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Commercial Airplanes 737 Service Bulletin ALERT Number: 737-28A1227 Original Issue: August 02, 2010 Revision 1: July 18, 2011 ATA System: 2822 SUBJECT: FUEL - Distribution - Center and Auxiliary Tank Boost Pumps Fuel Control System Un-Commanded On Relay Installation and Related Wiring Changes 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BOEING PROPRIETARY, CONFIDENTIAL, AND/OR TRADE SECRET Copyright © 2010 The Boeing Company Unpublished Work - All Rights Reserved Boeing claims copyright in each page of this document only to the extent that the page contains copyrightable subject matter.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.
BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: August 02, 2010 737-28A1227Revision 1: July 18, 2011 1 of 202
6.0
BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: August 02, 2010 737-28A1227Revision 1: July 18, 2011 2 of 202 BOEING SERVICE BULLETIN 737-28A1227
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BLANK PAGE
Table of Contents
Revision Transmittal Sheet5
Summary9
1. PLANNING INFORMATION ........................................ 1 3 A. Effectivity ............................................... 1 3
1. Airplanes ............................................ 1 3
2. Spares Affected ........................................ 2 7 B. Concurrent Requirements ...................................... 2 7 C. Reason ................................................ 2 7 D. Description .............................................. 2 8 E. Compliance .............................................. 3 0 F. Approval ............................................... 3 0 G. Manpower .............................................. 3 0 H. Weight and Balance Changes .................................... 3 4 I. Electrical Load Data ......................................... 3 4 J. References .............................................. 3 5
1. Existing Data: ......................................... 3 5
2. Data supplied with this Service Bulletin: ........................... 3 5
3. Installation Drawings Used in the Preparation of this Service Bulletin: ........... 3 6 K. Publications Affected ........................................ 3 6 L. Interchangeability and Intermixability of Parts ........................... 3 6
2. MATERIAL INFORMATION ........................................ 3 7 A. Material - Price and Availability ................................... 3 7 B. Industry Support Information .................................... 3 9 C. Parts Necessary For Each Airplane ................................. 3 9
1. Kits/Parts: ........................................... 3 9
2. Parts and Materials Supplied by the Operator: ........................ 4 7
3. Parts Modified and Reidentified: ............................... 4 8
4. Parts Removed and Not Replaced: .............................. 4 8 D. Parts Necessary to Change Spares ................................. 4 8 E. Special Tooling - Price and Availability ............................... 4 8 F. Special Tooling Necessary to do this Service Bulletin ....................... 4 8
3. ACCOMPLISHMENT INSTRUCTIONS .................................. 4 9 A. GENERAL INFORMATION ..................................... 4 9 B. WORK INSTRUCTIONS ....................................... 5 0 FIGURE 1: J2802 BOX ASSEMBLY - RELAYS AND SWITCHES INSTALLATION [Group 2-4; Group 5-8, Configuration 1] ......................................... 8 4 FIGURE 2: WIRE BUNDLE W1760 AND W1770 IN THE J2802 BOX ASSEMBLY - INSTALLATION [Group 2-4; Group 5-8, Configuration 1] ................................ 8 9 FIGURE 3: WIRE BUNDLE W1760 THE J2802 BOX ASSEMBLY - CONNECTION [Group 2-4; Group 5-8, Configuration 1] ......................................... 9 0 FIGURE 4: WIRE BUNDLE W1770 THE J2802 BOX ASSEMBLY - CONNECTION [Group 2-4; Group 5-8, Configuration 1] ......................................... 9 3 FIGURE 5: J2802 BOX ASSEMBLY - RELAYS AND SWITCHES INSTALLATION [Group 5-8, Configuration 2 ] ................................................ 9 6 FIGURE 6: WIRE BUNDLE W1760 AND W1770 IN THE J2802 BOX ASSEMBLY - INSTALLATION [Group 5-8, Configuration 2] ..................................... 1 0 1
