Boeing ASB 737-28A1216: Revision 1, text

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Commercial Airplanes 737 Service Bulletin ALERT Number: 737-28A1216 Original Issue: July 29, 2010 Revision 1: March 26, 2012 ATA System: 2822 SUBJECT: FUEL - Engine Fuel Feed System - Installation of the Auto Shutoff Protection for the Center and Auxiliary Fuel Tank Boost Pumps 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BOEING PROPRIETARY, CONFIDENTIAL, AND/OR TRADE SECRET Copyright © 2010 The Boeing Company Unpublished Work - All Rights Reserved Boeing claims copyright in each page of this document only to the extent that the page contains copyrightable subject matter.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, KC-10, KDC-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.

Original Issue: July 29, 2010 737-28A1216Revision 1: March 26, 2012 1 of 434

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Original Issue: July 29, 2010 737-28A1216Revision 1: March 26, 2012 2 of 434 BOEING SERVICE BULLETIN 737-28A1216

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Table of Contents

Revision Transmittal Sheet7

S u m m a r y..................................................... 1 1

1. PLANNING INFORMATION ........................................ 1 7 A . E f f e c t i v i t y ............................................... 1 7

1. Airplanes ............................................ 1 7 2 . S p a r e s A f f e c t e d ........................................ 2 8 B. Concurrent Requirements ...................................... 2 8 C. Reason ................................................ 2 8 D . D e s c r i p t i o n .............................................. 3 0 E. Compliance .............................................. 3 5 F . A p p r o v a l ............................................... 3 5 G. Manpower .............................................. 3 5 H. Weight and Balance Changes .................................... 8 1 I. Electrical Load Data ......................................... 8 1 J . R e f e r e n c e s .............................................. 8 2

1. Existing Data: ......................................... 8 2

2. Data supplied with this Service Bulletin: ........................... 8 2

3. Installation Drawings Used in the Preparation of this Service Bulletin: ........... 8 3 K. Publications Affected ........................................ 8 3 L. Interchangeability and Intermixability of Parts ........................... 8 3

2. MATERIAL INFORMATION ........................................ 8 5 A. Material - Price and Availability ................................... 8 5 B. Industry Support Information .................................... 8 7 C . P a r t s N e c e s s a r y F o r E a c h A i r p l a n e ................................. 8 7 1 . K i t s / P a r t s : ........................................... 8 7

2. Parts and Materials Supplied by the Operator: ....................... 1 1 6

3. Parts Modified and Reidentified: ............................... 1 1 6

4. Parts Removed and Not Replaced: ............................. 1 1 7 D. Parts Necessary to Change Spares ................................ 1 1 7 E. Special Tooling - Price and Availability .............................. 1 1 7 F. Special Tooling Necessary to do this Service Bulletin ...................... 1 1 7

3. ACCOMPLISHMENT INSTRUCTIONS ................................. 1 1 9 A. GENERAL INFORMATION .................................... 1 1 9 B. WORK INSTRUCTIONS ...................................... 1 2 0 FIGURE 1: REMOVAL OF THE J2802 BOX ASSEMBLY COVER [Group 1-13, 15-16] ........ 1 4 6 FIGURE 2: REMOVAL OF THE J2802 BOX ASSEMBLY COVER [Group 19-20] ........... 1 4 7 FIGURE 3: LABELS INSTALLATION, AND WIRE BUNDLES W1760/W1770 INSTALLATION IN THE J2802 BOX ASSEMBLY [Group 1-13, 15-16] ............................ 1 4 8 FIGURE 4: CONNECTION OF THE WIRE BUNDLE W1760 [Group 1-16, 21-29, 31] ......... 1 5 1 FIGURE 5: CONNECTION OF THE WIRE BUNDLE W1770 [Group 1-16, 21-29, 31] ......... 1 5 4 FIGURE 6: WIRE BUNDLES W1760/W1770 INSTALLATION IN THE J2802 BOX ASSEMBLY [Group 19-20] ................................................. 1 5 7 FIGURE 7: CONNECTION OF THE WIRE BUNDLE W1760 [Group 17-20, 30] ............ 1 6 0 FIGURE 8: CONNECTION OF THE WIRE BUNDLE W1760 [Group 17-20, 30] ............ 1 6 2 FIGURE 9: CONNECTION OF THE WIRE BUNDLE W1770 [Group 17-20, 30] ............ 1 6 5

