies are immediately
inboard of the outboard aileron on each wing.
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Compensators.
There are three compensators, one in each tank. The compensators send a
reference signal to the processor to compute fuel volume.
Wiring Harness.
There are four wiring harnesses, one in each main tank and two in the center
tank. The wiring harnesses are vendor components.
Densitometers.
There are three densitometers, one in each tank. They send signals to the
processor which computes the fuel density.
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FUEL Q
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