# Boeing Alert Service Bulletin 737-28A1227: Boeing - Service Bulletin - Rights: © The Boeing Company. Filed by the FAA in regulations.gov docket FAA-2011-1068; AD 2016-18-16 incorporates this document by reference. Not covered by OpenAirDocs’ CC0 dedication. - Document: [Boeing Alert Service Bulletin 737-28A1227](https://openairdocs.org/service-documents/boeing/737-28a1227.md) - Title as filed: Boeing - Service Bulletin - Pages: 202 - PDF: https://openairdocs.org/files/sha256/a1/a6/a1a67d1fb686695926026a700f1c4e0bc720aa38935ae64a1429a25be5ea7b1d - Page: https://openairdocs.org/service-documents/boeing/737-28a1227/file/a1a67d1fb686 ## Text Some pages are OCR from a scan. OCR can misread letters and numbers. Each page's text from the PDF; open the PDF at a page with #page=N. ### Page 1 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all export laws. 9E991ECCN: BOEING PROPRIETARY, CONFIDENTIAL, AND/OR TRADE SECRET Copyright © 2010 The Boeing Company Unpublished Work - All Rights Reserved Boeing claims copyright in each page of this document only to the extent that the page contains copyrightable subject matter.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 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.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 ### Page 2 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 ALERTALERT BLANK PAGE ### Page 3 Table of Contents Revision Transmittal Sheet ............................................ 5 Summary ...................................................... 9 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 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: August 02, 2010 737-28A1227Revision 1: July 18, 2011 3 of 202 BOEING SERVICE BULLETIN 737-28A1227 ALERTALERT ### Page 4 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 ALERTALERT ### Page 5 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: BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: August 02, 2010 737-28A1227Revision 1: July 18, 2011 5 of 202 ### Page 6 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 ALERTALERT ### Page 7 REVISION HISTORY August 02, 2010Original Issue: July 18, 2011Revision 1: BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: August 02, 2010 737-28A1227Revision 1: July 18, 2011 7 of 202 BOEING SERVICE BULLETIN 737-28A1227 ALERTALERT ### Page 8 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 ### Page 9 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. BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: August 02, 2010 737-28A1227Revision 1: July 18, 2011 9 of 202 ### Page 10 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. BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: August 02, 2010 737-28A1227Revision 1: July 18, 2011 10 of 202 BOEING SERVICE BULLETIN 737-28A1227 ALERTALERT ### Page 11 (OCR) 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 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 11 of 202 ### Page 12 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: August 02, 2010 737-28A1227Revision 1: July 18, 2011 12 of 202 BOEING SERVICE BULLETIN 737-28A1227 ALERTALERT BLANK PAGE ### Page 13 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 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. 1. PLANNING INFORMATION A. Effectivity 1. Airplanes Refer to Service Bulletin Index Document D6-19567 Part 3 for Airplane Variable Number, Line Number, and Serial Number data. This service bulletin is for the airplanes shown below. Refer to PRR 35443-RS for data about this change. DESCRIPTIONCONFIGURATIONGROUP 737-100/200/200C airplanes, that have a center tank but do not have a auxiliary tank, with a unique wiring configuration. -1 737-200/200C airplanes, that have a center tank but do not have an auxiliary tank, with a unique wiring configuration. -2 737-300/400/500 airplanes, that have a center tank but do not have an auxiliary tank. -3 737-200/200C airplanes, that have a center tank but do not have an auxiliary tank, with a unique wiring configuration. -4 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: August 02, 2010 737-28A1227Revision 1: July 18, 2011 13 of 202 ### Page 14 DESCRIPTIONCONFIGURATIONGROUP 737-300 airplanes, which were delivered with a center tank and an active auxiliary tank or delivered with a center tank and wiring provision for an auxiliary tank. -5 Airplanes that, since delivery have removed or deactivated the auxiliary tank, or have wiring provision for an auxiliary tank only. 1 Airplanes that, since delivery, have kept the auxiliary tank active or have completed the wiring provision, installed and activated the auxiliary tank. 2 737-400 airplanes, which were delivered with a center tank and an active auxiliary tank or delivered with a center tank and wiring provision for an auxiliary tank. -6 Airplanes that, since delivery have removed or deactivated the auxiliary tank, or have wiring provision for an auxiliary tank only. 1 Airplanes that, since delivery, have kept the auxiliary tank active or have completed the wiring provision, installed and activated the auxiliary tank. 2 737-200 airplanes, which were delivered with a center tank and an active auxiliary tank or delivered with a center tank and wiring provision for an auxiliary tank, with a unique wiring configuration. -7 Airplanes that, since delivery have removed or deactivated the auxiliary tank, or have wiring provision for an auxiliary tank only. 1 Airplanes that, since delivery, have kept the auxiliary tank active or have completed the wiring provision, installed and activated the auxiliary tank. 2 737-200 airplanes, which were delivered with a center tank and an active auxiliary tank or delivered with a center tank and wiring provision for an auxiliary tank, with a unique wiring configuration. -8 Airplanes that, since delivery have removed or deactivated the auxiliary tank, or have wiring provision for an auxiliary tank only. 1 Airplanes that, since delivery, have kept the auxiliary tank active or have completed the wiring provision, installed and activated the auxiliary tank. 2 Airplane Models: 737-100, 737-200, 737-200C, 737-300, 737-400, 737-500 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: August 02, 2010 737-28A1227Revision 1: July 18, 2011 14 of 202 BOEING SERVICE BULLETIN 737-28A1227 ALERTALERT ### Page 15 GroupVariable Number 1PA001 - PA022 1PA099 1PA231 - PA232 1PC001 - PC005 1PG001 - PG075 1PG199 1PG201 - PG230 1PG251 - PG255 1PG271 - PG279 1PG301 - PG314 1PG331 - PG332 1PG351 - PG356 1PG375 1PG401 - PG403 1PG431 - PG442 1PG471 - PG475 1PG501 - PG505 1PG571 - PG583 2PG584 - PG586 1PG621 - PG630 1PG651 - PG652 1PG701 - PG705 2PH001 2PH011 - PH013 2PH021 - PH024 1PH701 - PH715 1PH731 - PH732 1PH741 - PH742 2PH743 1PJ001 - PJ002 2PJ003 - PJ006 7PJ007 - PJ009 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: August 02, 2010 737-28A1227Revision 1: July 18, 2011 15 of 202 BOEING SERVICE BULLETIN 737-28A1227 ALERTALERT ### Page 16 GroupVariable Number 1PJ031 - PJ032 1PJ071 - PJ072 1PJ101 - PJ104 4PJ105 - PJ119 7PJ201 - PJ219 3PJ301 - PJ302 3PJ551 - PJ561 3PJ601 - PJ615 6PJ811 3PJ816 - PJ817 2PK026 - PK029 2PK041 - PK053 2PK061 - PK067 7PK068 - PK070 2PK081 - PK082 2PK091 - PK099 2PK101 - PK103 2PK111 - PK120 2PK141 - PK146 2PK201 - PK204 2PK211 - PK223 2PK231 - PK241 2PK251 - PK256 7PK257 2PK258 2PK271 - PK274 2PK281 - PK289 2PK291 2PK301 - PK318 2PK341 2PK351 - PK355 7PK356 - PK360 2PK361 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: August 02, 2010 737-28A1227Revision 1: July 18, 2011 16 of 202 BOEING SERVICE BULLETIN 737-28A1227 ALERTALERT ### Page 17 GroupVariable Number 2PK391 2PK431 - PK433 2PK451 - PK452 2PK461 - PK469 2PK495 2PK501 7PK502 - PK504 2PK511 - PK515 2PK519 2PK521 - PK528 2PK541 - PK565 2PK581 2PK591 - PK599 4PK601 - PK606 7PK607 - PK610 2PK611 - PK617 2PK621 - PK637 2PK641 - PK642 7PK661 2PK662 - PK666 2PK671 - PK681 2PK691 - PK697 2PK711 - PK716 2PK731 - PK765 2PK771 - PK779 2PK801 - PK804 4PK819 - PK827 4PK830 2PK861 - PK863 7PK871 - PK874 2PK881 - PK884 2PK901 - PK938 2PK971 - PK974 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: August 02, 2010 737-28A1227Revision 1: July 18, 2011 17 of 202 BOEING SERVICE BULLETIN 737-28A1227 ALERTALERT ### Page 18 GroupVariable Number 2PL001 - PL028 2PL061 2PL081 2PL101 - PL113 2PL151 2PL171 - PL172 2PL201 - PL203 2PL221 2PL401 - PL408 7PL409 - PL410 2PL411 7PL412 2PL413 - PL417 7PL421 2PL441 2PL451 - PL456 2PL471 2PL491 8PL501 - PL506 2PL551 - PL562 2PL581 7PL601 - PL603 2PL611 2PL621 - PL626 7PL631 - PL632 1PL711 - PL712 1PL716 2PL717 - PL747 2PL756 2PL758 2PL761 - PL770 2PL781 - PL788 2PL793 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: August 02, 2010 737-28A1227Revision 1: July 18, 2011 18 of 202 BOEING SERVICE BULLETIN 737-28A1227 ALERTALERT ### Page 19 GroupVariable Number 1PL801 - PL803 2PM001 - PM006 2PM016 - PM017 2PM021 - PM023 2PM051 - PM066 7PM101 - PM119 7PM141 - PM142 2PM171 2PM181 2PM251 - PM255 2PM281 - PM283 3PM381 - PM399 3PM401 - PM417 3PM541 - PM564 7PN001 - PN002 