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FIGURE 10: CONNECTION OF THE WIRE BUNDLE W1770 [Group 17-20, 30] ............ 1 6 7 FIGURE 11: INSTALLATION OF THE J2802 BOX ASSEMBLY COVER [Group 1-13, 15-16, 19-20] . 170 FIGURE 12: ATTACHMENT OF THE J2802 BOX ASSEMBLY [Group 1-13, 15-16] .......... 1 7 1 FIGURE 13: ATTACHMENT OF THE J2802 BOX ASSEMBLY [Group 19-20] ............. 1 7 4 FIGURE 14: DRILLING OF HOLES ON THE J2802 BOX ASSEMBLY AND E3 SUPPORT POST [Group 1 - 1 3 , 1 5 - 1 6 , 1 9 - 2 0 ] ...................................... 1 7 7 FIGURE 15: PREPARATION OF THE J2802 BOX ASSEMBLY, E2 AND E3 SUPPORT POSTS [Group 1-13, 1 5 - 1 6 , 1 9 - 2 0 ] ......................................... 1 8 0 FIGURE 16: INSTALLATION THE J2802 BOX ASSEMBLY ON THE E2 AND E3 SUPPORT POSTS [Group 1 - 1 3 , 1 5 - 1 6 ] .......................................... 1 8 2 FIGURE 17: INSTALLATION THE J2802 BOX ASSEMBLY ON THE E2 AND E3 SUPPORT POSTS [Group 1 9 - 2 0 ]............................................. 1 8 4 FIGURE 18: INSTALLATION THE BONDING JUMPER AND CLAMPS [Group 1-13, 15-16, 19-20] . . 186 FIGURE 19: REMOVAL OF THE RELAYS FROM THE P6 PANEL [Group 1-16, 21-29, 31] ...... 1 8 9 FIGURE 20: INSTALLATION OF THE P5 PANEL WIRE BUNDLE W036 [Group 1-16, 21-29, 31] . . . 191 FIGURE 21: CONNECTION OF THE WIRE BUNDLE W036 [Group 1, 21] ............... 1 9 2 FIGURE 22: CONNECTION OF THE WIRE BUNDLE W036 [Group 2-3, 22-23] ............ 1 9 5 FIGURE 23: CONNECTION OF THE WIRE BUNDLE W036 [Group 4-5, 24] .............. 1 9 8 FIGURE 24: CONNECTION OF THE WIRE BUNDLE W036 [Group 6-7, 25] .............. 2 0 1 FIGURE 25: CONNECTION OF THE WIRE BUNDLE W036 [Group 8, 26] ............... 2 0 4 FIGURE 26: CONNECTION OF THE WIRE BUNDLE W036 [Group 9, 31] ............... 2 0 7 FIGURE 27: CONNECTION OF THE WIRE BUNDLE W036 [Group 10-11, 27-28] ........... 2 1 0 FIGURE 28: CONNECTION OF THE WIRE BUNDLE W036 [Group 12, 29] .............. 