Date: 201307
Local time of day: 1801-2400
Location: ZZZ.Airport, US
Light: Dusk
Aircraft: B767-300 and 300 ER
Operator: Air Carrier
Operating under: Part 121
Flight phase: Parked
Aircraft component: Pneumatic Valve/Bleed Valve
Component problem: Malfunctioning
Reporter organization: Air Carrier
Reporter function: Technician
Reporter qualification: Maintenance Airframe; Maintenance Powerplant
Human factors: Training / Qualification; Confusion; Communication Breakdown; Situational Awareness
Anomaly: Aircraft Equipment Problem Critical; Deviation / Discrepancy - Procedural Published Material / Policy
Detector: Person Flight Crew
When detected: In-flight
Result: Flight Crew Diverted; Flight Crew Returned To Departure Airport; General Maintenance Action; General Flight Cancelled / Delayed
Contributing factors: Human Factors; Incorrect / Not Installed / Unavailable Part; Logbook Entry; Procedure; Aircraft
Primary problem: Procedure

Narrative: A B767-300 aircraft had a Maintenance Control deferral on the RT ENG HPSOV slow to open in flight. [Maintenance] Analyst remarks stated to perform a 'Manual Operational Check' of the [HPSOV] valve to check for smoothness and for any leaks.  Also stated to perform Test 'J' of Aircraft Maintenance Manual (AMM) Chapter 36-11-07; this picture showed the High Pressure Shut-Off (HPSOV) in the place of the Pressure Regulating Valve (PRV).  So I tested; changed and Mel'd the wrong valve.  No problems were found on the valve installed; so per Analyst remarks; changed HPSOV.  As I was waiting for the part to arrive from Stores/Parts; I reviewed the paperwork.  I did not review the pictures in the Remove and Install (R/I) paperwork.  These pictures were correct.  After I was contacted by Maintenance Control about the aircraft returning; I went back into the Aircraft Maintenance Manual (AMM) and realized what had happened.  I changed the wrong valve and locked-out the wrong valve.  I notified Maintenance Control of the faulty Manual picture.  Maintenance Control put in for a [AMM] Manual change (has since been updated with a technical revision and new picture).  I believe that this [AMM] Manual change will help the situation in the future.  I have been a part of changing these valves and locking these out for MEL purposes.  Once I reviewed the AMM procedures; I was very confident in changing out and MEL'ing the valve.  I have since changed out a HPSOV on another B767-300 aircraft and definitely learned from the mistake I made in the past.  A friend and co-worker suggested that I submit this NASA form.

Callback: Reporter stated the HPSOV valve was not originally 'locked-out;' was still functioning slowly; but the valve signals were showing intermittent spikes. So Maintenance Control wanted to have an Operational Check of the HPSOV valve accomplished using the Test 'J' procedures from the AMM and the results would be entered in the Logbook as 'Info'.  Part of the 'J' Test procedure was to disconnect a muscle (pressure) line and manually 'Open' the valve. If the valve electrically returned to the 'Closed' position; then the valve tests 'OK' and the electrical spike signals most likely indicated the valve was starting to short internally.Reporter stated the PRV and HPSOV valves are identical; have the same Part Numbers (P/N); are interchangeable and located practically one over the other on the Pratt-Whitney 4000 Engine. He did not check the Aircraft Maintenance Manual (AMM) HPSOV valve 'Remove/Replace' (R/R) procedures to verify the HPSOV location since he was already using a reference picture from the 'J' Test procedures.



Synopsis: After being informed of an air turnback of a company B767-300 aircraft; a Line Aircraft Maintenance Technician (AMT) realizes the reference material picture he had used to locate and replace a High Pressure Shut-Off Valve (HPROV) on a PW-4000 Engine was actually the Pressure Regulating Valve (PRV). The location of the valves had been mislabeled.