2PN021 - PN043 2PN081 - PN086 2PN101 - PN117 2PN131 - PN163 2PN401 - PN420 2PN431 - PN433 2PN451 - PN456 2PN471 - PN474 2PN481 2PN491 - PN493 2PN501 - PN502 2PN511 - PN512 7PN521 3PP001 - PP054 3PP101 - PP169 3PP181 - PP199 3PP201 - PP205 3PP221 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: August 02, 2010 737-28A1227Revision 1: July 18, 2011 19 of 202 BOEING SERVICE BULLETIN 737-28A1227 ALERTALERT ### Page 20 GroupVariable Number 3PP231 - PP243 3PP281 - PP286 3PP301 - PP305 3PP351 - PP353 3PP376 - PP384 3PP391 - PP393 3PP401 - PP440 5PP471 - PP475 5PP501 - PP520 3PP521 - PP522 3PP631 - PP634 3PP651 - PP652 3PP671 - PP689 5PP690 - PP694 3PP695 - PP699 3PP701 - PP706 5PP707 - PP716 3PP717 - PP733 3PP771 - PP779 3PP801 - PP808 3PP821 - PP827 3PP831 - PP848 3PP851 - PP852 3PP861 - PP877 3PP891 - PP899 3PP901 - PP936 3PP946 - PP948 3PP951 - PP952 3PP961 - PP967 3PP981 - PP991 3PP993 3PQ001 - PQ016 3PQ026 - PQ041 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: August 02, 2010 737-28A1227Revision 1: July 18, 2011 20 of 202 BOEING SERVICE BULLETIN 737-28A1227 ALERTALERT ### Page 21 GroupVariable Number 3PQ051 - PQ092 3PQ101 - PQ199 3PQ201 - PQ202 3PQ221 - PQ237 3PQ241 - PQ243 3PQ251 - PQ267 3PQ281 - PQ299 3PQ301 - PQ307 3PQ331 - PQ332 3PQ341 - PQ348 3PQ361 - PQ373 3PQ391 - PQ395 3PQ401 - PQ418 3PQ421 3PQ431 - PQ438 3PQ447 - PQ448 3PQ451 3PQ454 3PQ471 - PQ475 3PQ479 - PQ481 3PQ486 - PQ487 3PQ491 - PQ493 3PQ771 - PQ772 3PQ791 - PQ793 3PQ801 - PQ805 3PQ931 - PQ935 3PQ951 3PQ971 - PQ997 3PR001 - PR017 3PR021 - PR034 3PR041 - PR045 3PR061 - PR072 3PR077 - PR082 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: August 02, 2010 737-28A1227Revision 1: July 18, 2011 21 of 202 BOEING SERVICE BULLETIN 737-28A1227 ALERTALERT ### Page 22 GroupVariable Number 3PR091 - PR092 3PR096 3PR101 3PR121 - PR122 3PR131 - PR132 3PR141 - PR143 3PR161 - PR172 3PR181 3PS601 - PS631 3PS636 - PS638 3PS641 - PS644 3PS651 - PS657 3PS666 - PS669 3PS691 - PS692 3PS701 - PS706 3PS751 - PS799 3PS811 3PS836 - PS837 3PS841 - PS846 3PS851 - PS852 3PS856 5PS861 - PS863 5PS866 - PS868 3PS871 - PS874 3PS896 - PS897 3PS901 - PS941 5PS956 - PS957 3PS961 - PS963 3PS971 - PS978 3PT001 - PT015 3PT021 - PT031 3PT041 - PT064 3PT101 - PT105 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: August 02, 2010 737-28A1227Revision 1: July 18, 2011 22 of 202 BOEING SERVICE BULLETIN 737-28A1227 ALERTALERT ### Page 23 GroupVariable Number 3PT121 - PT138 3PT146 - PT148 3PT161 - PT170 3PT181 - PT188 3PT211 - PT220 3PT295 3PT301 - PT309 3PT331 - PT360 3PT381 - PT399 3PT401 - PT438 3PT501 - PT517 3PT561 - PT565 3PT581 - PT586 3PT611 - PT621 3PT641 - PT644 3PT651 - PT656 3PT671 - PT672 3PT681 - PT685 3PT701 - PT703 3PT716 - PT717 3PT721 - PT725 3PT801 - PT834 3PT851 - PT854 3PT871 - PT886 3PT901 - PT930 3PT971 - PT973 3PT981 - PT985 3PT996 3PU001 - PU025 3PU301 3PU311 - PU313 3PV001 - PV055 3PV201 - PV209 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: August 02, 2010 737-28A1227Revision 1: July 18, 2011 23 of 202 BOEING SERVICE BULLETIN 737-28A1227 ALERTALERT ### Page 24 GroupVariable Number 3PV226 - PV229 3PV231 - PV237 3PV271 - PV272 3PV281 - PV287 3PV296 3PV301 - PV302 3PV351 3PV356 - PV357 3PW001 - PW054 3PW061 - PW068 3PW072 3PW086 - PW088 3PW091 - PW094 3PW101 - PW102 3PW106 3PW111 - PW120 3PW156 - PW157 3PW161 - PW171 3PW201 - PW252 3PW261 - PW268 3PW271 - PW276 3PW278 3PW281 - PW293 3PW296 3PW301 - PW327 3PW401 - PW408 3PW411 - PW418 3PW421 - PW424 3PW431 - PW435 3PW441 - PW450 3PW461 - PW467 3PW501 - PW504 6PW511 - PW522 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: August 02, 2010 737-28A1227Revision 1: July 18, 2011 24 of 202 BOEING SERVICE BULLETIN 737-28A1227 ALERTALERT ### Page 25 GroupVariable Number 6PW524 3PW525 - PW529 6PW530 3PW531 - PW550 3PW556 - PW557 3PW561 - PW564 3PW571 - PW576 3PW591 - PW596 3PW611 - PW622 3PW631 - PW637 3PW661 - PW662 3PW681 - PW683 6PW701 - PW702 3PW711 - PW717 3PW741 - PW742 3PW761 3PW771 3PW831 3PW851 - PW856 1PX071 1PX701 1PY001 - PY008 1PY021 2PY022 1PY031 2PY036 - PY037 2PY046 - PY048 2PY051 - PY053 2PY056 - PY057 2PY101 - PY103 2PY111 - PY113 2PY131 - PY135 2PY141 - PY143 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: August 02, 2010 737-28A1227Revision 1: July 18, 2011 25 of 202 BOEING SERVICE BULLETIN 737-28A1227 ALERTALERT ### Page 26 GroupVariable Number 2PY151 - PY154 2PY156 - PY157 2PY161 - PY162 2PY166 2PY191 2PY201 2PY221 - PY222 2PY231 2PY241 - PY244 2PY270 - PY275 2PY281 2PY286 1PY301 - PY304 1PY321 - PY323 1PY341 - PY346 1PY361 - PY362 1PY381 2PY401 2PY409 - PY411 2PY421 - PY422 2PY441 2PY451 2PY461 - PY463 2PY591 - PY595 2PY611 - PY612 2PY621 2PY631 2PY651 2PY671 - PY672 2PY721 2PY741 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: August 02, 2010 737-28A1227Revision 1: July 18, 2011 26 of 202 BOEING SERVICE BULLETIN 737-28A1227 ALERTALERT ### Page 27 2. Spares Affected None. B. Concurrent Requirements The service bulletin(s) listed below must be done before or at the same time as this service bulletin: Group 1: Operators should contact Boeing to obtain engineering and accomplishment instructions for this modification and do the instructions. Group 2-8: DescriptionService BulletinCompany Replacement of the P5-2 Fuel System Module to Supply Low Fuel Pressure Mas- ter Caution Annunciation. 737-28A1210 Revision 1Boeing Group 3, 5-6: DescriptionService BulletinCompany Installation of the Auto Shutoff Protection for the Center and Auxiliary Fuel Tank Boost Pumps. 737-28A1216 Original IssueBoeing Group 2, 4, 7-8: DescriptionService BulletinCompany Installation of the Auto Shutoff Protection for the Center and Auxiliary Fuel Tank Boost Pumps. 737-28A1228 Original IssueBoeing C. Reason 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 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: August 02, 2010 737-28A1227Revision 1: July 18, 2011 27 of 202 BOEING SERVICE BULLETIN 737-28A1227 ALERTALERT ### Page 28 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 control 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. 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. Revision 01 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. The data given in Information Notice 737-28A1227 IN 01, IN 02, and IN 05 are included in this revision. Boeing Fleet Team Digest (FTD) 737 FTD 28-04004 is related to this service bulletin. D. Description 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. BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: August 02, 2010 737-28A1227Revision 1: July 18, 2011 28 of 202 BOEING SERVICE BULLETIN 737-28A1227 ALERTALERT ### Page 29 Operators with Group 1 airplanes should contact Boeing to obtain engineering and accomplishment instructions for this modification and do the instructions. Revision 01 - 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. The work in this service bulletin is done in the maintenance zone(s) given below. Group 1: Affected Maintenance Zones ZoneModel 1-1, 1-2, 2-5737-100, 737-200, 737-200C Group 2: Affected Maintenance Zones ZoneModel 1-1, 1-2, 2-5737-200, 737-200C Group 3: Affected Maintenance Zones ZoneModel 101, 102, 205737-300, 737-400, 737-500 Group 4, 7-8: Affected Maintenance Zones ZoneModel 1-1, 1-2, 2-5737-200 Group 5: Affected Maintenance Zones ZoneModel 101, 102, 205737-300 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: August 02, 2010 737-28A1227Revision 1: July 18, 2011 29 of 202 BOEING SERVICE BULLETIN 737-28A1227 ALERTALERT ### Page 30 Group 6: Affected Maintenance Zones ZoneModel 101, 102, 205737-400 E. 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. F. Approval This service bulletin was examined by the Federal Aviation Administration (FAA). The changes specified in this service bulletin comply with the applicable regulations and are FAA approved, as well as European Aviation Safety Agency (EASA)/Joint Aviation Authorities (JAA) approved for all EASA/JAA approved airplanes listed in the service bulletin effectivity. This service bulletin and its approval were based on the airplane in its original Boeing delivery configuration or as modified by other approved Boeing changes. If an airplane has a non-Boeing modification or repair that affects a component or system also affected by this service bulletin, the operator is responsible for obtaining appropriate regulatory agency approval before incorporating this service bulletin. G. Manpower The table below shows an estimate of the task-hours necessary to do this service bulletin for each airplane. This estimate is for direct labor only, done by an experienced crew. Adjust the estimate with operator task-hour data if necessary. The estimate does not include lost time. These are some examples of lost time: — Time to adjust to the workplace — Time to schedule the work — Time to examine the work — Time to cure the materials — Time to make the parts — Time to find the tools. Group 1: Operators should contact Boeing to obtain engineering and accomplishment instructions for this modification and do the