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Commercial Airplanes 737 Service Bulletin ALERT Number: 737-28A1228 Original Issue: August 02, 2010 Revision 1: June 28, 2012 ATA System: 2822 SUBJECT: FUEL - Distribution - Installation of the Auto Shutoff Protection for the Center and Auxiliary Fuel Tank Boost Pumps Export of this technology is controlled under the United States Export Administration Regulations (EAR) (15 CFR 300-774). 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 Boeing.
Unpublished Work. All Rights Reserved.
Treatment of this document and its content is governed by contract with Boeing. Rights to use this document are licensed on a per aircraft basis and such rights may not be transferable. For more information, contact The Boeing Company.
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 Boeing liveries 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 is a trademark of Boeing Management Company.
Original Issue: August 02, 2010 737-28A1228Revision 1: June 28, 2012 1 of 344
5.0
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: August 02, 2010 737-28A1228Revision 1: June 28, 2012 2 of 344 BOEING SERVICE BULLETIN 737-28A1228
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Table of Contents
Revision Transmittal Sheet7
S u m m a r y..................................................... 1 1
1. PLANNING INFORMATION ........................................ 1 7 A . E f f e c t i v i t y ............................................... 1 7
1. Airplanes ............................................ 1 7 2 . S p a r e s A f f e c t e d ........................................ 2 7 B. Concurrent Requirements ...................................... 2 7 C. Reason ................................................ 2 8 D. Description .............................................. 2 9 E. Compliance .............................................. 3 2 F . A p p r o v a l ............................................... 3 2 G. Manpower .............................................. 3 3 H. Weight and Balance Changes .................................... 6 8 I. Electrical Load Data ......................................... 6 8 J . R e f e r e n c e s .............................................. 6 9
1. Existing Data: ......................................... 6 9
2. Data Supplied with this Service Bulletin: ........................... 6 9
3. Installation Drawings Used in the Preparation of this Service Bulletin: ........... 6 9 K. Publications Affected ........................................ 7 0 L. Interchangeability and Intermixability of Parts ........................... 7 0 M. Software Accomplishment Summary ................................ 7 0
2. MATERIAL INFORMATION ........................................ 7 1 A. Material - Price and Availability ................................... 7 1 B. Industry Support Information .................................... 7 3 C. Parts Necessary for Each Airplane ................................. 7 3 1 . K i t s / P a r t s : ........................................... 7 3
2. Parts and Materials Supplied by the Operator: ........................ 9 6
3. Parts Modified and Reidentified: ............................... 9 7