2 1 3 FIGURE 29: CONNECTION OF THE WIRE BUNDLE W036 [Group 13] ................ 2 1 6 FIGURE 30: CONNECTION OF THE WIRE BUNDLE W036 [Group 14] ................ 2 1 9 FIGURE 31: CONNECTION OF THE WIRE BUNDLE W036 [Group 15] ................ 2 2 2 FIGURE 32: CONNECTION OF THE WIRE BUNDLE W036 [Group 16] ................ 2 2 5 FIGURE 33: REMOVAL OF THE RELAYS FROM THE P6 PANEL [Group 17-20, 30] ......... 2 2 8 FIGURE 34: INSTALLATION OF THE P5 PANEL WIRE BUNDLE W036 [Group 17-20, 30] ...... 2 3 0 FIGURE 35: CONNECTION OF THE WIRE BUNDLE W036 [Group 19, 30] .............. 2 3 1 FIGURE 36: CONNECTION OF THE WIRE BUNDLE W036 [Group 19, 30] .............. 2 3 4 FIGURE 37: CONNECTION OF THE WIRE BUNDLE W036 [Group 19, 30] .............. 2 3 7 FIGURE 38: CONNECTION OF THE WIRE BUNDLE W036 [Group 17] ................ 2 4 0 FIGURE 39: CONNECTION OF THE WIRE BUNDLE W036 [Group 17] ................ 2 4 3 FIGURE 40: CONNECTION OF THE WIRE BUNDLE W036 [Group 17] ................ 2 4 6 FIGURE 41: CONNECTION OF THE WIRE BUNDLE W036 [Group 18, 20] .............. 2 4 9 FIGURE 42: CONNECTION OF THE WIRE BUNDLE W036 [Group 18, 20] .............. 2 5 2 FIGURE 43: CONNECTION OF THE WIRE BUNDLE W036 [Group 18, 20] .............. 2 5 5 FIGURE 44: INSTALLATION OF THE P6 PANEL WIRE BUNDLE W044 [Group 1-16, 21-29, 31] . . . 258 FIGURE 45: CONNECTION OF THE WIRE BUNDLE W044 [Group 1, 21] ............... 2 5 9 FIGURE 46: CONNECTION OF THE WIRE BUNDLE W044 [Group 2, 22, Configuration 1] ...... 2 6 1 FIGURE 47: CONNECTION OF THE WIRE BUNDLE W044 [Group 2, 22, Configuration 2] ...... 2 6 3 FIGURE 48: CONNECTION OF THE WIRE BUNDLE W044 [Group 3, 16, 23] ............. 2 6 5 FIGURE 49: CONNECTION OF THE WIRE BUNDLE W044 [Group 4, Configuration 1] ........ 2 6 7 FIGURE 50: CONNECTION OF THE WIRE BUNDLE W044 [Group 4, Configuration 2] ........ 2 6 9 FIGURE 51: CONNECTION OF THE WIRE BUNDLE W044 [Group 5, 8, 24, 26] ............ 2 7 1 FIGURE 52: CONNECTION OF THE WIRE BUNDLE W044 [Group 6, 25, Configuration 1] ...... 2 7 3