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Original Issue: August 02, 2010 737-28A1227Revision 1: July 18, 2011 3 of 202 BOEING SERVICE BULLETIN 737-28A1227
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FIGURE 7: WIRE BUNDLE W1760 THE J2802 BOX ASSEMBLY - CONNECTION [Group 5-8, Configuration 2 ] ................................................ 1 0 2 FIGURE 8: WIRE BUNDLE W1770 THE J2802 BOX ASSEMBLY - CONNECTION [Group 5-8, Configuration 2 ] ................................................ 1 0 6 FIGURE 9: WIRE BUNDLE W0368, W0386, W1764 AND W1774 FROM P6 DISCONNECT PANELS TO J2802 BOX ASSEMBLY - ROUTING [Group 2; Group 7-8, Configuration 1] ....... 1 1 0 FIGURE 10: WIRE BUNDLE W0368 AND W1764 FROM P6 DISCONNECT PANELS TO J2802 BOX ASSEMBLY - WIRING CHANGE [Group 2; Group 7-8, Configuration 1] ......... 1 1 5 FIGURE 11: WIRE BUNDLE W0386 AND W1774 FROM P6 DISCONNECT PANELS TO J2802 BOX ASSEMBLY - WIRING CHANGE [Group 2; Group 7-8, Configuration 1] ......... 1 1 8 FIGURE 12: WIRE BUNDLE W0368, W0386, W1764 AND W1774 FROM P6 DISCONNECT PANELS TO J2802 BOX ASSEMBLY - ROUTING [Group 3; Group 5-6, Configuration 1] ....... 1 2 1 FIGURE 13: WIRE BUNDLE W0368 AND W1764 FROM DISCONNECT PANEL A TO J2802 BOX ASSEMBLY
- WIRING CHANGES [Group 3; Group 5-6, Configuration 1] ................ 1 2 6 FIGURE 14: WIRE BUNDLE W0386 AND W1774 FROM P6 DISCONNECT PANEL TO J2802 BOX ASSEMBLY - WIRING CHANGES [Group 3; Group 5-6, Configuration 1] ......... 1 2 9 FIGURE 15: WIRE BUNDLE W0368, W0386, W1764 AND W1774 FROM P6 DISCONNECT PANELS TO J2802 BOX ASSEMBLY - ROUTING [Group 4] ....................... 1 3 2 FIGURE 16: WIRE BUNDLE W0368 AND W1764 FROM P6 DISCONNECT PANEL TO J2802 BOX ASSEMBLY - WIRING CHANGE [Group 4] ......................... 1 3 7 FIGURE 17: WIRE BUNDLE W0386 AND W1774 FROM P6 DISCONNECT PANEL TO J2802 BOX ASSEMBLY - WIRING CHANGE [Group 4] ......................... 1 4 0 FIGURE 18: WIRE BUNDLE W0368, W0386, W1034, W1046, W1764 AND W1774 FROM P6 DISCONNECT PANELS TO J2802 BOX ASSEMBLY - ROUTING [Group 5, Configuration 2] ...... 1 4 2 FIGURE 19: WIRE BUNDLE W0368, W1046 AND W1764 FROM P6 DISCONNECT PANEL TO J2802 BOX ASSEMBLY - WIRING CHANGE [Group 5, Configuration 2] ................ 1 4 7 FIGURE 20: WIRE BUNDLE W0386, W1034 AND W1774 FROM P6 DISCONNECT PANEL TO J2802 BOX ASSEMBLY - WIRING CHANGE [Group 5, Configuration 2] ................ 1 5 2 FIGURE 21: WIRE BUNDLE W0368, W0386, W1034, W1046, W1764 AND W1774 FROM P6 DISCONNECT PANELS TO J2802 BOX ASSEMBLY - ROUTING [Group 6, Configuration 2] ...... 1 5 7 FIGURE 22: WIRE BUNDLE W0368, W1046 AND W1764 FROM P6 DISCONNECT PANEL TO J2802 BOX ASSEMBLY - WIRING CHANGE [Group 6, Configuration 2] ................ 1 6 5 FIGURE 23: WIRE BUNDLE W0386, W1034 AND W1774 FROM P6 DISCONNECT PANEL TO J2802 BOX ASSEMBLY - WIRING CHANGE [Group 6, Configuration 2] ................ 1 7 0 FIGURE 24: WIRE BUNDLE W0368, W0386, W1034, W1046, W1764 AND W1774 FROM P6 DISCONNECT PANELS TO J2802 BOX ASSEMBLY - ROUTING [Group 7, Configuration 2] ...... 1 7 5 FIGURE 25: WIRE BUNDLE W0368, W1046 AND W1764 FROM P6 DISCONNECT PANEL TO J2802 BOX ASSEMBLY - WIRING CHANGE [Group 7, Configuration 2] ................ 1 8 0 FIGURE 26: WIRE BUNDLE W0386, W1034 AND W1774 FROM P6 DISCONNECT PANEL TO J2802 BOX ASSEMBLY - WIRING CHANGE [Group 7, Configuration 2] ................ 