instructions. BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: August 02, 2010 737-28A1227Revision 1: July 18, 2011 30 of 202 BOEING SERVICE BULLETIN 737-28A1227 ALERTALERT ### Page 31 Group 2; Group 7-8, Configuration 1: Elapsed Hours Task-HoursNumber of Persons Task 1.503.002Open Access 1.751.751FIGURE 1 ---FIGURE 2 (Wire Routing only) 4.008.002FIGURE 3 4.008.002FIGURE 4 ---FIGURE 9 (Wire Routing only) 3.406.802FIGURE 10 3.406.802FIGURE 11 0.250.251FIGURE 30 0.500.501Test 1.503.002Close Access 20.3038.10TOTAL FOR EACH AIRPLANE Group 3; Group 5-6, Configuration 1: Elapsed Hours Task-HoursNumber of Persons Task 1.503.002Open Access 1.751.751FIGURE 1 ---FIGURE 2 (Wire Routing only) 4.008.002FIGURE 3 4.008.002FIGURE 4 ---FIGURE 12 (Wire Routing only) 3.406.802FIGURE 13 3.406.802FIGURE 14 0.250.251FIGURE 30 0.500.501Test 1.503.002Close Access 20.3038.10TOTAL FOR EACH AIRPLANE Group 4: Elapsed Hours Task-HoursNumber of Persons Task 1.503.002Open Access 1.751.751FIGURE 1 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: August 02, 2010 737-28A1227Revision 1: July 18, 2011 31 of 202 BOEING SERVICE BULLETIN 737-28A1227 ALERTALERT ### Page 32 Group 4: Elapsed Hours Task-HoursNumber of Persons Task ---FIGURE 2 (Wire Routing only) 4.008.002FIGURE 3 4.008.002FIGURE 4 ---FIGURE 15 (Wire Routing only) 3.406.802FIGURE 16 3.406.802FIGURE 17 0.250.251FIGURE 30 0.500.501Test 1.503.002Close Access 20.3038.10TOTAL FOR EACH AIRPLANE Group 5, Configuration 2: Elapsed Hours Task-HoursNumber of Persons Task 1.503.002Open Access 3.003.001FIGURE 5 ---FIGURE 6 (Wire Routing only) 8.0016.002FIGURE 7 8.0016.002FIGURE 8 ---FIGURE 18 (Wire Routing only) 5.5011.002FIGURE 19 5.5011.002FIGURE 20 0.250.251FIGURE 30 1.001.001Test 1.503.002Close Access 34.2564.25TOTAL FOR EACH AIRPLANE Group 6, Configuration 2: Elapsed Hours Task-HoursNumber of Persons Task 1.503.002Open Access 3.003.001FIGURE 5 ---FIGURE 6 (Wire Routing only) 8.0016.002FIGURE 7 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: August 02, 2010 737-28A1227Revision 1: July 18, 2011 32 of 202 BOEING SERVICE BULLETIN 737-28A1227 ALERTALERT ### Page 33 Group 6, Configuration 2: Elapsed Hours Task-HoursNumber of Persons Task 8.0016.002FIGURE 8 ---FIGURE 21 (Wire Routing only) 5.5011.002FIGURE 22 5.5011.002FIGURE 23 0.250.251FIGURE 30 1.101.101Test 1.503.002Open Access 34.3564.35TOTAL FOR EACH AIRPLANE Group 7, Configuration 2: Elapsed Hours Task-HoursNumber of Persons Task 1.503.002Open Access 3.003.001FIGURE 5 ---FIGURE 6 (Wire Routing only) 8.0016.002FIGURE 7 8.0016.002FIGURE 8 ---FIGURE 24 (Wire Routing only) 5.5011.002FIGURE 25 5.5011.002FIGURE 26 0.250.251FIGURE 30 1.101.101Test 1.503.002Close Access 34.3564.35TOTAL FOR EACH AIRPLANE Group 8, Configuration 2: Elapsed Hours Task-HoursNumber of Persons Task 1.503.002Open Access 3.003.001FIGURE 5 ---FIGURE 6 (Wire Routing only) 8.0016.002FIGURE 7 8.0016.002FIGURE 8 ---FIGURE 27 (Wire Routing only) BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: August 02, 2010 737-28A1227Revision 1: July 18, 2011 33 of 202 BOEING SERVICE BULLETIN 737-28A1227 ALERTALERT ### Page 34 Group 8, Configuration 2: Elapsed Hours Task-HoursNumber of Persons Task 5.5011.002FIGURE 28 5.5011.002FIGURE 29 0.250.251FIGURE 30 0.500.501Test 1.503.002Close Access 33.7563.75TOTAL FOR EACH AIRPLANE H. Weight and Balance Changes Group 1: Operators should contact Boeing to obtain engineering and accomplishment instructions for this modification and do the instructions. Group 2-4; Group 5-8, Configuration 1: Change in Moment (Pound-Inches) Change in Weight (Pounds) Airplane +2,100+7737-100 +1,850+7737-200 +1,540+7737-300 +1,040+7737-400 +1,920+7737-500 Group 5-8, Configuration 2: Change in Moment (Pound-Inches) Change in Weight (Pounds) Airplane +2,640+10737-200 +2,200+10737-300 +1,480+10737-400 I. Electrical Load Data 1. Direct Current (DC) Loads Group 1: Operators should contact Boeing to obtain engineering and accomplishment instructions for this modification and do the instructions. BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: August 02, 2010 737-28A1227Revision 1: July 18, 2011 34 of 202 BOEING SERVICE BULLETIN 737-28A1227 ALERTALERT ### Page 35 Group 2-4; Group 5-8, Configuration 1: BusAmperesCircuit Breaker 28V DC Bus 1+0.25C64 28V DC Bus 2+0.25C65 Group 5-8, Configuration 2: BusAmperesCircuit Breaker 28V DC Bus 1+0.50C64 28V DC Bus 2+0.50C65 2. Alternating Current (AC) Loads No Change. 3. Type Continuous. J. References 1. Existing Data: a. Engineering Change Memo PRR 35443-RS b. Boeing Service Bulletin 737-28A1210, 737-28A1216, 737-28A1228 c. Standard Overhaul Practices Manual (SOPM) 20-41-02, 20-50-05, 20-50-10 d. Standard Wiring Practices Manual (SWPM) 20-10-11, 20-10-12, 20-10-15, 20-10-18, 20-10-19, 20-20-11, 20-30-11, 20-30-12, 20-30-17, 20-30-22, 20-60-08, 20-60-09, 20-61-11, 20-81-19 e. 737-100/200/200C/300/400/500 Airworthiness Limitations (AWLs) and Certification Maintenance Requirements (CMRs), D6-38278-CMR f. 737 Fleet Team Digest (FTD) 28-04004 g. 737-100/200 Wiring Diagram 28-23-01, 28-23-02 h. 737-300/400/500 Wiring Diagram 28-23-01, 28-23-02 i. 737-100/200 Aircraft Maintenance Manual (AMM) 12-31-11, 24-22-0, 24-31-11, 25-11-0, 25-16-11, 25-31-11, 25-31-51, 25-51-01, 32-00-01, 52-48-41, 52-61-0, 52-61-100 j. 737-300/400/500 Aircraft Maintenance Manual (AMM) 12-31-11, 24-22-00, 24-31-11, 25-10-00, 25-11-21, 25-31-11, 25-51-01, 32-00-01, 52-48-41, 52-61-00, 52-61-10 2. Data supplied with this Service Bulletin: None. BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: August 02, 2010 737-28A1227Revision 1: July 18, 2011 35 of 202 BOEING SERVICE BULLETIN 737-28A1227 ALERTALERT ### Page 36 3. Installation Drawings Used in the Preparation of this Service Bulletin: TitleDrawing Number KIT - EQUIPMENT / WIRE INSTALLATION, J2802 PANEL65C38484 This drawing was used to prepare this service bulletin. This drawing is not necessary to make the specified changes, and is not supplied with this service bulletin. This drawing may not be applicable to all airplane configurations or operators. K. Publications Affected 1. Publications: Chapter-SectionPublication 28-22737 Aircraft Maintenance Manual 28-23737 Wiring Diagram Manual 28-23737 Illustrated Parts Catalog 28-23737 Schematic Diagram Manual Section C., Fuel Systems Airworthiness Limitations 737-100/200/200C300/400/500 Airworthiness Limitations (AWLs) and Certification Maintenance Requirements (CMRs), D6-38278-CMR 2. Damage Tolerance Based Structural Inspections: Boeing has evaluated the repairs and/or changes in this service bulletin for effects on Fatigue Critical Structure (FCS) and for changes to Damage Tolerance Inspections (DTI) required in the Maintenance Program. This service bulletin does not affect FCS, therefore DTIs are not necessary. L. Interchangeability and Intermixability of Parts Accomplishment of this service bulletin does not affect interchangeability or intermixability of parts. BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: August 02, 2010 737-28A1227Revision 1: July 18, 2011 36 of 202 BOEING SERVICE BULLETIN 737-28A1227 ALERTALERT ### Page 37 2. MATERIAL INFORMATION A. Material - Price and Availability Boeing can supply the kits shown in Paragraph 2.C., Parts Necessary for Each Airplane. Operators are encouraged to share schedule requirements with Boeing for incorporation of the service bulletin. The kits are subject to the terms and conditions of the Boeing standard purchase order acknowledgment. Prices are in United States Dollars. Terms: Net 30 days. Reference this service bulletin and submit your purchase order by one of these methods: 1. Order on-line via ATA Spec 2000 or The Boeing PART Page 2. Fax to (206) 662-7145 NOTE: Airplanes in Group 5-6 Configuration 1, that are going to activate the auxiliary tank at a later date, need to purchase Top Kits 65C38537-2 and 65C38537-7. 1. 