Original Issue: July 29, 2010 737-28A1216Revision 1: March 26, 2012 4 of 434 BOEING SERVICE BULLETIN 737-28A1216

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FIGURE 53: CONNECTION OF THE WIRE BUNDLE W044 [Group 6, 25, Configuration 2] ...... 2 7 5 FIGURE 54: CONNECTION OF THE WIRE BUNDLE W044 [Group 9, 31] ............... 2 7 7 FIGURE 55: CONNECTION OF THE WIRE BUNDLE W044 [Group 10, 27] .............. 2 7 9 FIGURE 56: CONNECTION OF THE WIRE BUNDLE W044 [Group 12, 29, Configuration 1] ..... 2 8 1 FIGURE 57: CONNECTION OF THE WIRE BUNDLE W044 [Group 12, 29, Configuration 2] ..... 2 8 3 FIGURE 58: CONNECTION OF THE WIRE BUNDLE W044 [Group 13] ................ 2 8 5 FIGURE 59: CONNECTION OF THE WIRE BUNDLE W044 [Group 7] ................. 2 8 7 FIGURE 60: CONNECTION OF THE WIRE BUNDLE W044 [Group 14, Configuration 1] ....... 2 8 9 FIGURE 61: CONNECTION OF THE WIRE BUNDLE W044 [Group 14, Configuration 2] ....... 2 9 1 FIGURE 62: CONNECTION OF THE WIRE BUNDLE W044 [Group 11, 28, Configuration 1] ..... 2 9 3 FIGURE 63: CONNECTION OF THE WIRE BUNDLE W044 [Group 11, 28, Configuration 2] ..... 2 9 5 FIGURE 64: CONNECTION OF THE WIRE BUNDLE W044 [Group 15, Configuration 1] ....... 2 9 7 FIGURE 65: CONNECTION OF THE WIRE BUNDLE W044 [Group 15, Configuration 2] ....... 2 9 9 FIGURE 66: INSTALLATION OF THE P6 PANEL WIRE BUNDLE W044 [Group 17-20, 30] ...... 3 0 1 FIGURE 67: CONNECTION OF THE WIRE BUNDLE W044 [Group 17, Configuration 1] ....... 3 0 2 FIGURE 68: CONNECTION OF THE WIRE BUNDLE W044 [Group 17, Configuration 2] ....... 3 0 5 FIGURE 69: CONNECTION OF WIRE BUNDLE W044 [Group 17, Configuration 1] .......... 3 0 8 FIGURE 70: CONNECTION OF THE WIRE BUNDLE W044 [Group 17, Configuration 2] ....... 3 1 1 FIGURE 71: CONNECTION OF THE WIRE BUNDLE W044 [Group 18, Configuration 1] ....... 3 1 4 FIGURE 72: CONNECTION OF THE WIRE BUNDLE W044 [Group 18, Configuration 2] ....... 3 1 7 FIGURE 73: CONNECTION OF THE WIRE BUNDLE W044 [Group 18, Configuration 1] ....... 3 2 0 FIGURE 74: CONNECTION OF THE WIRE BUNDLE W044 [Group 18, Configuration 2] ....... 3 2 3 FIGURE 75: CONNECTION OF THE WIRE BUNDLE W044 [Group 19, 30] .............. 3 2 6 FIGURE 76: CONNECTION OF WIRE BUNDLE W044 [Group 19, 30, Configuration 1] ........ 3 2 9 FIGURE 77: CONNECTION OF THE WIRE BUNDLE W044 [Group 19, 30, Configuration 2] ..... 3 3 2 FIGURE 78: CONNECTION OF THE WIRE BUNDLE W044 [Group 20, Configuration 1] ....... 3 3 5 FIGURE 79: CONNECTION OF THE WIRE BUNDLE W044 [Group 20, Configuration 2] ....... 3 3 8 FIGURE 80: CONNECTION OF THE WIRE BUNDLE W044 [Group 20, Configuration 1] ....... 3 4 1 FIGURE 81: CONNECTION OF THE WIRE BUNDLE W044 [Group 20, Configuration 2] ....... 3 4 4 FIGURE 82: INSTALLATION OF WIRE BUNDLE W368, W386, W1764 AND W1774 [Group 1-16, 19-20] ................................................. 3 4 7 FIGURE 83: CONNECTION OF WIRE BUNDLE W368 AND W1764 [Group 1-16, 21-29, 31] ..... 3 5 1 FIGURE 84: CONNECTION OF WIRE BUNDLE W368 AND W1764 [Group 17-20, 30] ........ 3 5 4 FIGURE 85: CONNECTION OF WIRE BUNDLE W386 / W1774 [Group 8, 16, 26] ........... 3 5 7 FIGURE 86: CONNECTION OF WIRE BUNDLE W386 / W1774 [Group 1-7, 9-15, 21-25, 27-29, 31] . 359 FIGURE 87: CONNECTION OF WIRE BUNDLE W386 / W1774 [Group 17-20, 30] .......... 3 6 1 FIGURE 88: INSTALLATION OF THE RELAYS AND STRAPS ON THE J2802 BOX ASSEMBLY [Group 1 - 1 6 ].............................................. 3 6 4 FIGURE 89: INSTALLATION OF THE RELAYS AND STRAPS ON THE J2802 BOX ASSEMBLY [Group 1 9 - 2 0 ]............................................. 3 6 7 FIGURE 90: INSTALLATION OF THE RELAYS IN THE P6 PANEL [Group 1-16, 21-29, 31] ...... 3 7 0 FIGURE 91: INSTALLATION OF THE RELAYS IN THE P6 PANEL [Group 17-20, 30] ......... 3 7 2 FIGURE 92: CHANGE OF THE J2802 BOX ASSEMBLY FOR AIRPLANES WITH AIRSTAIRS [Group 14, 2 1 - 2 9 , 3 1 ] ........................................... 3 7 4 FIGURE 93: CHANGE OF THE J2802 BOX ASSEMBLY FOR AIRPLANES WITH AIRSTAIRS [Group 17-18, 3 0 ]............................................... 3 7 7