1 8 4 FIGURE 27: WIRE BUNDLE W0368, W0386, W1034, W1046, W1764 AND W1774 FROM P6 DISCONNECT PANELS TO J2802 BOX ASSEMBLY - ROUTING [Group 8, Configuration 2] ...... 1 8 8 FIGURE 28: WIRE BUNDLE W0368, W1046 AND W1764 FROM P6 DISCONNECT PANEL TO J2802 BOX ASSEMBLY - WIRING CHANGE [Group 8, Configuration 2] ................ 1 9 3 FIGURE 29: WIRE BUNDLE W0386, W1034 AND W1774 FROM P6 DISCONNECT PANEL TO J2802 BOX ASSEMBLY - WIRING CHANGE [Group 8, Configuration 2] ................ 1 9 7 FIGURE 30: J2802 BOX ASSEMBLY - CLOSE ACCESS [Group 2-8] .................. 2 0 1
BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: August 02, 2010 737-28A1227Revision 1: July 18, 2011 4 of 202 BOEING SERVICE BULLETIN 737-28A1227
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Commercial Airplanes 737 Service Bulletin ALERT Revision Transmittal SheetNumber: 737-28A1227Original Issue: August 02, 2010 Revision 1: July 18, 2011 ATA System: 2822 SUBJECT: FUEL - Distribution - Center and Auxiliary Tank Boost Pumps Fuel Control System Un-Commanded On Relay Installation and Related Wiring Changes This revision includes all pages of the service bulletin.
COMPLIANCE INFORMATION RELATED TO THIS REVISION No more work is necessary on the airplane(s) changed in accordance with the original issue of this service bulletin and also if the relay cutouts in the J2802 Panel Assembly have been made larger, as applicable, to fit the body of relays R3334, R3336, R3338, R3340, and the screws BACS12HN08-10 were used for the installation of the relays, as described in Information Notice 737-28A1227 IN 05. However, during the regular maintenance, operators have to install the markers that identify the function of the switches installed on the J2802 box, in accordance with Figure 1 or Figure 5, as applicable.
REASON FOR REVISION This revision is sent to give group configurations that describe the possible current status of auxiliary tanks for applicable airplanes in this service bulletin. Since the development of this service bulletin, operators could have removed or deactivated their auxiliary tank. This revision also tells operators that the J2802 Panel Assembly, part number 65C38484-12, which is included in the kits of concurrent Boeing service bulletins 737-28A1216 (for 737-300/400/500 airplanes) and 737-28A1228 (for 737-100/200/200C airplanes), is made with nutplates incorrectly positioned. These nutplates are related to the installation of relays R3334, R3336, R3338 and R3340. Because of their incorrect position, the related relays cannot be installed in accordance with Figures 1 and 5 of this service bulletin at the original issue. These related relays can be installed if their cutouts in the J2802 Panel Assembly are made larger to fit the body of the relays through them. Operators should make the changes shown in this service bulletin revision 01 to keep the installation of the relays the same as the design intent. Also, new fastener kits will be available from Boeing spares, 65C38537-6 (airplanes without auxiliary tank) and 65C38537-7 (airplanes with auxiliary tanks). The fasteners supplied in these kits were omitted from the 65C38537-1, -2 and -3 Top Kits listed in Paragraph 2.C.1., Kits/Parts. Only the missing screws and washers to install the relays are in these kits, no other parts are included. Figures 1, 2, 5, and 6 are changed to give correct ground block locations for GDY001 and GDY002, and Figure 7 is changed to correct Thermofit Sleeve part number 61-74485-2008 to part number 61-74482-2007. Also Figures 3, 4, 7, and 8 are changed to give correct test switch nomenclature. This revision is also adding markers on the J2802 Box that identify the function of each of the switch installed.