2. Airplanes in Group 7-8 Configuration 1, that are going to activate the auxiliary tank at a later date, need to purchase Top Kits 65C38537-3 and 65C38537-7. Group 1: Operators should contact Boeing to obtain engineering and accomplishment instructions for this modification and do the instructions. Group 2-4; Group 5-8, Configuration 1: REFER TO THE BOEING PART PAGE ON MYBOEINGFLEET.COM OR CONTACT FIRST RESPONDER AT FR@BOEING.COM FOR THE LATEST REORDER LEAD TIME (ROLT) AND PRICE INFORMATION Unit Price as of the Revision 01 date of this Ser- vice Bulletin (US Dollars) ROLT as of the Revision 01 date of this Service Bulletin (Calendar Days) QTYDateNameKit Number $3,715.00(b)1Jul 13, 2010Boost Pump, Fuel Uncom- manded On - Top Kit, Cen- ter Tank 737/100/200/300/400/500 65C38537-1 (a) 100Aug 13, 2010 100Aug 20, 2010 100Aug 27, 2010 100Sep 03, 2010 100Sep 13, 2010 100Sep 20, 2010 100Sep 27, 2010 (a) Operators that have already received Top Kit 65C38537-1 at the original issue of this service bulletin but have not accomplished this service bulletin must procure Top Kit 65C38537-6 which has the necessary parts to install relays R3334 and R3336 in accordance with revision 01 of this service bulletin. (b) Contact Boeing Spares. BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: August 02, 2010 737-28A1227Revision 1: July 18, 2011 37 of 202 BOEING SERVICE BULLETIN 737-28A1227 ALERTALERT ### Page 38 Group 5-6, Configuration 2: REFER TO THE BOEING PART PAGE ON MYBOEINGFLEET.COM OR CONTACT FIRST RESPONDER AT FR@BOEING.COM FOR THE LATEST REORDER LEAD TIME (ROLT) AND PRICE INFORMATION Unit Price as of the Revision 01 date of this Service Bulletin (US Dollars) ROLT as of the Revi- sion 01 date of this Service Bulletin (Cal- endar Days) QTYDateNameKit Number $3,936.00(b)1Jul 15, 2010Boost Pump, Fuel Uncommanded On - Top Kit, Center & Auxiliary Tanks 65C38537-2 (a) 10Aug 13, 2010 (a) Operators that have already received Top Kit 65C38537-2 at the original issue of this service bulletin but have not accomplished this service bulletin must procure Top Kit 65C38537-7 which has the necessary parts to install relays R3334, R3336, R3338, and R3340 in accordance with revision 01 of this service bulletin. (b) Contact Boeing Spares. Group 7-8, Configuration 2: REFER TO THE BOEING PART PAGE ON MYBOEINGFLEET.COM OR CONTACT FIRST RESPONDER AT FR@BOEING.COM FOR THE LATEST REORDER LEAD TIME (ROLT) AND PRICE INFORMATION Unit Price as of the Revision 01 date of this Service Bulletin (US Dollars) ROLT as of the Revi- sion 01 date of this Service Bulletin (Cal- endar Days) QTYDateNameKit Number $4,066.00(b)20Aug 13, 2010Boost Pump, Fuel Uncommanded On - Top Kit, Center & Auxiliary Tanks 65C38537-3 (a) (a) Operators that have already received Top Kit 65C38537-3 at the original issue of this service bulletin but have not accomplished this service bulletin must procure Top Kit 65C38537-7 which has the necessary parts to install relays R3334, R3336, R3338, and R3340 in accordance with revision 01 of this service bulletin. (b) Contact Boeing Spares. Group 2-4; Group 5-8, Configuration 1: REFER TO THE BOEING PART PAGE ON MYBOEINGFLEET.COM OR CONTACT FIRST RESPONDER AT FR@BOEING.COM FOR THE LATEST REORDER LEAD TIME (ROLT) AND PRICE INFORMATION Unit Price as of the Revision 01 date of this Service Bulletin (US Dollars) ROLT as of the Revision 01 date of this Service Bulletin (Calendar Days) NameKit Number $15.00(a)Boost Pump, Fuel Uncommanded On - Top Kit, Center Tank Without Aux Tank 65C38537-6 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: August 02, 2010 737-28A1227Revision 1: July 18, 2011 38 of 202 BOEING SERVICE BULLETIN 737-28A1227 ALERTALERT ### Page 39 Group 2-4; Group 5-8, Configuration 1: REFER TO THE BOEING PART PAGE ON MYBOEINGFLEET.COM OR CONTACT FIRST RESPONDER AT FR@BOEING.COM FOR THE LATEST REORDER LEAD TIME (ROLT) AND PRICE INFORMATION Unit Price as of the Revision 01 date of this Service Bulletin (US Dollars) ROLT as of the Revision 01 date of this Service Bulletin (Calendar Days) NameKit Number (a) At the time of the release of the service bulletin the ROLT and Price were not available. Contact Boeing Spares. Group 5-8, Configuration 2: REFER TO THE BOEING PART PAGE ON MYBOEINGFLEET.COM OR CONTACT FIRST RESPONDER AT FR@BOEING.COM FOR THE LATEST REORDER LEAD TIME (ROLT) AND PRICE INFORMATION Unit Price as of the Revision 01 date of this Service Bulletin (US Dollars) ROLT as of the Revision 01 date of this Service Bulletin (Calendar Days) NameKit Number $30.00(a)Boost Pump, Fuel Uncommanded On - Top Kit, Center & Auxiliary Tanks 65C38537-7 (a) At the time of the release of the service bulletin the ROLT and Price were not available. Contact Boeing Spares. B. Industry Support Information Boeing warranty remedies are not available for the configuration changes given in this service bulletin. C. Parts Necessary For Each Airplane 1. Kits/Parts: To get the kits shown below, refer to Paragraph 2.A., Material - Price and Availability. NOTE: Two top kits and the items shown in Paragraph 2.C.2., Parts and Materials Supplied by the Operator, are necessary for each airplane. Kit 65C38537 NotesNameQTYNew Part Number -7-6-3-2-1 BOOST PUMP, FUEL UNCOMMANDED ON - TOP KIT, CENTER TANK 737/100/200/300/400/500 ....-65C38537-1 BOOST PUMP, FUEL UNCOMMANDED ON - TOP KIT, CENTER & AUXILIARY TANKS ...-.65C38537-2 BOOST PUMP, FUEL UNCOMMANDED ON - TOP KIT, CENTER & AUXILIARY TANKS ..-..65C38537-3 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: August 02, 2010 737-28A1227Revision 1: July 18, 2011 39 of 202 BOEING SERVICE BULLETIN 737-28A1227 ALERTALERT ### Page 40 Kit 65C38537 NotesNameQTYNew Part Number -7-6-3-2-1 BOOST PUMP, FUEL UNCOMMANDED ON - TOP KIT, CENTER TANK WITHOUT AUX TANK .-...65C38537-6 BOOST PUMP, FUEL UNCOMMANDED ON - TOP KIT, CENTER & AUXILIARY TANKS -....65C38537-7 WIRE KIT - UNCOMMANDED ON RELAYS - NO AUX TANK CONFIGURATION ....161-74482-1 WIRE KIT - UNCOMMANDED ON RELAYS - AUX TANK CONFIGURATION - 737-300/-400/- 500 ...1.61-74482-2 WIRE KIT - UNCOMMANDED ON RELAYS - AUX TANK CONFIGURATION - 737-100/-200 ..1..61-74482-3 WIRE BUNDLE INSTALLATION FOR AIR- PLANES WITHOUT AUX TANK - PUMP UN- COMMANDED ON ....165C38510-1 WIRE BUNDLE INSTALLATION FOR AIR- PLANES WITH AUX TANK - PUMP UNCOM- MANDED ON ..11.65C38510-2 (a) (b)SCREW168...BACS12HN08-10 (b)WASHER, PLAIN168...NAS1149DN816H (a) If grip length shown is not available at Boeing, fasteners supplied in kits may be up to two grip length longer than indicated. Also, if any fasteners part numbers listed are not available or have been superseded, substitute fasteners may be supplied in kits. Use the approved fastener substitutions in accordance with SRM Chapter 51. (b) The operator can also supply these parts as shown in "Parts and Materials Supplied by the Operators" table. Kit 65C38510 NotesNameQTYNew Part Number -1-2 WIRE BUNDLE INSTALLATION FOR AIRPLANES WITHOUT AUX TANK - PUMP UNCOMMANDED ON -.65C38510-1 WIRE BUNDLE INSTALLATION FOR AIRPLANES WITH AUX TANK - PUMP UNCOMMANDED ON .-65C38510-2 TOGGLE SWITCH - LOCKED IN CENTER POSITION2264AT23-7E (a)RELAY249324-7424 (MS27418- 2B optional) BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: August 02, 2010 737-28A1227Revision 1: July 18, 2011 40 of 202 BOEING SERVICE BULLETIN 737-28A1227 ALERTALERT ### Page 41 Kit 65C38510 NotesNameQTYNew Part Number -1-2 (a) There are more parts than are necessary for Operators in Group 5-8 Configuration 1 that have kit 65C38510- 2. Kit 61-74482 NotesNameQTYNew Part Number -1 WIRE KIT - UNCOMMANDED ON RELAYS - NO AUX TANK CONFIGU- RATION -61-74482-1 ASSY - W1760161-74482-103 ASSY - W1770161-74482-105 ASSY - W368, W1764161-74482-107 ASSY - W386, W1774161-74482-110 LACING TAPE - WHITE161-74482-2001 THERMOFIT SLEEVE - 0.093 IN. I.D.161-74482-2006 THERMOFIT SLEEVE - YELLOW, .375 IN I.D.161-74482-2009 EXPANDABLE SLEEVE - 0.25 IN. I.D.161-74482-2010 THERMOFIT SLEEVE - YELLOW, .125 IN I.D.161-74482-2014 THERMOFIT SLEEVE - YELLOW, .187 IN I.D.161-74482-2015 Kit 61-74482 NotesNameQTYNew Part Number -2 WIRE KIT - UNCOMMANDED ON RELAYS - AUX TANK CONFIGURA- TION - 737-300/-400/-500 -61-74482-2 ASSY - W1760161-74482-104 ASSY - W1770161-74482-106 ASSY - W368, W1046, W1764161-74482-108 ASSY - W386, W1034, W1774161-74482-111 LACING TAPE - WHITE161-74482-2001 (a)THERMOFIT SLEEVE - 0.093 IN. I.D.161-74482-2007 (a)THERMOFIT SLEEVE - 0.25 IN. I.D.161-74482-2008 THERMOFIT SLEEVE - YELLOW, .375 IN I.D.161-74482-2009 (a)EXPANDABLE SLEEVE - 0.25 IN. I.D.161-74482-2011 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: August 02, 2010 737-28A1227Revision 1: July 18, 2011 41 of 202 BOEING SERVICE BULLETIN 737-28A1227 ALERTALERT ### Page 42 Kit 61-74482 NotesNameQTYNew Part Number -2 (a)EXPANDABLE SLEEVE - 0.5 IN. I.D.161-74482-2012 THERMOFIT SLEEVE - YELLOW, .125 IN I.D.161-74482-2014 THERMOFIT SLEEVE - YELLOW, .187 IN I.D.161-74482-2015 (a) Operators in Group 5-6 Configuration 1 that have Top Kit 65C38537-2, this part is not used. Kit 61-74482 NotesNameQTYNew Part Number -3 WIRE KIT - UNCOMMANDED ON RELAYS - AUX TANK CONFIGURA- TION - 737-200 -61-74482-3 ASSY - W1760161-74482-104 ASSY - W1770161-74482-106 ASSY - W368, W1046, W1764161-74482-109 ASSY - W386, W1034, W1774161-74482-112 LACING TAPE - WHITE161-74482-2001 (a)THERMOFIT SLEEVE - 0.093 IN. I.D.161-74482-2007 THERMOFIT SLEEVE - YELLOW, .375 IN I.D.161-74482-2009 (a)EXPANDABLE SLEEVE - 0.25 IN. I.D.161-74482-2011 (a)EXPANDABLE SLEEVE - 0.5 IN. I.D.161-74482-2013 THERMOFIT SLEEVE - YELLOW, .125 IN I.D.161-74482-2014 THERMOFIT SLEEVE - YELLOW, .187 IN I.D.161-74482-2015 (a) Operators in Group 7-8 Configuration 1 that have Top Kit 65C38537-3, this part is not used. Kit 61-74482 NotesNameQTYNew Part Number -103-104-105-106-107-108 ASSY - W1760-.....61-74482-103 ASSY - W1760.-....61-74482-104 ASSY - W1770..-...61-74482-105 ASSY - W1770...-..61-74482-106 ASSY - W368, W1764....-.61-74482-107 ASSY - W368, W1046, W1764.....