Boeing ASB 737-28A1228: Revision 1, text

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Commercial Airplanes 737 Service Bulletin ALERT Number: 737-28A1228 Original Issue: August 02, 2010 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 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BOEING PROPRIETARY, CONFIDENTIAL, AND/OR TRADE SECRET Copyright © 2010 The Boeing Company Unpublished Work - All Rights Reserved Boeing claims copyright in each page of this document only to the extent that the page contains copyrightable subject matter.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.

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Original Issue: August 02, 2010 737-28A1228 2 of 261 BOEING SERVICE BULLETIN 737-28A1228

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Table of Contents

Summary7

1. PLANNING INFORMATION ........................................ 1 1 A. Effectivity ............................................... 1 1

1. Airplanes ............................................ 1 1

2. Spares Affected ........................................ 2 0 B. Concurrent Requirements ...................................... 2 0 C. Reason ................................................ 2 1 D. Description .............................................. 2 1 E. Compliance .............................................. 2 3 F. Approval ............................................... 2 3 G. Manpower .............................................. 2 4 H. Weight and Balance Changes .................................... 5 2 I. Electrical Load Data ......................................... 5 2 J. References .............................................. 5 3

1. Existing Data: ......................................... 5 3

2. Data supplied with this Service Bulletin: ........................... 5 4

3. Installation Drawings Used in the Preparation of this Service Bulletin: ........... 5 4 K. Publications Affected ........................................ 5 4 L. Interchangeability and Intermixability of Parts ........................... 5 5

2. MATERIAL INFORMATION ........................................ 5 7 A. Material - Price and Availability ................................... 5 7 B. Industry Support Information .................................... 5 8 C. Parts Necessary For Each Airplane ................................. 5 8

1. Kits/Parts: ........................................... 5 8

2. Parts and Materials Supplied by the Operator: ........................ 7 9

3. Parts Modified and Reidentified: ............................... 7 9

4. Parts Removed and Not Replaced: .............................. 7 9 D. Parts Necessary to Change Spares ................................. 8 0 E. Special Tooling - Price and Availability ............................... 8 0 F. Special Tooling Necessary to do this Service Bulletin ....................... 8 0

3. ACCOMPLISHMENT INSTRUCTIONS .................................. 8 1 A. GENERAL INFORMATION ..................................... 8 1 B. WORK INSTRUCTIONS ....................................... 8 2 FIGURE 1: REMOVAL OF THE J2802 BOX ASSEMBLY COVER [Group 2-11] ............ 9 8 FIGURE 2: REMOVAL OF THE J2802 BOX ASSEMBLY COVER [Group 12-16] ............ 9 9 FIGURE 3: WIRE BUNDLES W1760/W1770 INSTALLATION IN THE J2802 BOX ASSEMBLY [Group 2-11] ................................................. 1 0 0 FIGURE 4: CONNECTION OF THE WIRE BUNDLE W1760 [Group 2-11] ............... 1 0 1 FIGURE 5: CONNECTION OF THE WIRE BUNDLE W1770 [Group 2-11] ............... 1 0 4 FIGURE 6: WIRE BUNDLES W1760/W1770 INSTALLATION IN THE J2802 BOX ASSEMBLY [Group 12-16] ................................................. 1 0 7 FIGURE 7: CONNECTION OF THE WIRE BUNDLE W1760 [Group 12-16] .............. 1 0 8 FIGURE 8: CONNECTION OF THE WIRE BUNDLE W1760 [Group 12-16] .............. 1 1 0 FIGURE 9: CONNECTION OF THE WIRE BUNDLE W1770 [Group 12-16] .............. 1 1 3 FIGURE 10: CONNECTION OF THE WIRE BUNDLE W1770 [Group 12-16] .............. 1 1 5