4. Parts Removed and Not Replaced: .............................. 9 7 D. Parts Necessary to Change Spares ................................. 9 7 E. Special Tooling - Price and Availability ............................... 9 7 F. Special Tooling Necessary to do this Service Bulletin ....................... 9 7
3. ACCOMPLISHMENT INSTRUCTIONS .................................. 9 9 A. GENERAL INFORMATION ..................................... 9 9 B. WORK INSTRUCTIONS ...................................... 1 0 0 FIGURE 1: REMOVAL OF THE J2802 BOX ASSEMBLY COVER [Group 4-6, 11] .......... 1 2 1 FIGURE 2: REMOVAL OF THE J2802 BOX ASSEMBLY COVER [Group 12-16] ........... 1 2 2 FIGURE 3: WIRE BUNDLES W1760/W1770 INSTALLATION IN THE J2802 BOX ASSEMBLY [Group 2-11] ................................................. 1 2 3 FIGURE 4: CONNECTION OF THE WIRE BUNDLE W1760 [Group 2-11, 17-19] ........... 1 2 6 FIGURE 5: CONNECTION OF THE WIRE BUNDLE W1770 [Group 2-11, 17-19] ........... 1 2 9 FIGURE 6: WIRE BUNDLES W1760/W1770 INSTALLATION IN THE J2802 BOX ASSEMBLY [Group 12-16] ................................................. 1 3 2 FIGURE 7: CONNECTION OF THE WIRE BUNDLE W1760 [Group 12-16] .............. 1 3 5 FIGURE 8: CONNECTION OF THE WIRE BUNDLE W1760 [Group 12-16] .............. 1 3 7 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
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FIGURE 9: CONNECTION OF THE WIRE BUNDLE W1770 [Group 12-16] .............. 1 4 0 FIGURE 10: CONNECTION OF THE WIRE BUNDLE W1770 [Group 12-16] .............. 1 4 2 FIGURE 11: INSTALLATION OF THE J2802 BOX ASSEMBLY COVER [Group 4-6, 11] ........ 1 4 5 FIGURE 12: ATTACHMENT OF THE J2802 BOX ASSEMBLY [Group 4-6, 11] ............. 1 4 6 F I G U R E 1 3 : T H I S F I G U R E I S D E L E T E D ................................. 1 4 9 FIGURE 14: DRILLING OF HOLES ON THE J2802 BOX ASSEMBLY AND E2 SUPPORT POST [Group 4-6, 1 1 ]............................................... 1 5 0 FIGURE 15: PREPARE THE J2802 BOX ASSEMBLY AND E2 AND E3 SUPPORT POSTS [Group 4-6, 11] ................................................. 1 5 3 FIGURE 16: INSTALLATION OF THE J2802 BOX ASSEMBLY, E2 AND E3 SUPPORT POSTS [Group 4-6, 1 1 ]............................................... 1 5 5 F I G U R E 1 7 : T H I S F I G U R E I S D E L E T E D ................................. 1 5 7 FIGURE 18: INSTALLATION THE BONDING JUMPER AND CLAMPS [Group 4-6, 11] ........ 1 5 8 FIGURE 19: REMOVAL OF THE RELAYS FROM THE P6 PANEL [Group 2-11, 17-19] ........ 1 6 1 FIGURE 20: INSTALLATION OF THE P5 PANEL WIRE BUNDLE W036 [Group 2-11, 17-19] ..... 1 6 3 FIGURE 21: CONNECTION OF THE WIRE BUNDLE W036 [Group 2, 10-11, 17] ........... 1 6 4 FIGURE 22: CONNECTION OF WIRE BUNDLE W036 [Group 8-9] ................... 1 6 7 FIGURE 23: CONNECTION OF THE WIRE BUNDLE W036 [Group 3] ................. 1 7 0 FIGURE 24: CONNECTION OF THE WIRE BUNDLE W036 [Group 4, 18] ............... 1 7 3 FIGURE 25: CONNECTION OF THE WIRE BUNDLE W036 [Group 5] ................. 1 7 6 FIGURE 26: CONNECTION OF THE WIRE BUNDLE W036 [Group 6, 19] ............... 1 7 9 FIGURE 27: CONNECTION OF THE WIRE BUNDLE W036 [Group 7] ................. 1 8 2 FIGURE 28: REMOVAL OF THE RELAYS, P6 PANEL [Group 12-16] .................. 1 8 5 FIGURE 29: INSTALLATION OF THE P5 PANEL WIRE BUNDLE W036 [Group 12-16] ........ 