-61-74482-108 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: August 02, 2010 737-28A1227Revision 1: July 18, 2011 42 of 202 BOEING SERVICE BULLETIN 737-28A1227 ALERTALERT ### Page 43 Kit 61-74482 NotesNameQTYNew Part Number -103-104-105-106-107-108 (a)CONTACTS3535..60789-2 (640024-1 optional) WIRE LIST1.....61-74482-103W WIRE LIST.1....61-74482-104W WIRE LIST..1...61-74482-105W WIRE LIST...1..61-74482-106W WIRE LIST....1.61-74482-107W (b)WIRE LIST.....161-74482-108W CONNECTOR I.D. TAPE - D05208J11....61-74478-10502 CONNECTOR I.D. TAPE - D1096611....61-74478-10503 (c)CONNECTOR I.D. TAPE - D10970.1....61-74478-10601 CONNECTOR I.D. TAPE - D05210J..11..61-74478-10702 CONNECTOR I.D. TAPE - D10968..11..61-74478-10703 (c)CONNECTOR I.D. TAPE - D10972...1..61-74478-10801 CONNECTOR I.D. TAPE - D05208P....1161-74478-10904 CONNECTOR I.D. TAPE - D04202J....1.61-74482-10701 CONNECTOR I.D. TAPE - D04202J....1161-74482-10702 SPLICE I.D. SLEEVE - SP4514....1161-74482-10703 SPLICE I.D. SLEEVE - SP4516....1161-74482-10704 SPLICE I.D. SLEEVE - SP4522....1161-74482-10705 (c)CONNECTOR I.D. TAPE - D04900P.....161-74482-10801 (c)CONNECTOR I.D. TAPE - D04900P.....161-74482-10802 (c)SPLICE I.D. SLEEVE - SP4536.....161-74482-10803 (c)SPLICE I.D. SLEEVE - SP4538.....161-74482-10804 (c)SPLICE I.D. SLEEVE - SP4540.....161-74482-10805 (c)WIRE I.D. TAPE - W1764-301B,2R,3Y- 18 .....261-74482-10806 (c)WIRE I.D. TAPE - W1764-304B,5R,6Y- 18 .....261-74482-10807 (a)CONTACT, PIN714714.4BACC47CN2 (a)CONTACT....1017BACC47CP2T (a)CONTACT2323..BACC47DE7A BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: August 02, 2010 737-28A1227Revision 1: July 18, 2011 43 of 202 BOEING SERVICE BULLETIN 737-28A1227 ALERTALERT ### Page 44 Kit 61-74482 NotesNameQTYNew Part Number -103-104-105-106-107-108 (a)CONTACT, SOCKET3535..BACC47ER1 (a) (c)STRAP.....2BACS38K5 (a)TERMINAL, LUG3535..BACT12AC2 (a)TERMINAL, LUG714714..BACT12AC49 (a)TERMINAL, LUG2323..BACT12AC53 (a)SPLICE....47D-436-37 (a) There are more parts than are necessary. (b) Operators in Group 5-6 Configuration 1 that have Top Kit 65C38537-2, wires W1764-301-18B, W1764- 302-18R, W1764-303-18Y, W1764-304-18B, W1764-305-18R, and W1764-306-18Y are not used. (c) Operators in Group 5-6 Configuration 1 that have Top Kit 65C38537-2, this part is not used. Kit 61-74482 NotesNameQTYNew Part Number -109-110-111-112-2001-2006 ASSY - W368, W1046, W1764-.....61-74482-109 ASSY - W386, W1774.-....61-74482-110 ASSY - W386, W1034, W1774..-...61-74482-111 ASSY - W386, W1034, W1774...-..61-74482-112 LACING TAPE - WHITE....-.61-74482-2001 THERMOFIT SLEEVE - 0.093 IN. I.D......-61-74482-2006 (b)WIRE LIST1.....61-74482-109W WIRE LIST.1....61-74482-110W (c)WIRE LIST..1...61-74482-111W (d)WIRE LIST...1..61-74482-112W CONNECTOR I.D. TAPE - D05208P1.....61-74478-10904 CONNECTOR I.D. TAPE - D05210P.111..61-74478-11104 CONNECTOR I.D. TAPE - D04202J1.....61-74482-10701 SPLICE I.D. SLEEVE - SP45141.....61-74482-10703 SPLICE I.D. SLEEVE - SP45161.....61-74482-10704 SPLICE I.D. SLEEVE - SP45221.....61-74482-10705 (e)SPLICE I.D. SLEEVE - SP45361.....61-74482-10803 (e)SPLICE I.D. SLEEVE - SP45381.....61-74482-10804 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: August 02, 2010 737-28A1227Revision 1: July 18, 2011 44 of 202 BOEING SERVICE BULLETIN 737-28A1227 ALERTALERT ### Page 45 Kit 61-74482 NotesNameQTYNew Part Number -109-110-111-112-2001-2006 (e)SPLICE I.D. SLEEVE - SP45401.....61-74482-10805 (e)CONNECTOR I.D. TAPE - D04900P1.....61-74482-10901 CONNECTOR I.D. TAPE - D04084J.1....61-74482-11002 CONNECTOR I.D. TAPE - D04208P.1.1..61-74482-11003 CONNECTOR I.D. TAPE - D04208P.11...61-74482-11004 SPLICE I.D. SLEEVE - SP4524.111..61-74482-11005 SPLICE I.D. SLEEVE - SP4526.111..61-74482-11006 SPLICE I.D. SLEEVE - SP4528.111..61-74482-11007 (f)CONNECTOR I.D. TAPE - D04898P..1...61-74482-11101 (f)CONNECTOR I.D. TAPE - D04898P..1...61-74482-11102 (e) (f)SPLICE I.D. SLEEVE - SP4530..11..61-74482-11103 (e) (f)SPLICE I.D. SLEEVE - SP4532..11..61-74482-11104 (e) (f)SPLICE I.D. SLEEVE - SP4534..11..61-74482-11105 (e) (f)WIRE I.D. TAPE - W1774-301B,2R,3Y- 18 ..2...61-74482-11106 (e) (f)WIRE I.D. TAPE - W1774-304B,5R,6Y- 18 ..2...61-74482-11107 (e)CONNECTOR I.D. TAPE - D04898P...1..61-74482-11201 (a)CONTACT, PIN4474..BACC47CN2 (a)CONTACT17101417..BACC47CP2T (a) (e) (f) STRAP2.22..BACS38K5 (a)SPLICE7477..D-436-37 INSULATION SLEEVING, HEAT SHRINKABLE, POLYOLEFIN, FLEXI- BLE, X-LINKED .....1M23053/5-103-4 BMS 13-54....1.NA374H2 (a) There are more parts than are necessary. (b) Operators in Group 7-8 Configuration 1 that have Top Kit 65C38537-3, wires W1764-015-18, W1764-016- 18, W1764-017-18, W1764-018-18, W1764-019-18, and W1764-020-18 are not used. (c) Operators in Group 5-6 Configuration 1 that have Top Kit 65C38537-2, wires W1774-301-18B, W1774- 302-18R, W1774-303-18Y, W1774-304-18B, W1774-305-18R, and W1774-306-18Y are not used. (d) Operators in Group 7-8 Configuration 1 that have Top Kit 65C38537-3, wires W1774-015-18, W1774-016- 18, W1774-017-18, W1774-018-18, W1774-019-18, and W1774-020-18 are not used. BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: August 02, 2010 737-28A1227Revision 1: July 18, 2011 45 of 202 BOEING SERVICE BULLETIN 737-28A1227 ALERTALERT ### Page 46 Kit 61-74482 NotesNameQTYNew Part Number -109-110-111-112-2001-2006 (e) Operators in Group 7-8 Configuration 1 that have Top Kit 65C38537-3, this part is not used. (f) Operators in Group 5-6 Configuration 1 that have Top Kit 65C38537-2, this part is not used. Kit 61-74482 NotesNameQTYNew Part Number -2007-2008-2009-2010-2011-2012 THERMOFIT SLEEVE - 0.093 IN. I.D. -.....61-74482-2007 THERMOFIT SLEEVE - 0.25 IN. I.D. .-....61-74482-2008 THERMOFIT SLEEVE - YELLOW, .375 IN I.D. ..-...61-74482-2009 EXPANDABLE SLEEVE - 0.25 IN. I.D. ...-..61-74482-2010 EXPANDABLE SLEEVE - 0.25 IN. I.D. ....-.61-74482-2011 EXPANDABLE SLEEVE - 0.5 IN. I.D. .....-61-74482-2012 INSULATION SLEEVING, HEAT SHRINKABLE, POLYOLEFIN, FLEXIBLE, X-LINKED 1.....M23053/5-103-4 POLYOLEFIN HEAT SHRINKABLE SLEEVE RAW MATERIAL .1....M23053/5-106-4 INSULATION SLEEVING, HEAT SHRINKABLE, POLYOLEFIN, FLEXIBLE, X-LINKED ..1...M23053/5-107-4 BMS 13-52 EXPANDABLE S...111NA728R99 Kit 61-74482 NotesNameQTYNew Part Number -2013-2014-2015 EXPANDABLE SLEEVE - 0.5 IN. I.D.-..61-74482-2013 THERMOFIT SLEEVE - YELLOW, .125 IN I.D..-.61-74482-2014 THERMOFIT SLEEVE - YELLOW, .187 IN I.D...-61-74482-2015 INSULATION SLEEVING, HEAT SHRINKABLE, POLY- OLEFIN, FLEXIBLE, X-LINKED .1.M23053/5-104-4 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: August 02, 2010 737-28A1227Revision 1: July 18, 2011 46 of 202 BOEING SERVICE BULLETIN 737-28A1227 ALERTALERT ### Page 47 Kit 61-74482 NotesNameQTYNew Part Number -2013-2014-2015 INSULATION SLEEVING, HEAT SHRINKABLE, POLY- OLEFIN, FLEXIBLE, X-LINKED ..1M23053/5-105-4 BMS 13-52 EXPANDABLE S1..NA728R99 Kit 65C38639 NotesNameQTYNew Part Number -115 THREAD LOCK COMPOUND-65C38639-115 LOCTITE;222 KIT1NK442N 2. Parts and Materials Supplied by the Operator: NotesNameQTYPart Number / Specification (a) (b)TAPE - 0.5 INCH WIDTH161-74482-2004 (Permacel P421) (f)Screw, Hex Head with Cross Recess(d)BACS12HN08-10 (e)NAS1149DN816H (g)PRIMER12 OuncesBMS10-11, TYPE 1 (c) (g)BRADY LABEL4BACT19J2 (g)Plastic Film For Markers1 Square Foot BMS10-26, Type I, Grade A or Grade B or BMS10-26, Type III, Grade A or Grade B (g)TOP COAT1 OunceBAC5710, TYPE 41 (a) Permacel (99742), One Tower Center BLVD. 14th Floor, New Brunswick NJ 08903. (b) Required for Groups 5 thru 8. (c) As an option operators can use Vinyl Marker BMS10-26, Type I Grade A or Grade B, or Type III Grade A or Grade B, or other equivalent materials. Refer to SOPM 20-50-05 as an accepted procedure. (d) Groups 2-4 and Groups 5-8 Configuration 1 need (8) screws. Groups 5-8 Configuration 2 need (16) screws. (e) Groups 2-4 and Groups 5-8 Configuration 1 need (8) washers. Groups 5-8 Configuration 2 need (16) washers. (f) If grip length shown is not available fasteners may be up to two grip length longer than indicated. Also, if any fasteners part numbers listed are not available or have been superseded, substitute fasteners may be used. Use the approved fastener substitutions in accordance with SRM Chapter 51 (g) See the Qualified Products List at the end of the Boeing Material Specification (BMS) for supplier data. BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: August 02, 2010 737-28A1227Revision 1: July 18, 2011 47 of 202 BOEING SERVICE BULLETIN 737-28A1227 ALERTALERT ### Page 48 3. Parts Modified and Reidentified: The parts shown below are changed as shown in this service bulletin. The quantity (QTY) is the number of parts changed on each airplane. NotesNew Part NumberNameQTYExisting Part Number (a) (b)-J2802 PANEL ASSEMBLY165C38484-12 (a) Make the change in accordance with this service bulletin. (b) There is no equivalent Boeing part number for the changed part. Apply on the part "SB 737-28A1227 R1 is Incorporated" to identify that the change is done in accordance with this service bulletin. 