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FIGURE 11: INSTALLATION OF THE J2802 BOX ASSEMBLY COVER [Group 2-16] ......... 1 1 8 FIGURE 12: ATTACHMENT OF THE J2802 BOX ASSEMBLY [Group 2-11] .............. 1 1 9 FIGURE 13: ATTACHMENT OF THE J2802 BOX ASSEMBLY [Group 12-16] ............. 1 2 2 FIGURE 14: DRILLING OF HOLES ON THE J2802 BOX ASSEMBLY AND E2 SUPPORT POST [Group 2-16] .............................................. 1 2 5 FIGURE 15: DRILLING OF HOLES ON THE J2802 BOX ASSEMBLY AND E2 SUPPORT POST [Group 2-16] .............................................. 1 2 8 FIGURE 16: INSTALLATION OF THE J2802 BOX ASSEMBLY, E2 AND E3 SUPPORT POSTS [Group 2-11] ................................................. 1 3 0 FIGURE 17: INSTALLATION THE J2802 BOX ASSEMBLY ON THE E2 AND E3 SUPPORT POSTS [Group 12-16] ............................................. 1 3 2 FIGURE 18: INSTALLATION THE BONDING JUMPER AND CLAMPS [Group 2-16] ......... 1 3 4 FIGURE 19: REMOVAL OF THE RELAYS FROM THE P6 PANEL [Group 2-11] ............ 1 3 7 FIGURE 20: INSTALLATION OF THE P5 PANEL WIRE BUNDLE W036 [Group 2-11] ......... 1 3 9 FIGURE 21: CONNECTION OF THE WIRE BUNDLE W036 [Group 2, 10-11] ............. 1 4 0 FIGURE 22: CONNECTION OF WIRE BUNDLE W036 [Group 8-9] ................... 1 4 3 FIGURE 23: CONNECTION OF THE WIRE BUNDLE W036 [Group 3] ................. 1 4 6 FIGURE 24: CONNECTION OF THE WIRE BUNDLE W036 [Group 4] ................. 1 4 9 FIGURE 25: CONNECTION OF THE WIRE BUNDLE W036 [Group 5] ................. 1 5 2 FIGURE 26: CONNECTION OF THE WIRE BUNDLE W036 [Group 6] ................. 1 5 5 FIGURE 27: CONNECTION OF THE WIRE BUNDLE W036 [Group 7] ................. 1 5 8 FIGURE 28: REMOVAL OF THE RELAYS, P6 PANEL [Group 12-16] .................. 1 6 1 FIGURE 29: INSTALLATION OF THE P5 PANEL WIRE BUNDLE W036 [Group 12-16] ........ 1 6 3 FIGURE 30: CONNECTION OF THE WIRE BUNDLE W036 [Group 12-13, 15] ............. 1 6 4 FIGURE 31: CONNECTION OF THE WIRE BUNDLE W036 [Group 12-13, 15] ............. 1 6 7 FIGURE 32: CONNECTION OF THE WIRE BUNDLE W036 [Group 12-13, 15] ............. 1 6 9 FIGURE 33: CONNECTION OF THE WIRE BUNDLE W036 [Group 14, 16] .............. 1 7 1 FIGURE 34: CONNECTION OF THE WIRE BUNDLE W036 [Group 14, 16] .............. 1 7 4 FIGURE 35: CONNECTION OF THE WIRE BUNDLE W036 [Group 14, 16] .............. 1 7 6 FIGURE 36: INSTALLATION OF THE P6 PANEL WIRE BUNDLE W044 [Group 2-11] ......... 1 7 8 FIGURE 37: CONNECTION OF WIRE BUNDLE W044 [Group 2] .................... 1 7 9 FIGURE 38: CONNECTION OF WIRE BUNDLE W044 [Group 3, 8-11, Configuration 1] ........ 1 8 2 FIGURE 39: CONNECTION OF THE WIRE BUNDLE W044 [Group 3, 8-11, Configuration 2] ..... 1 8 5 FIGURE 40: CONNECTION OF THE WIRE BUNDLE W044 [Group 4, Configuration 1] ........ 1 8 8 FIGURE 41: CONNECTION OF THE WIRE BUNDLE W044 [Group 4, Configuration 2] ........ 1 9 1 FIGURE 42: CONNECTION OF THE WIRE BUNDLE W044 [Group 5-6, Configuration 1] ....... 1 9 4 FIGURE 43: CONNECTION OF THE WIRE BUNDLE W044 [Group 5-6, Configuration 2] ....... 1 9 6 FIGURE 44: CONNECTION OF THE WIRE BUNDLE W044 [Group 7, Configuration 1] ........ 1 9 8 FIGURE 45: CONNECTION OF THE WIRE BUNDLE W044 [Group 7, Configuration 2] ........ 2 0 0 FIGURE 46: INSTALLATION OF THE P6 PANEL WIRE BUNDLE W044 [Group 12-16] ........ 2 0 2 FIGURE 47: CONNECTION OF THE WIRE BUNDLE W044 [Group 13] ................ 2 0 3 FIGURE 48: CONNECTION OF THE WIRE BUNDLE W044 [Group 13, Configuration 1] ....... 2 0 6 FIGURE 49: CONNECTION OF THE WIRE BUNDLE W044 [Group 13, Configuration 2] ....... 2 0 9 FIGURE 50: CONNECTION OF THE WIRE BUNDLE W044 [Group 12, 14-16, Configuration 1] . . . 212 FIGURE 51: CONNECTION OF THE WIRE BUNDLE W044 [Group 12, 14-16, Configuration 2] . . . 215 FIGURE 52: CONNECTION OF THE WIRE BUNDLE W044 [Group 12, 14-16, Configuration 1] . . . 218 FIGURE 53: CONNECTION OF THE WIRE BUNDLE W044 [Group 12, 14-16, Configuration 2] . . . 221