1 8 7 FIGURE 30: CONNECTION OF THE WIRE BUNDLE W036 [Group 12-13, 15] ............. 1 8 8 FIGURE 31: CONNECTION OF THE WIRE BUNDLE W036 [Group 12-13, 15] ............. 1 9 1 FIGURE 32: CONNECTION OF THE WIRE BUNDLE W036 [Group 12-13, 15] ............. 1 9 3 FIGURE 33: CONNECTION OF THE WIRE BUNDLE W036 [Group 14, 16] .............. 1 9 5 FIGURE 34: CONNECTION OF THE WIRE BUNDLE W036 [Group 14, 16] .............. 1 9 8 FIGURE 35: CONNECTION OF THE WIRE BUNDLE W036 [Group 14, 16] .............. 2 0 0 FIGURE 36: INSTALLATION OF THE P6 PANEL WIRE BUNDLE W044 [Group 2-11, 17-19] ..... 2 0 2 FIGURE 37: CONNECTION OF WIRE BUNDLE W044 [Group 2] .................... 2 0 3 FIGURE 38: CONNECTION OF WIRE BUNDLE W044 [Group 3, 8-11, 17, Configuration 1] ...... 2 0 6 FIGURE 39: CONNECTION OF THE WIRE BUNDLE W044 [Group 3, 8-11, 17, Configuration 2] . . . 209 FIGURE 40: CONNECTION OF THE WIRE BUNDLE W044 [Group 4, 18, Configuration 1] ...... 2 1 2 FIGURE 41: CONNECTION OF THE WIRE BUNDLE W044 [Group 4, 18, Configuration 2] ...... 2 1 5 FIGURE 42: CONNECTION OF THE WIRE BUNDLE W044 [Group 5-6, 19, Configuration 1] ..... 2 1 8 FIGURE 43: CONNECTION OF THE WIRE BUNDLE W044 [Group 5-6, 19, Configuration 2] ..... 2 2 0 FIGURE 44: CONNECTION OF THE WIRE BUNDLE W044 [Group 7, Configuration 1] ........ 2 2 2 FIGURE 45: CONNECTION OF THE WIRE BUNDLE W044 [Group 7, Configuration 2] ........ 2 2 4 FIGURE 46: INSTALLATION OF THE P6 PANEL WIRE BUNDLE W044 [Group 12-16] ........ 2 2 6 FIGURE 47: CONNECTION OF THE WIRE BUNDLE W044 [Group 13] ................ 2 2 7 FIGURE 48: CONNECTION OF THE WIRE BUNDLE W044 [Group 13, Configuration 1] ....... 2 3 0 FIGURE 49: CONNECTION OF THE WIRE BUNDLE W044 [Group 13, Configuration 2] ....... 2 3 3 FIGURE 50: CONNECTION OF THE WIRE BUNDLE W044 [Group 12, 14-16, Configuration 1] . . . 236 FIGURE 51: CONNECTION OF THE WIRE BUNDLE W044 [Group 12, 14-16, Configuration 2] . . . 239 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: August 02, 2010 737-28A1228Revision 1: June 28, 2012 4 of 344 BOEING SERVICE BULLETIN 737-28A1228
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FIGURE 52: CONNECTION OF THE WIRE BUNDLE W044 [Group 12, 14-16, Configuration 1] . . . 242 FIGURE 53: CONNECTION OF THE WIRE BUNDLE W044 [Group 12, 14-16, Configuration 2] . . . 245 FIGURE 54: INSTALLATION OF WIRE BUNDLE W368, W386, W1764 AND W1774 [Group 2-16] . . 248 FIGURE 55: CONNECTION OF WIRE BUNDLE W368 AND W1764 [Group 2, 4-5, 11, 17-18] .... 2 5 2 FIGURE 56: CONNECTION OF THE WIRE BUNDLE W368 AND WIRE BUNDLE W1764 [Group 8] . 255 FIGURE 57: CONNECTION OF THE WIRE BUNDLE W368 AND WIRE BUNDLE W1764 [Group 9] . 257 FIGURE 58: CONNECTION OF WIRE BUNDLE W368 AND W1764 [Group 10] ............ 2 5 9 FIGURE 59: CONNECTION OF WIRE BUNDLE W368 / W1764 [Group 3, 6-7, 19] .......... 2 6 1 FIGURE 60: CONNECTION OF WIRE BUNDLE W368 AND W1764 [Group 12-16] .......... 2 6 4 FIGURE 61: CONNECTION OF WIRE BUNDLE W386 AND W1774 [Group 2, 4-5, 7-11, 17-18] . . . 267 FIGURE 62: CONNECTION OF WIRE BUNDLE W386 / W1774 [Group 3, 6, 19] ............ 2 7 0 FIGURE 63: CONNECTION OF WIRE BUNDLE W386 AND W1774 [Group 12-16] .......... 2 7 3 FIGURE 64: INSTALLATION OF THE RELAYS AND STRAPS ON THE J2802 BOX ASSEMBLY [Group 4-6, 1 1 ]............................................... 