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FIGURE 94: ASSEMBLE THE J2802 BOX ASSEMBLY FOR AIRPLANES WITH AIRSTAIRS [Group 14, 2 1 - 2 9 , 3 1 ] ........................................... 3 8 1 FIGURE 95: ASSEMBLE THE J2802 BOX ASSEMBLY FOR AIRPLANES WITH AIRSTAIRS [Group 17-18, 3 0 ]............................................... 3 8 7 FIGURE 96: WIRE BUNDLES W1760/W1770 INSTALLATION IN THE J2802 BOX ASSEMBLY FOR AIRPLANES WITH AIRSTAIRS [Group 14, 21-29, 31] ................... 3 9 3 FIGURE 97: WIRE BUNDLES W1760/W1770 INSTALLATION IN THE J2802 BOX ASSEMBLY FOR AIRPLANES WITH AIRSTAIRS [Group 17-18, 30] ..................... 3 9 7 FIGURE 98: DRILLING OF HOLES ON THE J2802 BOX ASSEMBLY AND E3 SUPPORT POST FOR AIRPLANES WITH AIRSTAIRS [Group 14, 21-29, 31] ................... 4 0 1 FIGURE 99: DRILLING OF HOLES ON THE J2802 BOX ASSEMBLY AND E3 SUPPORT POST FOR AIRPLANES WITH AIRSTAIRS [Group 17-18, 30] ..................... 4 0 6 FIGURE 100: PREPARATION OF THE J2802 BOX ASSEMBLY, E2 AND E3 SUPPORT POSTS FOR AIRPLANE WITH AIRSTAIRS [Group 14, 21-29, 31] .................... 4 1 1 FIGURE 101: PREPARATION OF THE J2802 BOX ASSEMBLY, E2 AND E3 SUPPORT POSTS FOR AIRPLANES WITH AIRSTAIRS [Group 17-18, 30] ..................... 4 1 3 FIGURE 102: INSTALLATION THE J2802 BOX ASSEMBLY ON THE E2 AND E3 SUPPORT POSTS FOR AIRPLANES WITH AIRSTAIRS [Group 14, 21-29, 31] ................... 4 1 5 FIGURE 103: INSTALLATION THE J2802 BOX ASSEMBLY ON THE E2 AND E3 SUPPORT POSTS FOR AIRPLANES WITH AIRSTAIRS [Group 17-18, 30] ..................... 4 1 7 FIGURE 104: INSTALLATION THE BONDING JUMPER AND CLAMPS FOR AIRPLANES WITH AIRSTAIRS [Group 14, 17-18, 21-31] ................................... 4 1 9 FIGURE 105: INSTALLATION OF WIRE BUNDLE W368, W386, W1764 AND W1774 FOR AIRPLANES WITH AIRSTAIRS [Group 14, 17-18, 21-31] ............................ 4 2 5 FIGURE 106: INSTALLATION OF THE RELAYS ON THE J2802 BOX ASSEMBLY FOR AIRPLANES WITH AIRSTAIRS [Group 14, 21-29, 31] .............................. 4 3 1 FIGURE 107: INSTALLATION OF THE RELAYS ON THE J2802 BOX ASSEMBLY FOR AIRPLANES WITH AIRSTAIRS [Group 17-18, 30] ................................ 4 3 3

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Commercial Airplanes 737 Service Bulletin ALERT Revision Transmittal SheetNumber: 737-28A1216Original Issue: July 29, 2010 Revision 1: March 26, 2012 ATA System: 2822 SUBJECT: FUEL - Engine Fuel Feed System - Installation of the Auto Shutoff Protection for the Center and Auxiliary Fuel Tank Boost Pumps This revision includes all pages of the service bulletin.