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FIGURE 54: INSTALLATION OF WIRE BUNDLE W368, W386, W1764 AND W1774 [Group 2-16] . . 224 FIGURE 55: CONNECTION OF WIRE BUNDLE W368 AND W1764 [Group 2, 4-5, 11] ........ 2 2 8 FIGURE 56: CONNECTION OF THE WIRE BUNDLE W368 AND WIRE BUNDLE W1764 [Group 8] . 231 FIGURE 57: CONNECTION OF THE WIRE BUNDLE W368 AND WIRE BUNDLE W1764 [Group 9] . 233 FIGURE 58: CONNECTION OF WIRE BUNDLE W368 AND W1764 [Group 10] ............ 2 3 5 FIGURE 59: CONNECTION OF WIRE BUNDLE W368 / W1764 [Group 3, 6-7] ............. 2 3 7 FIGURE 60: CONNECTION OF WIRE BUNDLE W368 AND W1764 [Group 12-16] .......... 2 4 0 FIGURE 61: CONNECTION OF WIRE BUNDLE W386 AND W1774 [Group 2, 4-5, 7-11] ....... 2 4 3 FIGURE 62: CONNECTION OF WIRE BUNDLE W386 / W1774 [Group 3, 6] .............. 2 4 6 FIGURE 63: CONNECTION OF WIRE BUNDLE W386 AND W1774 [Group 12-16] .......... 2 4 9 FIGURE 64: INSTALLATION OF THE RELAYS AND STRAPS ON THE J2802 BOX ASSEMBLY [Group 2-11] .............................................. 2 5 2 FIGURE 65: INSTALLATION OF THE RELAYS AND STRAPS ON THE J2802 BOX ASSEMBLY [Group 12-16] ............................................. 2 5 5 FIGURE 66: INSTALLATION OF THE RELAYS IN THE P6 PANEL [Group 2-11] ........... 2 5 8 FIGURE 67: INSTALLATION OF THE RELAYS, P6 PANEL [Group 12-16] ............... 2 6 0

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Original Issue: August 02, 2010 737-28A1228 6 of 261 BOEING SERVICE BULLETIN 737-28A1228

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Commercial Airplanes 737 Service Bulletin ALERT SummaryNumber: 737-28A1228Original Issue: August 02, 2010 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) andCertification 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).

Original Issue: August 02, 2010 737-28A1228 7 of 261

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ACTION (PRR 35442-RS) Group 1:

Operators should tell Boeing about this modification to get the engineering and accomplishment instructions.

Group 2-16:

Operators do these to change the airplane:

NOTE: Airplanes in group 15 and 16 were delivered, or modified by other Boeing change, to have only Auxiliary Fuel Tank wire provisions installed on airplane. Operators that installed AUX tanks with Fuel Boost Pumps on these airplanes need to install an Auto Shutoff system. FAA may release an AD to require that all airplanes that have AUX tanks with Fuel Boost Pumps should install an Auto Shutoff system.