2 7 6 F I G U R E 6 5 : T H I S F I G U R E I S D E L E T E D ................................. 2 7 9 FIGURE 66: INSTALLATION OF THE RELAYS IN THE P6 PANEL [Group 2-11, 17-19] ........ 2 8 0 FIGURE 67: INSTALLATION OF THE RELAYS, P6 PANEL [Group 12-16] ............... 2 8 2 FIGURE 68: CHANGE OF THE J2802 BOX ASSEMBLY FOR AIRPLANES WITH AIRSTAIRS AND NO AUXILIARY TANK [Group 2-3, 7-10, 17-19] ......................... 2 8 4 FIGURE 69: CHANGE OF THE J2802 BOX ASSEMBLY FOR AIRPLANES WITH AIRSTAIRS AND AUXILIARY TANK [Group 12-16] .............................. 2 8 7 FIGURE 70: ASSEMBLE THE J2802 BOX ASSEMBLY FOR AIRPLANES WITH AIRSTAIRS AND NO AUXILIARY TANK [Group 2-3, 7-10, 17-19] ......................... 2 9 1 FIGURE 71: ASSEMBLE THE J2802 BOX ASSEMBLY FOR AIRPLANES WITH AIRSTAIR AND AUXILIARY TANK [Group 12-16] ..................................... 2 9 7 FIGURE 72: WIRE BUNDLES W1760/W1770 INSTALLATION IN THE J2802 BOX ASSEMBLY FOR AIRPLANES WITH AIRSTAIRS AND NO AUXILIARY TANK [Group 2-3, 7-10, 17-19] . . 303 FIGURE 73: WIRE BUNDLES W1760/W1770 INSTALLATION IN THE J2802 BOX ASSEMBLY FOR AIRPLANES WITH AIRSTAIRS AND AUXILIARY TANK [Group 12-16] .......... 3 0 7 FIGURE 74: DRILLING OF HOLES ON THE J2802 BOX ASSEMBLY AND E3 SUPPORT POST [Group 2-3, 7 - 1 0 , 1 7 - 1 9 ] .......................................... 3 1 1 FIGURE 75: DRILLING OF HOLES ON THE J2802 BOX ASSEMBLY AND E3 SUPPORT POST [Group 1 2 - 1 6 ]............................................. 3 1 6 FIGURE 76: PREPARATION OF THE J2802 BOX ASSEMBLY, E2 AND E3 SUPPORT POSTS [Group 2-3, 7 - 1 0 , 1 7 - 1 9 ] .......................................... 3 2 1 FIGURE 77: PREPARATION OF THE J2802 BOX ASSEMBLY, E2 AND E3 SUPPORT POSTS [Group 1 2 - 1 6 ]............................................. 3 2 3 FIGURE 78: INSTALLATION THE J2802 BOX ASSEMBLY ON THE E2 AND E3 SUPPORT POSTS [Group 2 - 3 , 7 - 1 0 , 1 7 - 1 9 ] ....................................... 3 2 5 FIGURE 79: INSTALLATION THE J2802 BOX ASSEMBLY ON THE E2 AND E3 SUPPORT POSTS [Group 1 2 - 1 6 ]............................................. 3 2 7 FIGURE 80: INSTALLATION THE BONDING JUMPER AND CLAMPS [Group 2-3, 7-10, 12-19] . . . 329 FIGURE 81: INSTALLATION OF WIRE BUNDLE W368, W386, W1764 AND W1774 [Group 2-3, 7-10, 17-19] ................................................. 3 3 5 FIGURE 82: INSTALLATION OF THE RELAYS ON THE J2802 BOX ASSEMBLY [Group 2-3, 7-10, 17-19] ................................................. 3 4 1 FIGURE 83: INSTALLATION OF THE RELAYS ON THE J2802 BOX ASSEMBLY [Group 12-16] . . . 343 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: August 02, 2010 737-28A1228Revision 1: June 28, 2012 5 of 344 BOEING SERVICE BULLETIN 737-28A1228
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Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: August 02, 2010 737-28A1228Revision 1: June 28, 2012 6 of 344 BOEING SERVICE BULLETIN 737-28A1228
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Commercial Airplanes 737 Service Bulletin ALERT Revision Transmittal SheetNumber: 737-28A1228Original Issue: August 02, 2010 Revision 1: June 28, 2012 ATA System: 2822 SUBJECT: FUEL - Distribution - Installation of the Auto Shutoff Protection for the Center and Auxiliary Fuel Tank Boost Pumps This revision includes all pages of the service bulletin.