These sections are changed:
1. Summary:
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Original Issue: August 02, 2010 737-28A1227Revision 1: July 18, 2011 5 of 202
a. Background first and fourth paragraphs are updated.
b. Material Information paragraph added Operator Supplied Parts/Materials.
2. Planning Information:
a. Paragraph 1.C Reason: First and fourth paragraphs are updated. Added a paragraph that list the main changes.
b. Paragraph 1.D. Description: Maintenance zone tables are added.
c. Paragraph 1.G. Manpower: Group effectivities and tables are updated.
d. Paragraph 1.H. Weight and Balance Changes: Group effectivities are updated.
e. Paragraph 1.I.1. Direct Current (DC) Loads: Group effectivities are updated.
3. Material Information:
a. Paragraph 2.A. Material - Price and Availability: Notes are added, kit pricing data is updated, and new top kits are added.
b. Paragraph 2.C.1. Parts Necessary For Each Airplane: New top kits and 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 table is added
4. Paragraph 3.B. Work Instructions: Group effectivities and test switch nomenclature are updated.
5. Figures 1-14, and 18-29: Group effectivities are updated.
6. Figure 1, sheets 1, 2, and Step table are updated, new sheet 3 is added.
7. Figures 2 and 6, sheet 1 is updated.
8. Figures 3 and 4, sheet 1 and Step table are updated.
9. Figure 5, sheets 1, 2, and Step table are updated, new sheet 3 is added.
10. Figure 7, sheets 1, 2, and Step table are updated.
11. Figure 8, sheets 1 and 2 are updated
12. Figures 10, 11, 13, and 14, Step tables are updated.
The data given in Information Notice 737-28A1227 IN 01, IN 02, and IN 05 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.
BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: August 02, 2010 737-28A1227Revision 1: July 18, 2011 6 of 202 BOEING SERVICE BULLETIN 737-28A1227
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REVISION HISTORY August 02, 2010Original Issue:
July 18, 2011Revision 1:
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Original Issue: August 02, 2010 737-28A1227Revision 1: July 18, 2011 7 of 202 BOEING SERVICE BULLETIN 737-28A1227
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BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: August 02, 2010 737-28A1227Revision 1: July 18, 2011 8 of 202 BOEING SERVICE BULLETIN 737-28A1227
ALERTALERT
BLANK PAGE
Commercial Airplanes 737 Service Bulletin ALERT SummaryNumber: 737-28A1227Original Issue: August 02, 2010 Revision 1: July 18, 2011 ATA System: 2822 SUBJECT: FUEL - Distribution - Center and Auxiliary Tank Boost Pumps Fuel Control System Un-Commanded On Relay Installation and Related Wiring Changes
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 affects the 737-200/-200C/-300/-400/-500 airplanes with line numbers 292 thru 3132 that have center tanks, and center and auxiliary fuel tanks. Operators with 737-100/-200/-200C airplanes with line numbers 1 thru 291 should contact Boeing to obtain engineering and accomplishment instructions for this modification. This service bulletin is sent to give 'un-commanded on' protection for the fuel pump control system.
Instructions are given to add one more relay, as a fail safe, for each fuel pump in the center and auxiliary fuel tanks. If this service bulletin is not done, the fuel pumps could run dry, which increases the pumps temperature and could cause an ignition source for fuel vapor in the fuel tank. Ignition of the flammable fuel vapors in the fuel tanks, could cause a fire or explosion which will put the airplane in an unsafe condition.