COMPLIANCE INFORMATION RELATED TO THIS REVISION Federal Aviation Administration (FAA) Notice of Proposed Rule Making NPRM 2010-NM-189-AD, is related to this service bulletin.

More work is necessary on the airplane(s) changed in accordance with the original issue of this service bulletin.

Operators that incorporated the original issue of this SB have to change the labels and wire termination in the J2802 relay box assembly in accordance with Figures 3, 4, 5, 6, 7, 8, 9, or 10 as applicable, and do a functional test within the compliance time specified in paragraph 1. E. Also, operators have to inspect the imprinted text on the ID tape of wire W368-031-20 installed in accordance with Figures 82 and 83 or Figures 82 and 84 within the compliance time specified in paragraph 1. E. Some wires W368-031-20 delivered in the kits have been identified incorrectly as "W036-031-20". If they are imprinted as "W036-031-20", then correct that text of the I.D.

tapes to "W0368-031-20" using a permanent marker.

REASON FOR REVISION This revision is sent to tell the operators that for airplanes with Airstairs the J2802 Box provided in the original release can not be installed in the main equipment compartment on the E2 and E3 support posts in accordance with Figure 12 or Figure 13. When J2802 Box is installed in accordance with Figure 12 or 13, the forward face of the box interferes with the Airstairs and the Airstairs support structure. Also there is no good access to the Airstairs relays, and to the wires connected to the Airstairs relays. A new J2802 Box Assembly was designed and added to this revision that can be installed on airplanes with Airstairs with no interference with Airstairs and the Airstairs support structure. The airplanes with Airstairs were moved from the existing groups into new groups based on the wires configuration and Auxiliary Tank installation. Figures 92 through 107 were added for airplanes with Airstairs.

This revision is also sent to tell the Operators that the switches S03318 and S03321 installed on J2802 box have two positions (for each switch) identified as "POS 1" and "POS 2". POS 1 of the test switch S03318 is for Left Fuel Boost Pump of the Center Tank. POS 1 of the test switch S03321 is for Right Fuel Boost Pump of the Center Tank. POS 2 of the test switches S03318 and S03321 are only used for airplanes with Auxiliary Tanks.

POS 2 of the test switch S03318 is for Aft Fuel Boost Pump of the Auxiliary Tank. POS 2 of the test switch S03321 is for Fwd Fuel Boost Pump of the Auxiliary Tank. The wires terminated at switches S03318 and S03321 were incorrectly terminated in Figures 4, 5, 7, 8, 9, 10. The wire terminations at switches S03318 and S03321 are changed in order for the switches to function as indicated.

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New steps are added to Figure 3 that instruct the operators to install markers on the J2802 Box that will identify S03318 and S003321 as "TEST SWITCHES". Also instructions are added to install markers that will identify the function of the switch S03318 POS 1 as "CTR-L", and the function of the switch S03321 POS 1 as "CTR-R".

New steps are added to Figure 6 that instruct the operators to install markers on the J2802 Box that will identify S03318 and S003321 as "TEST SWITCHES". Also instructions are added to install markers that will identify the functions of the switch S03318 as follows: POS 1 as "CTR-L",and POS 2 as "AUX-AFT". Also instructions are added to install markers that will identify the functions of the switch S03321 as follows: POS 1 as "CTR-R", and POS 2 as "AUX-FWD".