COMPLIANCE INFORMATION RELATED TO THIS REVISION Federal Aviation Administration (FAA) Notice of Proposed Rule Making NPRM 2010-NM-189-AD, is related to this service bulletin.
More work is necessary on the airplane(s) changed in accordance with the original issue of this service bulletin.
Operators that incorporated the original issue of this SB have to change the labels and wire termination in the J2802 relay box assembly in accordance with Figures 3, 4, 5, 6, 7, 8, 9, or 10 as applicable, and do a functional test within the compliance time specified in paragraph 1. E.
REASON FOR REVISION This revision is sent to tell the operators that for airplanes with Airstairs the J2802 Box provided in the original release can not be installed in the main equipment compartment on the E2 and E3 support posts in accordance with Figure 12 or Figure 13. When J2802 Box is installed in accordance with Figure 12 or 13, the forward face of the box interferes with the Airstairs and the Airstairs support structure. Also there is no good access to the Airstairs relays, and to the wires connected to the Airstairs relays. A new J2802 Box Assembly was designed and added to this revision that can be installed on airplanes with Airstairs with no interference with Airstairs and the Airstairs support structure. The airplanes with Airstairs were moved from the existing groups into new groups based on the wires configuration and Auxiliary Tank installation. Figures 68 through 83 were added for airplanes with Airstairs.
This revision is also sent to tell the Operators that the switches S03318 and S03321 installed on J2802 box have two positions (for each switch) identified as "POS 1" and "POS 2". POS 1 of the test switch S03318 is for Left Fuel Boost Pump of the Center Tank. POS 1 of the test switch S03321 is for Right Fuel Boost Pump of the Center Tank. POS 2 of the test switches S03318 and S03321 are only used for airplanes with Auxiliary Tanks.
POS 2 of the test switch S03318 is for Aft Fuel Boost Pump of the Auxiliary Tank. POS 2 of the test switch S03321 is for Fwd Fuel Boost Pump of the Auxiliary Tank. The wires terminated at switches S03318 and S03321 were incorrectly terminated in Figures 4, 5, 7, 8, 9, 10. The wire terminations at switches S03318 and S03321 are changed in order for the switches to function as indicated.
New steps are added to Figure 3 that instruct the operators to install markers on the J2802 Box that will identify S03318 and S003321 as "TEST SWITCHES". Also instructions are added to install markers that will identify the function of the switch S03318 POS 1 as "CTR-L", and the function of the switch S03321 POS 1 as "CTR-R".
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: August 02, 2010 737-28A1228Revision 1: June 28, 2012 7 of 344
New steps are added to Figure 6 that instruct the operators to install markers on the J2802 Box that will identify S03318 and S003321 as "TEST SWITCHES". Also instructions are added to install markers that will identify the functions of the switch S03318 as follows: POS 1 as "CTR-L",and POS 2 as "AUX-AFT". Also instructions are added to install markers that will identify the functions of the switch S03321 as follows: POS 1 as "CTR-R", and POS 2 as "AUX-FWD".
This revision moves airplanes with airstairs from existing groups 4, 6 and 11 to new groups, 17, 18, 19. All airplanes in Groups 2, 3, 7, 8, 9, 10, 12, 13, 14, 15, 16, 17, 18 and 19 have airstairs. All airplanes in Groups 4, 5, 6 and 11 do not have airstairs.