4. Parts Removed and Not Replaced: None. D. Parts Necessary to Change Spares None. E. Special Tooling - Price and Availability None. F. Special Tooling Necessary to do this Service Bulletin No special tools or equipment are necessary to do the change in this service bulletin. But, maintenance and overhaul tools in the manuals given in Paragraph 1.J., References, can be necessary. Examine operator tool supply to make sure all necessary tools are available. BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: August 02, 2010 737-28A1227Revision 1: July 18, 2011 48 of 202 BOEING SERVICE BULLETIN 737-28A1227 ALERTALERT ### Page 49 3. ACCOMPLISHMENT INSTRUCTIONS A. GENERAL INFORMATION CAUTION: KEEP THE WORK AREA, WIRES AND ELECTRICAL BUNDLES CLEAN OF METAL PARTICLES OR CONTAMINATION WHEN YOU USE TOOLS. UNWANTED MATERIAL, METAL PARTICLES OR CONTAMINATION CAUGHT IN WIRE BUNDLES CAN CAUSE DAMAGE TO THE BUNDLES. DAMAGED WIRE BUNDLES CAN CAUSE SPARKS OR OTHER ELECTRICAL DAMAGE. NOTE: 1. Manual titles are referred to by acronyms. Refer to Paragraph 1.J., References, for definition of the acronyms. 2. Obey all of the warnings and cautions given in the specified manual sections. 3. Unless shown differently, these dimensions and tolerances are used: – Linear dimensions are in inches – Tolerance on linear dimensions, other than rivet and bolt edge margins, is plus or minus 0.03 inch – Torque limits to tighten nuts and bolts are in SRM Chapter 51 4. Use the approved fastener and process material substitutions in accordance with SRM Chapter 51. 5. Refer to the SWPM 20-10-11 and SWPM 20-10-12 for the wire installation procedures, and SWPM 20-10-19 for the wire separation requirements, as accepted procedures. 6. If the length of any fastener specified in this service bulletin does not meet installation standards given in SRM Chapter 51, then a fastener of the same specification, or an approved substitute, with a length which meets the installation standards given in SRM Chapter 51 may be used. In addition, washers may be installed for fastener grip length in accordance with SRM Chapter 51. 7. These work instructions refer to procedures included in other Boeing documents. When the words "refer to" are used and the operator has an accepted alternative procedure, the accepted alternative procedure can be used. When the words "in accordance with" are included in the instruction, the procedure in the Boeing document must be used. 8. If it is necessary to remove more parts for access, you can remove those parts. If you can get access without removing identified parts, it is not necessary to remove all of the identified parts. Jacking and shoring limitations must be observed. 9. Where the work instructions include installation of a kept part, a new or serviceable part with the same part number can be installed as an alternative to the kept part. The removed part can be discarded if a new or serviceable part is installed. 10. It is necessary to use a low input impedance voltmeter to check voltages at all relay contact terminals. A recommended low input impedance voltmeter is a Simpson 260 VOM (Volt-Ohm meter) or an alternative is a Megger Model 8 mK7 analogue multimeter. BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: August 02, 2010 737-28A1227Revision 1: July 18, 2011 49 of 202 BOEING SERVICE BULLETIN 737-28A1227 ALERTALERT ### Page 50 B. WORK INSTRUCTIONS Group 1: 1. Operators should contact Boeing to obtain engineering and accomplishment instructions for this modification and do the instructions. Group 2; Group 7-8, Configuration 1: 1. At the lower forward fuselage, below the E/E bay, open the access door to get access to the work area. Refer to 737-100/200 AMM 52-48-41 as an accepted procedure. 2. Do the steps below as applicable: a. For airplanes with airstairs, do the forward airstairs extension to give better access to the work area. Refer to 737-100/200 AMM 52-61-0 or 737-100/200 AMM 52-61-100 as an accepted procedure. b. For airplanes with airstairs, in the E/E bay, remove and keep the drip pan to get better access to the work area. Refer to 737-100/200 AMM 25-51-01 as an accepted procedure. c. For airplanes without airstairs, in the E/E bay, remove and keep the moisture shroud from above the access door to get better access to the work area. Refer to 737-100/200 AMM 25-51-01 as an accepted procedure. 3. Remove electrical power from the airplane. Refer to 737-100/200 AMM 24-22-0 as an accepted procedure. 4. In the E/E bay, remove and keep the moisture shroud from above the E3 rack to get access to the work area. Refer 737-100/200 AMM 25-51-01 as an accepted procedure. 5. In the E/E bay, disconnect the battery power cables from the battery. Refer to 737-100/200 AMM 24-31-11 as an accepted procedure. 6. Install the Nose Landing Gear (NLG) ground lock. Refer to 737-100/200 AMM 32-00-01 as an accepted procedure. 7. In the NLG wheel well, remove and keep the right side access panels, 3103R and 3105R to get access to the work area. Refer to 737-100/200 AMM 12-31-11 for panel locations. 8. In the flight compartment, move the first officer's seat to the forward position to get better access to the work area. Refer to 737-100/200 AMM 25-11-0 as an accepted procedure. 9. In the flight compartment, remove and keep aft and mid center ceiling linings and the ceiling linings adjacent and forward of the P6 Load Control Center to get access to the work area. Refer to 737-100/200 AMM 25-16-11 as an accepted procedure. 10. In the passenger compartment, as applicable, loosen and move the forward galley (galley no.1) in an aft direction to get access to the wire routing of the P6 Load Control Center. Refer to 737-100/200 AMM 25-31-11 or 737-100/200 AMM 25-31-51 as an accepted procedure. 11. At the E2 and E3 support post in the E/E bay, remove the cover from the J2802 box assembly and install new toggle switches and relays in accordance with FIGURE 1. BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: August 02, 2010 737-28A1227Revision 1: July 18, 2011 50 of 202 BOEING SERVICE BULLETIN 737-28A1227 ALERTALERT ### Page 51 12. Install and connect the W1760 and W1770 wire bundles in the J2802 box assembly in accordance with FIGURE 2, FIGURE 3, and FIGURE 4. 13. Between the P6 disconnect panels and the J2802 box assembly, make changes to wire bundles W0368, W0386, W1764 and W1774 in accordance with FIGURE 9, FIGURE 10, and FIGURE 11. 14. Do a continuity check between the P6 disconnect panel 'E', 'A' and the J2802 box assembly to make sure that the wiring connections are made correctly. 15. At the E2 and E3 support post in the E/E bay, install the cover on the J2802 box assembly in accordance with FIGURE 30. 16. In the passenger compartment, as applicable, move the forward galley (galley no.1) back to its position. Refer to 737-100/200 AMM 25-31-11 or 737-100/200 AMM 25-31-51 as an accepted procedure. 17. In the flight compartment, install the kept aft and mid center ceiling linings and the ceiling linings adjacent and forward of the P6 Load Control Center. Refer to 737-100/200 AMM 25-16-11 as an accepted procedure. 18. In the flight compartment, put the first officer's seat back to its usual position. Refer to 737-100/200 AMM 25-11-0 as an accepted procedure. 19. In the NLG wheel well, install the kept right side access panels, 3103R and 3105R. Refer to 737-100/200 AMM 12-31-11 for panel locations. 20. In the E/E bay, install the kept moisture shroud above the E3 rack. Refer 737-100/200 AMM 25-51-01 as an accepted procedure. 21. Do the steps below as applicable: a. For airplanes with airstairs, in the E/E bay, install the kept drip pan. Refer to 737-100/200 AMM 25-51-01 as an accepted procedure. b. For airplanes without airstairs, in the E/E bay, install the kept moisture shroud above the access door. Refer to 737-100/200 AMM 25-51-01 as an accepted procedure. c. For airplanes with airstairs, do the forward airstairs retraction. Refer to 737-100/200 AMM 52-61-0 or 737-100/200 AMM 52-61-100 as an accepted procedure. 22. In the E/E bay, connect the battery power cables to the battery. Refer to 737-100/200 AMM 24-31-11 as an accepted procedure. 23. Restore electrical power to the airplane. Refer to 737-100/200 AMM 24-22-0 as an accepted procedure. 