Also this revision moves airplanes with airstairs from existing groups in new groups, Group 21 through 31. All airplanes in Groups 14, 17, and 18 have airstairs.

Some wires W368-031-20 delivered in the kits have been identified incorrectly. The wire I.D. Tapes Part Number 61-74478-10906 installed on both ends of the wire W368-031-20 may be imprinted incorrectly as "W036-031-20".

Instructions are added to Figure 83 and Figure 84 to check the imprinted text on the wire I.D Tapes before installation and correct the text from "W036-031-20" to "W0368-031-20" if necessary.

These sections were changed:

1. Summary:

a. Background: Updated PART 1 and PART 3. Changed PART 2 for airplanes with Airstairs. Added PART 4, PART 5, and PART 6 for airplanes with Airstairs.

b. Material Information paragraph added Operator Supplied Parts/Materials.

c. Summary Illustration updated to include airplanes with Airstairs.

2. Planning Information:

a. Paragraph 1.A Effectivity: Changed the Group Configuration Table. Created new groups with airplane with Airstairs.

b. Paragraph 1.C Reason: Added the reason for Revision 1.

c. Paragraph 1.D. Description: Updated PART 1 and PART 3. Changed PART 2 for airplanes with Airstairs.

Added PART 4, PART 5, and PART 6 for airplanes with Airstairs.

d. Paragraph 1.G. Manpower: Changed Manpower Tables for Groups 14, 17, and 18. Added Manpower tables for Groups 21 through 31.

e. Paragraph 1.H. Weight and Balance Changes: Added Groups 21 and 31 to Weight and Balance table.

f. Paragraph 1.J.1. References, Existing Data: Updated the reference list.

g. Paragraph 1.J.3. Installation Drawings Used in the Preparation of this Service Bulletin: Updated the Drawings list.

h. Paragraph 1.K.1. Publications: Updated the publication list.

3. Material Information:

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a. Paragraph 2.A. Material - Price and Availability: Notes are added, kit pricing data is updated, and new top kits and supplemental kits are added.

b. Paragraph 2.C.1. Parts Necessary For Each Airplane: Parts for the new top kits and supplemental kits and new footnotes are added.

c. Paragraph 2.C.2. Part and Materials Supplied by the Operator: New materials are added.

d. Paragraph 2.C.3. Parts Modified and Reidentified: New data is added for airplanes with airstairs.

4. Paragraph 3.B. Work Instructions: Updated PART 1 and PART 3. Changed PART 2 for airplanes with Airstairs. Added PART 4, PART 5, and PART 6 for airplanes with Airstairs

5. Changed Figures 3-10, 12-18, 82-84, 88-89: Group effectivities are updated.

6. Figures 92-107: Added these figures for airplane with airstairs.

The data given in Information Notice 737-28A1216 IN 01, 737-28A1216 IN 02, and 737-28A1216 IN 03 are 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 July 29, 2010Original Issue:

March 26, 2012Revision 1:

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Commercial Airplanes 737 Service Bulletin ALERT SummaryNumber: 737-28A1216Original Issue: July 29, 2010 Revision 1: March 26, 2012 ATA System: 2822 SUBJECT: FUEL - Engine Fuel Feed System - Installation of the Auto Shutoff Protection for the Center and Auxiliary Fuel Tank Boost Pumps

THIS BULLETIN IS SENT TO THE OPERATORS OF RECORD OF THE AIRPLANES SHOWN IN PARAGRAPH

1.A., EFFECTIVITY. IF AN AIRPLANE HAS BEEN LEASED OR SOLD, SEND THIS SERVICE BULLETIN TO THE NEW OPERATOR. IF APPLICABLE SPARES HAVE BEEN SOLD, SEND THIS SERVICE BULLETIN TO THE NEW OWNER.

CONCURRENT REQUIREMENTS Refer to Paragraph 1.B., Concurrent Requirements.