These sections were changed:
1. Summary:
a. Background: Updated Part 1, Part 2, Part 3 and Part 4 for airplanes with Airstairs. Added Part 5 and Part 6 for airplanes with Airstairs. Added Part 7, Part 8 and Part 9 for airplanes with more work.
b. Material Information paragraph added Operator Supplied Parts/Materials.
c. Summary Illustration updated to include airplanes with Airstairs.
2. Planning Information:
a. Paragraph 1.A Effectivity: Changed the Group Configuration Table. Created new groups for airplanes with Airstairs
b. Paragraph 1.C Reason: Added the reason for Revision 1
c. Paragraph 1.D. Description: Changed PART 2, PART 3 and PART 4 for airplanes with Airstairs.
Added PART 5, and PART 6 for airplanes with Airstairs
d. Paragraph 1.G. Manpower: Changed Manpower Tables for Groups 2, 3, 7, 8, 9, 10, 12, 13, 14, 15, 16. Added Manpower tables for Groups 17, 18 and 19
e. Paragraph 1.H. Weight and Balance Changes: Added Groups 17, 18 and 19 to Weight and Balance table
f. Paragraph 1.J.1. References, Existing Data: Updated the reference list
g. Paragraph 1.J.3. Installation Drawings Used in the Preparation of this Service Bulletin: Updated the Drawings list
h. Paragraph 1.K.1. Publications: Updated the publication list.
3. Material Information:
a. Paragraph 2.A. Material - Price and Availability: Notes are added, kit pricing data is updated, and new top kits and supplemental kits are added
b. Paragraph 2.C.1. Parts Necessary For Each Airplane: Parts for the new top kits and supplemental kits and new footnotes are added Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: August 02, 2010 737-28A1228Revision 1: June 28, 2012 8 of 344 BOEING SERVICE BULLETIN 737-28A1228
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c. Paragraph 2.C.2. Part and Materials Supplied by the Operator: New materials are added
d. Paragraph 2.C.3. Parts Modified and Reidentified: New data is added for airplanes with airstairs
4. Paragraph 3.B. Work Instructions: Changed Part 2, Part 3 and Part 4. Added Part 5, Part 6, Part 7, Part 8 and Part 9
5. Changed Figures 1-67: Group effectivities are updated
6. Figures 68-83: Added for airplane with airstairs.
The data given in Information Notice 737-28A1228 IN 01, 737-28A1228 IN 02 and 737-28A1228 IN 03 are included in this revision.
Vertical lines are put on the left edge of each page, except in Paragraph 1.A., Effectivity, to show the location of important changes.
Pages with no vertical lines have no important changes.
REVISION HISTORY August 02, 2010Original Issue:
June 28, 2012Revision 1:
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: August 02, 2010 737-28A1228Revision 1: June 28, 2012 9 of 344 BOEING SERVICE BULLETIN 737-28A1228
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Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: August 02, 2010 737-28A1228Revision 1: June 28, 2012 10 of 344 BOEING SERVICE BULLETIN 737-28A1228
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Commercial Airplanes 737 Service Bulletin ALERT SummaryNumber: 737-28A1228Original Issue: August 02, 2010 Revision 1: June 28, 2012 ATA System: 2822 SUBJECT: FUEL - Distribution - Installation of the Auto Shutoff Protection for the Center and Auxiliary Fuel Tank Boost Pumps
THIS BULLETIN IS SENT TO THE OPERATORS OF RECORD OF THE AIRPLANES SHOWN IN PARAGRAPH
1.A., EFFECTIVITY. IF AN AIRPLANE HAS BEEN LEASED OR SOLD, SEND THIS SERVICE BULLETIN TO THE NEW OPERATOR. IF APPLICABLE SPARES HAVE BEEN SOLD, SEND THIS SERVICE BULLETIN TO THE NEW OWNER.
CONCURRENT REQUIREMENTS Refer to Paragraph 1.B., Concurrent Requirements.
BACKGROUND This service bulletin is the result of the safety analysis done by Boeing under SFAR 88, "Fuel Tank System Fault Tolerance Evaluation Requirements." Initial results from the fuel system safety analysis shows that fuel boost pumps that run dry could cause an overheat condition external of the fuel pump explosion resistance area that is open to the fuel pump inlet. An overheat condition in this area could possibly cause an unwanted ignition source for the fuel vapors in the fuel tank and could cause a fire or explosion.