24. Do the Fuel Control System Functional Test that follows to make sure the changed fuel control system operates correctly: BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: August 02, 2010 737-28A1227Revision 1: July 18, 2011 51 of 202 BOEING SERVICE BULLETIN 737-28A1227 ALERTALERT ### Page 52 FUEL CONTROL SYSTEM FUNCTIONAL TEST (CENTER TANKS) a. Make sure the center fuel tank has a minimum of 1000 - 1200 pounds (450 - 540 kilograms) of fuel. b. At the J2802 junction box in the E/E bay, open the circuit breakers that follow and attach DO-NOT-CLOSE tags: Circuit BreakerNamePanel Loca- tion/Position C3318FUEL CONTROL AUTO SHUTOFF CENTER TANK LEFT J2802 C3320FUEL CONTROL AUTO SHUTOFF CENTER TANK RIGHT J2802 c. At the P5-2 panel, put the Center Tank Left and Center Tank Right pump switches to the ON position. d. At the P5-2 panel, make sure that the Center Tank Left and Center Tank Right pump Low Pressure Lights come on and then go out. e. At the J2802 junction box in the E/E bay, push and hold the Pump Un-Commanded On Test Switch (S3324) to CTR-L (Center Left) position. f. At the P5-2 panel, make sure that the Center Left Low Pressure Light comes on. g. At the J2802 junction box in the E/E bay, release the Pump Un-Commanded On Test Switch (S3324). h. At the P5-2 panel, make sure that the Center Left Low Pressure Light goes out. i. At the J2802 junction box in the E/E bay, push and hold the Pump Un-Commanded On Test Switch (S3326) to CTR-R (Center Right) position. j. At the P5-2 panel, make sure that the Center Right Low Pressure Light comes on. k. At the J2802 junction box in the E/E bay, release the Pump Un-Commanded On Test Switch (S3326). l. At the P5-2 panel, make sure that the Center Right Low Pressure Light goes out. m. At the P5-2 panel, put the Center Tank Left and Center Tank Right pump switches to the OFF position. n. At the P5-2 panel, make sure that the Center Tank Left and Center Tank Right pump Low Pressure Lights are off. o. At the J2802 junction box in the E/E bay, check the voltage at the relay terminals that follow: BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: August 02, 2010 737-28A1227Revision 1: July 18, 2011 52 of 202 BOEING SERVICE BULLETIN 737-28A1227 ALERTALERT ### Page 53 VoltagePositionRelay Less than 10 Volts ACA2 to groundR3334 Less than 10 Volts ACB2 to ground Less than 10 Volts ACC2 to ground Less than 10 Volts ACA2 to groundR3336 Less than 10 Volts ACB2 to ground Less than 10 Volts ACC2 to ground p. At the J2802 junction box in the E/E bay, check the resistance between the relay terminals that follow: ResistancePositionRelay Greater than 1 megohmA2 to A1R3334 Greater than 1 megohmB2 to B1 Greater than 1 megohmC2 to C1 Greater than 1 megohmA2 to A1R3336 Greater than 1 megohmB2 to B1 Greater than 1 megohmC2 to C1 q. At the J2802 junction box in the E/E bay, remove the DO-NOT-CLOSE tags and close the circuit breakers that follow: Circuit BreakerNamePanel Loca- tion/Position C3318FUEL CONTROL AUTO SHUTOFF CENTER TANK LEFT J2802 C3320FUEL CONTROL AUTO SHUTOFF CENTER TANK RIGHT J2802 25. At the lower forward fuselage, below the E/E bay, close the access door. Refer to 737-100/200 AMM 52-48-41 as an accepted procedure. 26. Put the airplane back to a serviceable condition. Group 3; Group 5-6, Configuration 1: 1. At the lower forward fuselage, below the E/E bay, open the access door to get access to the work area. Refer to 737-300/400/500 AMM 52-48-41 as an accepted procedure. 2. Do the steps below as applicable: BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: August 02, 2010 737-28A1227Revision 1: July 18, 2011 53 of 202 BOEING SERVICE BULLETIN 737-28A1227 ALERTALERT ### Page 54 a. For airplanes with airstairs, do the forward airstairs extension to give better access to the work area. Refer to 737-300/400/500 AMM 52-61-10 as an accepted procedure. b. For airplanes with airstairs, in the E/E bay, remove and keep the drip pan to get better access to the work area. Refer to 737-300/400/500 AMM 25-51-01 as an accepted procedure. c. For airplanes without airstairs, in the E/E bay, remove and keep the moisture shroud from above the access door to get better access to the work area. Refer to 737-300/400/500 AMM 25-51-01 as an accepted procedure. 3. Remove electrical power from the airplane. Refer to 737-300/400/500 AMM 24-22-00 as an accepted procedure. 4. In the E/E bay, remove and keep the moisture shroud from above the E3 rack to get access to the work area. Refer 737-300/400/500 AMM 25-51-01 as an accepted procedure. 5. In the E/E bay, disconnect the battery power cables from the battery. Refer to 737-300/400/500 AMM 24-31-11 as an accepted procedure. 6. Install the Nose Landing Gear (NLG) ground lock. Refer to 737-300/400/500 AMM 32-00-01 as an accepted procedure. 7. In the NLG wheel well, remove and keep the right side access panels, 3103R and 3105R to get access to the work area. Refer to 737-300/400/500 AMM 12-31-11 for panel locations. 8. In the flight compartment, move the first officer's seat to the forward position to get better access to the work area. Refer to 737-300/400/500 AMM 25-10-00 as an accepted procedure. 9. In the flight compartment, remove and keep aft and mid center ceiling linings and the ceiling linings adjacent and forward of the P6 Load Control Center to get access to the work area. Refer to 737-300/400/500 AMM 25-11-21 as an accepted procedure. 10. In the passenger compartment, as applicable, loosen and move the forward galley (galley no.1) in an aft direction to get access to the wire routing of the P6 Load Control Center. Refer to 737-300/400/500 AMM 25-31-11 as an accepted procedure. 11. At the E2 and E3 support post in the E/E bay, remove the cover from the J2802 box assembly and install new toggle switches and relays in accordance with FIGURE 1. 12. Install and connect the W1760 and W1770 wire bundles in the J2802 box assembly in accordance with FIGURE 2, FIGURE 3, and FIGURE 4. 13. Between the P6 disconnect panels and the J2802 box assembly, make changes to wire bundles W0368, W0386, W1764 and W1774 in accordance with FIGURE 12, FIGURE 13, ana FIGURE 14. 14. Do a continuity check between the P6 disconnect panels 'AP0600B', 'AP1800A' and the J2802 box assembly to make sure that the wiring connections are made correctly. 15. At the E2 and E3 support post in the E/E bay, install the cover on the J2802 box assembly in accordance with FIGURE 30. BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: August 02, 2010 737-28A1227Revision 1: July 18, 2011 54 of 202 BOEING SERVICE BULLETIN 737-28A1227 ALERTALERT ### Page 55 16. In the passenger compartment, as applicable, move the forward galley (galley no.1) back to its position. Refer to 737-300/400/500 AMM 25-31-11 as an accepted procedure. 17. In the flight compartment, install the kept aft and mid center ceiling linings and the ceiling linings adjacent and forward of the P6 Load Control Center. Refer to 737-300/400/500 AMM 25-11-21 as an accepted procedure. 18. In the flight compartment, put the first officer's seat back to its usual position. Refer to 737-300/400/500 AMM 25-10-00 as an accepted procedure. 19. In the NLG wheel well, install the kept right side access panels, 3103R and 3105R. Refer to 737-300/400/500 AMM 12-31-11 for panel locations. 20. In the E/E bay, install the kept moisture shroud above the E3 rack. Refer 737-300/400/500 AMM 25-51-01 as an accepted procedure. 21. Do the steps below as applicable: a. For airplanes with airstairs, in the E/E bay, install the kept drip pan. Refer to 737-300/400/500 AMM 25-51-01 as an accepted procedure. b. For airplanes without airstairs, in the E/E bay, install the kept moisture shroud above the access door. Refer to 737-300/400/500 AMM 25-51-01 as an accepted procedure. c. For airplanes with airstairs, do the forward airstairs retraction. Refer to 737-300/400/500 AMM 52-61-10 as an accepted procedure. 22. In the E/E bay, connect the battery power cables to the battery. Refer to 737-300/400/500 AMM 24-31-11 as an accepted procedure. 23. Restore electrical power to the airplane. Refer to 737-300/400/500 AMM 24-22-00 as an accepted procedure. 24. Do the Fuel Control System Functional Test that follows to make sure the changed fuel control system operates correctly: FUEL CONTROL SYSTEM FUNCTIONAL TEST (CENTER TANKS) a. Make sure the center fuel tank has a minimum of 1000 - 1200 pounds (450 - 540 kilograms) of fuel. b. At the J2802 junction box in the E/E bay, open the circuit breakers that follow and attach DO-NOT-CLOSE tags: Circuit BreakerNamePanel Loca- tion/Position C3318FUEL CONTROL AUTO SHUTOFF CENTER TANK LEFT J2802 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: August 02, 2010 737-28A1227Revision 1: July 18, 2011 55 of 202 BOEING SERVICE BULLETIN 737-28A1227 ALERTALERT ### Page 56 Circuit BreakerNamePanel Loca- tion/Position C3320FUEL CONTROL AUTO SHUTOFF CENTER TANK RIGHT J2802 c. At the P5-2 panel, put the Center Tank Left and Center Tank Right pump switches to the ON position. d. At the P5-2 panel, make sure that the Center Tank Left and Center Tank Right pump Low Pressure Lights come on and then go out. e. At the J2802 junction box in the E/E bay, push and hold the Pump Un-Commanded On Test Switch (S3324) to CTR-L (Center Left) position. f. At the P5-2 panel, make sure that the Center Left Low Pressure Light comes on. g. At the J2802 junction box in the E/E bay, release the Pump Un-Commanded On Test Switch (S3324). h. At the P5-2 panel, make sure that the Center Left Low Pressure Light goes out. i. At the J2802 junction box in the E/E bay, push and hold the Pump Un-Commanded On Test Switch (S3326) to CTR-R (Center Right) position. j. At the P5-2 panel, make sure that the Center Right Low Pressure Light comes on. k. At the J2802 junction box in the E/E bay, release the Pump Un-Commanded On Test Switch (S3326). l. At the P5-2 panel, make sure that the Center Right Low Pressure Light goes out. m. At the P5-2 panel, put the Center Tank Left and Center Tank Right pump switches to the OFF position. n. At the P5-2 panel, make sure that the Center Tank Left and Center Tank Right pump Low Pressure Lights are off. o. At the J2802 junction box in the E/E bay, check the voltage at the relay terminals that follow: VoltagePositionRelay Less than 10 Volts ACA2 to groundR3334 Less than 10 Volts ACB2 to ground Less than 10 Volts ACC2 to ground BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: August 02, 2010 737-28A1227Revision 1: July 18, 2011 56 of 202 BOEING SERVICE BULLETIN 737-28A1227 ALERTALERT ### Page 57 VoltagePositionRelay Less than 10 Volts ACA2 to groundR3336 Less than 10 Volts ACB2 to ground Less than 10 Volts ACC2 to ground p. At the J2802 junction box in the E/E bay, check the resistance between the relay terminals that follow: ResistancePositionRelay Greater than 1 megohmA2 to A1R3334 Greater than 1 megohmB2 to B1 Greater than 1 megohmC2 to C1 Greater than 1 megohmA2 to A1R3336 Greater than 1 megohmB2 to B1 Greater than 1 megohmC2 to C1 q. At the J2802 junction box in the E/E bay, remove the DO-NOT-CLOSE tags and close the circuit breakers that follow: Circuit BreakerNamePanel Loca- tion/Position C3318FUEL CONTROL AUTO SHUTOFF CENTER TANK LEFT J2802 C3320FUEL CONTROL AUTO SHUTOFF CENTER TANK RIGHT J2802 25. At the lower forward fuselage, below the E/E bay, close the access door. Refer to 737-300/400/500 AMM 52-48-41 as an accepted procedure. 