BACKGROUND This service bulletin is the result of the safety analysis done by Boeing under SFAR 88, "Fuel Tank System Fault Tolerance Evaluation Requirements." Initial results from the fuel system safety analysis shows that fuel boost pumps that run dry could cause an overheat condition external of the fuel pump explosion resistance area that is open to the fuel pump inlet. An overheat condition in this area could possibly cause an unwanted ignition source for the fuel vapors in the fuel tank and could cause a fire or explosion.

This service bulletin gives the instructions and a kit of parts to install an automatic (auto) shut-off system for the fuel boost pumps. The fuel boost pumps are installed in the center fuel tank and if equipped, also in the auxiliary fuel tank. Time delay relays are installed in the new J2802 box assembly that will shut off the fuel boost pumps if the pumps operate with continuous low pressure for 15 seconds. The 15 second time delay relay prevents extended dry operation of the fuel boost pumps and allows for sufficient time for fuel pump inlet reprime to prevent nuisance automatic shutoff. The flight crew stays in primary control, with the auto shutoff system as a backup, to stop the fuel boost pumps after a low pressure indication.

The change installs an automatic shut off system that gives fuel boost pump inlet protection in the fuel tank against sparks possibly caused by friction overheat damage.

This change affects the Fuel Systems Airworthiness Limitations section of Boeing document "737-100/200/200C/300/400/500 Airworthiness Limitations (AWLs) and Certification Maintenance Requirements (CMRs), D6-38278-CMR." New AWL "28-AWL-20" will be added to include an operational check of the boost pump automatic shutoff system for the center fuel tank. AWL "28-AWL-21" will be added to include an operational check of the fuel boost pump automatic shutoff system for the auxiliary fuel tank, if installed by Boeing. This change also affects Section 1 and Section 3 of the FAA Approved Airplane Flight Manual (AFM).

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ACTION (PRR 35442-RS) The work instructions are divided into 31 airplane groups, 6 parts.

PART 1, PART 2, PART 3, PART 4, and PART 5 work instructions are divided into 3 work packages because of the different wire bundle changes and airplanes without and with Airstairs PART 6 work instructions are for Operators that already ordered the kit from the original release, and want to re-work the kit for airplanes with Airstairs.

NOTE: When submitting a Publication Change Request (PCR) to Boeing to incorporate this service bulletin in the affected manuals, please notify Boeing if Auxiliary Tanks are installed on these airplanes. If Boeing is not notified about the Auxiliary Tanks, Boeing will assume that the airplanes in these groups do not have Auxiliary (AUX) tanks and no AUX Tank changes to the affected manuals will be done.

Group 1-13, 15-16:

PART 1 - AIRPLANES WITH CENTER FUEL TANKS AND WITHOUT AUXILIARY (AUX) FUEL TANKS

1. Work Package 1:

In the J2802 box assembly, install the wire bundles W1760 and W1770.

2. Work Package 2:

Get access into the main electronics compartment. Between the E2 and E3 rack support posts, install the J2802 box assembly.

3. Work Package 3:

In the flight compartment, get access to the P5 overhead panel, P6 relay panel or P6 relay modules. Above the P5 overhead panel, make a change to the wire bundles W36, W368 and W386. Between the P6 disconnect panel and the fuel boost pump relays R54 and R55, make a change to the wire bundle W44.

In the flight and main electronics compartments, between the P6 disconnect panel and the J2802 box assembly, install the new wire bundles W1764 and W1774.

In the main electronics compartment, at the J2802 box assembly, install the time delay relays R3318 and R3321.

Do a functional test of the fuel boost pumps to make sure the changed control system operates correctly.

Group 17-18:

PART 2 - AIRPLANES WITH CENTER TANKS AND WIRE PROVISION FOR AUXILIARY (AUX) FUEL TANKS,

AND AIRSTAIRS

1. Work Package 1:

In the J2802 box assembly, install the wire bundles W1760 and W1770.

2. Work Package 2:

Original Issue: July 29, 2010 737-28A1216Revision 1: March 26, 2012 12 of 434 BOEING SERVICE BULLETIN 737-28A1216

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