The Boeing system safety assessment necessary for Special Federal Aviation Regulation (SFAR) 88, showed that electrical faults within the fuel tank pump system can cause a fuel pump to operate when the fuel pump switch is in the 'OFF' position. Boeing has developed a new system to prevent extended operation of the fuel tank boost pumps in this condition. This new system has a second relay to prevent the operation of a pump when its switch is in the 'OFF' position. The auto shutdown relay currently installed for each pump gives the same solution as the new additional relay, but is known to have caused in-service problems because its contacts have 'welded' closed and continued to let power be supplied. This condition is referred to as 'un-commanded on' (UCO) pump operation. This new second relay added to the existing fuel control circuit and interfaced with the P5-2 fuel control module, prevents UCO operation of the fuel boost pumps. The system senses if there is a voltage remaining in the fuel boost pump circuit and activates the UCO relay to remove the power. In the flight deck, the pump low pressure light in the P5-2 fuel systems module, and master caution light come on when the fuel pump is at low pressure. No additional indication is provided for dry running pumps.
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Original Issue: August 02, 2010 737-28A1227Revision 1: July 18, 2011 9 of 202
Accomplishment of this service bulletin installs new UCO relays and toggle switches in the J2802 box assembly located in the Electronic Equipment Bay (E/E bay). This service bulletin also changes and adds new wire bundles that route from the J2802 box assembly to the P5 Forward Overhead Panel and the P6 Disconnect Panels.
Installation of the new UCO relays for each pump will prevent "dry running" of the fuel pumps and reduce the risk of fuel tank fire or explosion.
The Airworthiness Limitations (AWL) 28-AWL-24 (Center Tank) and 28-AWL-25 (Auxiliary Fuel Tank) for 737-100/200/200C airplanes, and AWL 28-AWL-23 (Center Tank) and 28-AWL-24 (Auxiliary Fuel Tank) for 737-300/400/500 airplanes listed in 737-100/200/200C/300/400/500 Airworthiness Limitations (AWLs) and Certification Maintenance Requirements (CMRs), D6-38278-CMR, are related to this service bulletin.
Boeing Fleet Team Digest (FTD) 737 FTD 28-04004 is related to this service bulletin.
ACTION (PRR 35443-RS) Remove equipment as necessary to get access the J2802 box assembly on the E2 and E3 support posts in the E/E bay, P6 Load Control Center in the flight compartment/control cabin, and P6 disconnect panels. Remove the cover from the J2802 box assembly and install wire bundles W1760 and W1770 and relays. Change wire bundles W036, W368, W386, W1034, W1046, W1764 and W1774, as applicable, between the P6 disconnect panels and J2802 box assembly. Check the continuity of all the new and changed wires and do a functional test to make sure the changed fuel control system operates correctly.
Operators with Group 1 airplanes should contact Boeing to obtain engineering and accomplishment instructions for this modification and do the instructions.
EFFECTIVITY 737-100/200/200C/300/400/500 Airplanes. Refer to Paragraph 1.A., Effectivity for the list of affected airplanes.
COMPLIANCE Boeing recommends that the change given in this service bulletin be done within 60 months after the original issue date of this service bulletin.
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.
Operators with Group 1 airplanes should contact Boeing to obtain engineering and accomplishment instructions for this modification and do the instructions.
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.
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Original Issue: August 02, 2010 737-28A1227Revision 1: July 18, 2011 10 of 202 BOEING SERVICE BULLETIN 737-28A1227
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BOEING SERVICE BULLETIN 737-28A1227
ALERT ALERT Operator Supplied Parts/Materials.
Refer to Paragraph 2.A., Material - Price and Availability.
CHANGE WIRE BUNDLES CHANGE WIRE BUNDLES W0368/W0386 W1764/W1774
CHANGE WIRE BUNDLES W0386/W1034/W1046/W1764/W1774
INSTALL NEW TOGGLE
SWITCHES, RELAYS AND WIRE BUNDLES W1760 AND W1770 IN THE J2802 BOX ASSEMBLY 1308568 Original Issue: August 02, 2010 Revision 1: July 18, 2011 737-28A1227
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Original Issue: August 02, 2010 737-28A1227Revision 1: July 18, 2011 12 of 202 BOEING SERVICE BULLETIN 737-28A1227