26. Put the airplane back to a serviceable condition. Group 4: 1. At the lower forward fuselage, below the E/E bay, open the access door to get access to the work area. Refer to 737-100/200 AMM 52-48-41 as an accepted procedure. 2. Do the steps below as applicable: BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: August 02, 2010 737-28A1227Revision 1: July 18, 2011 57 of 202 BOEING SERVICE BULLETIN 737-28A1227 ALERTALERT ### Page 58 a. For airplanes with airstairs, do the forward airstairs extension to give better access to the work area. Refer to 737-100/200 AMM 52-61-0 or 737-100/200 AMM 52-61-100 as an accepted procedure. b. For airplanes with airstairs, in the E/E bay, remove and keep the drip pan to get better access to the work area. Refer to 737-100/200 AMM 25-51-01 as an accepted procedure. c. For airplanes without airstairs, in the E/E bay, remove and keep the moisture shroud from above the access door to get better access to the work area. Refer to 737-100/200 AMM 25-51-01 as an accepted procedure. 3. Remove electrical power from the airplane. Refer to 737-100/200 AMM 24-22-0 as an accepted procedure. 4. In the E/E bay, remove and keep the moisture shroud from above the E3 rack to get access to the work area. Refer 737-100/200 AMM 25-51-01 as an accepted procedure. 5. In the E/E bay, disconnect the battery power cables from the battery. Refer to 737-100/200 AMM 24-31-11 as an accepted procedure. 6. Install the Nose Landing Gear (NLG) ground lock. Refer to 737-100/200 AMM 32-00-01 as an accepted procedure. 7. In the NLG wheel well, remove and keep the right side access panels, 3103R and 3105R to get access to the work area. Refer to 737-100/200 AMM 12-31-11 for panel locations. 8. In the flight compartment, move the first officer's seat to the forward position to get better access to the work area. Refer to 737-100/200 AMM 25-11-0 as an accepted procedure. 9. In the flight compartment, remove and keep aft and mid center ceiling linings and the ceiling linings adjacent and forward of the P6 Load Control Center to get access to the work area. Refer to 737-100/200 AMM 25-16-11 as an accepted procedure. 10. In the passenger compartment, as applicable, loosen and move the forward galley (galley no.1) in an aft direction to get access to the wire routing of the P6 Load Control Center. Refer to 737-100/200 AMM 25-31-11 or 737-100/200 AMM 25-31-51 as an accepted procedure. 11. At the E2 and E3 support post in the E/E bay, remove the cover from the J2802 box assembly and install new toggle switches and relays in accordance with FIGURE 1. 12. Install and connect the W1760 and W1770 wire bundles in the J2802 box assembly in accordance with FIGURE 2, FIGURE 3, and FIGURE 4. 13. Between the P6 disconnect panels and the J2802 box assembly, make changes to wire bundles W0368, W0386, W1764 and W1774 in accordance with FIGURE 15, FIGURE 16, and FIGURE 17. 14. Do a continuity check between the P6 disconnect panels panel 'E', 'A' and the J2802 box assembly to make sure that the wiring connections are made correctly. 15. At the E2 and E3 support post in the E/E bay, install the cover on the J2802 box assembly in accordance with FIGURE 30. BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: August 02, 2010 737-28A1227Revision 1: July 18, 2011 58 of 202 BOEING SERVICE BULLETIN 737-28A1227 ALERTALERT ### Page 59 16. In the passenger compartment, as applicable, move the forward galley (galley no.1) back to its position. Refer to 737-100/200 AMM 25-31-11 or 737-100/200 AMM 25-31-51 as an accepted procedure. 17. In the flight compartment, install the kept aft and mid center ceiling linings and the ceiling linings adjacent and forward of the P6 Load Control Center. Refer to 737-100/200 AMM 25-16-11 as an accepted procedure. 18. In the flight compartment, put the first officer's seat back to its usual position. Refer to 737-100/200 AMM 25-11-0 as an accepted procedure. 19. In the NLG wheel well, install the kept right side access panels, 3103R and 3105R. Refer to 737-100/200 AMM 12-31-11 for panel locations. 20. In the E/E bay, install the kept moisture shroud above the E3 rack. Refer 737-100/200 AMM 25-51-01 as an accepted procedure. 21. Do the steps below as applicable: a. For airplanes with airstairs, in the E/E bay, install the kept drip pan. Refer to 737-100/200 AMM 25-51-01 as an accepted procedure. b. For airplanes without airstairs, in the E/E bay, install the kept moisture shroud above the access door. Refer to 737-100/200 AMM 25-51-01 as an accepted procedure. c. For airplanes with airstairs, do the forward airstairs retraction. Refer to 737-100/200 AMM 52-61-0 or 737-100/200 AMM 52-61-100 as an accepted procedure. 22. In the E/E bay, connect the battery power cables to the battery. Refer to 737-100/200 AMM 24-31-11 as an accepted procedure. 23. Restore electrical power to the airplane. Refer to 737-100/200 AMM 24-22-0 as an accepted procedure. 24. Do the Fuel Control System Functional Test that follows to make sure the changed fuel control system operates correctly: FUEL CONTROL SYSTEM FUNCTIONAL TEST (CENTER TANKS) a. Make sure the center fuel tank has a minimum of 1000 - 1200 pounds (450 - 540 kilograms) of fuel. b. At the J2802 junction box in the E/E bay, open the circuit breakers that follow and attach DO-NOT-CLOSE tags: Circuit BreakerNamePanel Loca- tion/Position C3318FUEL CONTROL AUTO SHUTOFF CENTER TANK LEFT J2802 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: August 02, 2010 737-28A1227Revision 1: July 18, 2011 59 of 202 BOEING SERVICE BULLETIN 737-28A1227 ALERTALERT ### Page 60 Circuit BreakerNamePanel Loca- tion/Position C3320FUEL CONTROL AUTO SHUTOFF CENTER TANK RIGHT J2802 c. At the P5-2 panel, put the Center Tank Left and Center Tank Right pump switches to the ON position. d. At the P5-2 panel, make sure that the Center Tank Left and Center Tank Right pump Low Pressure Lights come on and then go out. e. At the J2802 junction box in the E/E bay, push and hold the Pump Un-Commanded On Test Switch (S3324) to CTR-L (Center Left) position. f. At the P5-2 panel, make sure that the Center Left Low Pressure Light comes on. g. At the J2802 junction box in the E/E bay, release the Pump Un-Commanded On Test Switch (S3324). h. At the P5-2 panel, make sure that the Center Left Low Pressure Light goes out. i. At the J2802 junction box in the E/E bay, push and hold the Pump Un-Commanded On Test Switch (S3326) to CTR-R (Center Right) position. j. At the P5-2 panel, make sure that the Center Right Low Pressure Light comes on. k. At the J2802 junction box in the E/E bay, release the Pump Un-Commanded On Test Switch (S3326). l. At the P5-2 panel, make sure that the Center Right Low Pressure Light goes out. m. At the P5-2 panel, put the Center Tank Left and Center Tank Right pump switches to the OFF position. n. At the P5-2 panel, make sure that the Center Tank Left and Center Tank Right pump Low Pressure Lights are off. o. At the J2802 junction box in the E/E bay, check the voltage at the relay terminals that follow: VoltagePositionRelay Less than 10 Volts ACA2 to groundR3334 Less than 10 Volts ACB2 to ground Less than 10 Volts ACC2 to ground BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: August 02, 2010 737-28A1227Revision 1: July 18, 2011 60 of 202 BOEING SERVICE BULLETIN 737-28A1227 ALERTALERT The text continues at https://openairdocs.org/service-documents/boeing/737-28a1227/file/a1a67d1fb686.md?from=61 --- OpenAirDocs.org is an independent research project of [Contrail Labs](https://contraillabs.com/). It is not affiliated with the FAA or the NTSB. Source documents are U.S. government works in the public domain, except the copies of manufacturers’ service documents, which belong to their rights holders.