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.

— Work Package 1: In the J2802 box assembly, install the wire bundles W1760 and W1770.

— Work Package 2: Get access into the main electronics compartment. Between the E2 and E3 rack support posts, install the J2802 box assembly.

— 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.

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

— In the main electronics compartment, at the J2802 box assembly, install the time delay relays R3318 and R3321. For the airplanes that have auxiliary fuel tank, at the J2802 box assembly, install the time delay relays R3327 and R3329.

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

EFFECTIVITY All 737-100/200/200C airplanes. Refer to Paragraph 1.A.1., Airplanes for the list of affected airplanes.

COMPLIANCE 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.

Group 1:

Operators should tell Boeing about this modification to get the engineering and accomplishment instructions.

Original Issue: August 02, 2010 737-28A1228 8 of 261 BOEING SERVICE BULLETIN 737-28A1228

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Group 2-16:

Boeing recommends that the change given in this service bulletin be done within 36 months after the original issue date of this service bulletin.

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/Parts. Refer to Paragraph 2.A., Material - Price and Availability.

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BOEING SERVICE BULLETIN 737-28A1228

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CHANGE WIRE BUNDLES W036/W368/W386

INSTALL WIRE BUNDLES W1764/W1774 CHANGE WIRE BUNDLE WO44 P6 RELAY

PANEL/MODULE INSTALL WIRE BUNDLES W1760/W1770 INSTALL J2802 BOX ASSEMBLY

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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 This service bulletin is for the airplanes shown below. An equivalent change is on subsequent production airplanes. Refer to PRR 35442-RS for data about this change.

Refer to Service Bulletin Index Document D6-19567 Part 3 for Airplane Variable Number, Line Number, and Serial Number data.

DESCRIPTIONCONFIGURATIONGROUP Airplanes from line numbers 1 through 291.-1 737 airplanes with line numbers higher than 291 that do not have the auxiliary fuel tanks and have different wire configurations at the P5 and P6 panels.

-2 737 airplanes with line numbers higher than 291 that do not have the auxiliary fuel tanks and have different wire configurations at the P5 and P6 panels.

-3 737 airplanes with SB 737-28A1212 R0 or R1 not incorporated.1 737 airplanes with SB 737-28A1212 R0 or R1 incorporated.2

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DESCRIPTIONCONFIGURATIONGROUP 737 airplanes with line numbers higher than 291 that do not have the auxiliary fuel tanks and have different wire configurations at the P5 and P6 panels.

-4 737 airplanes with SB 737-28A1212 R0 or R1 not incorporated.1 737 airplanes with SB 737-28A1212 R0 or R1 incorporated.2 737 airplanes with line numbers higher than 291 that do not have the auxiliary fuel tanks and have different wire configurations at the P5 and P6 panels.

-5 737 airplanes with SB 737-28A1212 R0 or R1 not incorporated.1 737 airplanes with SB 737-28A1212 R0 or R1 incorporated.2 737 airplanes with line numbers higher than 291 that do not have the auxiliary fuel tanks and have different wire configurations at the P5 and P6 panels.

-6 737 airplanes with SB 737-28A1212 R0 or R1 not incorporated.1 737 airplanes with SB 737-28A1212 R0 or R1 incorporated.2 737 airplanes with line numbers higher than 291 that do not have the auxiliary fuel tanks and have different wire configurations at the P5 and P6 panels.

-7 737 airplanes with SB 737-28A1212 R0 or R1 not incorporated.1 737 airplanes with SB 737-28A1212 R0 or R1 incorporated.2 737 airplanes with line numbers higher than 291 that do not have the auxiliary fuel tanks and have different wire configurations at the P5 and P6 panels.

-8 737 airplanes with SB 737-28A1212 R0 or R1 not incorporated.1 737 airplanes with SB 737-28A1212 R0 or R1 incorporated.2 737 airplanes with line numbers higher than 291 that do not have the auxiliary fuel tanks and have different wire configurations at the P5 and P6 panels.

-9 737 airplanes with SB 737-28A1212 R0 or R1 not incorporated.1 737 airplanes with SB 737-28A1212 R0 or R1 incorporated.2

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