This service bulletin gives the instructions and a kit of parts to install an automatic (auto) shut-off system for the fuel boost pumps. The fuel boost pumps are installed in the center fuel tank and if equipped, also in the auxiliary fuel tank. Time delay relays are installed in the new J2802 box assembly that will shut off the fuel boost pumps if the pumps operate with continuous low pressure for 15 seconds. The 15 second time delay relay prevents extended dry operation of the fuel boost pumps and allows for sufficient time for fuel pump inlet reprime to prevent nuisance automatic shutoffs. The flight crew stays in primary control, with the auto shut off system as a backup, to stop the fuel boost pumps after a low pressure indication.
The change installs an automatic shut off system that gives fuel boost pump inlet protection in the fuel tank against sparks possibly caused by friction overheat damage.
This change affects the Fuel Systems Airworthiness Limitations section of Boeing document "737-100/200/200C/300/400/500 Airworthiness Limitations (AWLs) and Certification Maintenance Requirements (CMRs), D6-38278-CMR," New AWL"28-AWL-21" will be added to include an operational check of the boost pump automatic shutoff system for the center fuel tank. AWL "28-AWL-22" will be added to include an operational check of the fuel boost pump automatic shutoff system for the auxiliary fuel tank, if installed by Boeing. This change also affects Section 1 and Section 3 of the FAA approved Airplane Flight Manual (AFM).
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: August 02, 2010 737-28A1228Revision 1: June 28, 2012 11 of 344
ACTION (PRR 35442-RS) The work instructions are divided into 19 airplane groups, 6 parts.
Part 1, Part 2, Part 3, Part 4, and Part 5 work instructions are divided into 3 work packages because of the different wire bundle changes and airplanes without and with Airstairs Part 6 work instructions are for Operators that already ordered the kit from the original release, and want tor e-work the kit for airplanes with Airstairs.
Part 7, Part 8 and Part 9 work instructions are for Operators that already ordered the kit from the original release and have more work.
NOTE: When submitting a Publication Change Request (PCR) to Boeing to incorporate this service bulletin in the affected manuals, please notify Boeing if Auxiliary Tanks are installed on these airplanes. If Boeing is not notified about the Auxiliary Tanks, Boeing will assume that the airplanes in these groups do not have Auxiliary (AUX) tanks and no AUX Tank changes to the affected manuals will be done.
Group 1:
Operators should tell Boeing about this modification to get the engineering and accomplishment instructions.
Group 4-6, 11:
1. Work Package 1:
In the J2802 box assembly, install the wire bundles W1760 and W1770.
2. Work Package 2:
Get access into the main electronics compartment. Between the E2 and E3 rack support posts, install the J2802 box assembly.
3. Work Package 3:
In the flight compartment, get access to the P5 overhead panel, P6 relay panel or P6 relay modules.
Above the P5 overhead panel, make a change to the wire bundles W036, W368 and W386. Between the P6 disconnect panel and the fuel boost pump relays R54 and R55, make a change to the wire bundle W044. For the airplanes that have an auxiliary fuel tank, between the P6 disconnect panel and the fuel boost pump relays R146 and R147, make a change to the wire bundle W044.
4. In the flight and main electronics compartments, between the P6 disconnect panel and the J2802 box assembly, install the new wire bundles W1764 and W1774.
5. In the main electronics compartment, at the J2802 box assembly, install the time delay relays R3318 and R3321. For the airplanes that have auxiliary fuel tank, at the J2802 box assembly, install the time delay relays R3327 and R3329.
6. Do a functional test of the fuel boost pumps to make sure the changed control system operates correctly.
Group 2-3, 7-10, 12-13, 15-19:
1. Operators do these to change the airplane:
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: August 02, 2010 737-28A1228Revision 1: June 28, 2012 12 of 344 BOEING SERVICE BULLETIN 737-28A1228