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Commercial Airplane Group 737 Service Bulletin ALERT Number: 737-28A1248 Date: December 21, 2006 Revision 2: August 28, 2009 ATA System: 2822 SUBJECT: FUEL - Engine Fuel Feed System - Center Fuel Tank, Fuel Pumps - Power Failed ON Protection System (Un-commanded Pump ON) - Relays Installation 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BOEING PROPRIETARY, CONFIDENTIAL, AND/OR TRADE SECRET Copyright © 2006 The Boeing Company Unpublished Work - All Rights Reserved Boeing claims copyright in each page of this document only to the extent that the page contains copyrightable subject matter.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, 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BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
December 21, 2006 737-28A1248Revision 2: August 28, 2009 1 of 112
2.0
BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
December 21, 2006 737-28A1248Revision 2: August 28, 2009 2 of 112 BOEING SERVICE BULLETIN 737-28A1248
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Table of Contents
Revision Transmittal Sheet5
Summary7
1. PLANNING INFORMATION ........................................ 1 1 A. Effectivity ............................................... 1 1
1. Airplanes ............................................ 1 1
2. Spares Affected ........................................ 1 8 B. Concurrent Requirements ...................................... 1 8 C. Reason ................................................ 1 9 D. Description .............................................. 2 1 E. Compliance .............................................. 2 2 F. Approval ............................................... 2 2 G. Manpower .............................................. 2 2 H. Weight and Balance Changes .................................... 2 4 I. Electrical Load Data ......................................... 2 4 J. References .............................................. 2 5
1. Existing Data: ......................................... 2 5
2. Data supplied with this Service Bulletin: ........................... 2 5
3. Installation Drawings Used in the Preparation of this Service Bulletin: ........... 2 5 K. Publications Affected ........................................ 2 6 L. Interchangeability and Intermixability of Parts ........................... 2 6
2. MATERIAL INFORMATION ........................................ 2 7 A. Material - Price and Availability ................................... 2 7 B. Industry Support Information .................................... 2 7 C. Parts Necessary For Each Airplane ................................. 2 7
1. Kits/Parts: ........................................... 2 7
2. Parts and Materials Supplied by the Operator: ........................ 3 3
3. Parts Modified and Reidentified: ............................... 3 3
4. Parts Removed and Not Replaced: .............................. 3 3 D. Parts Necessary to Change Spares ................................. 3 3 E. Special Tooling - Price and Availability ............................... 3 4 F. Special Tooling Necessary to do this Service Bulletin ....................... 3 4
3. ACCOMPLISHMENT INSTRUCTIONS .................................. 3 5 A. GENERAL INFORMATION ..................................... 3 5 B. WORK INSTRUCTIONS ....................................... 3 6 FIGURE 1: R962, R963 RELAY INSTALLATION ............................. 4 4 FIGURE 2: W2218 WIRE BUNDLE ROUTING .............................. 5 1 FIGURE 3: W2112 WIRE BUNDLE ROUTING .............................. 5 6 FIGURE 4: P6-3 PANEL CIRCUIT BREAKER INSTALLATION ..................... 6 1 FIGURE 5: W0040, W0044 WIRE BUNDLE ROUTING .......................... 6 3 FIGURE 6: CIRCUIT BREAKER C1639 AND C1640 RE-IDENTIFICATION ............... 6 4 FIGURE 7: W0072 WIRE BUNDLE ROUTING .............................. 6 6 FIGURE 8: WIRE BUNDLE W0072 WIRING CHANGE .......................... 6 7 FIGURE 9: W0094 WIRE BUNDLE ROUTING - GROUP 1 AIRPLANES [Group 1] ........... 6 9 FIGURE 10: WIRE BUNDLE W0094 WIRING CHANGE - GROUP 1 AIRPLANES [Group 1] ...... 7 0 FIGURE 11: W0094 WIRE BUNDLE ROUTING - GROUP 2 AIRPLANES [Group 2] ........... 7 2 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
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FIGURE 12: WIRE BUNDLE W0094 WIRING CHANGE - GROUP 2 AIRPLANES [Group 2] ...... 7 3 FIGURE 13: W5158 WIRE BUNDLE ROUTING .............................. 7 5 FIGURE 14: WIRE BUNDLE W5158 WIRING CHANGE .......................... 7 8 FIGURE 15: W5160 WIRE BUNDLE ROUTING - GROUP 1 AIRPLANES [Group 1] ........... 7 9 FIGURE 16: WIRE BUNDLE W5160 WIRING CHANGE - GROUP 1 AIRPLANES [Group 1] ...... 8 4 FIGURE 17: W5160 WIRE BUNDLE ROUTING - GROUP 2 AIRPLANES [Group 2] ........... 8 5 FIGURE 18: WIRE BUNDLE W5160 WIRING CHANGE - GROUP 2 AIRPLANES [Group 2] ...... 9 0 FIGURE 19: W0212 WIRE BUNDLE ROUTING .............................. 9 1 FIGURE 20: WIRE BUNDLE W0212, W2112 WIRING CHANGE ..................... 9 2 FIGURE 21: W0422 WIRE BUNDLE ROUTING .............................. 9 4 FIGURE 22: WIRE BUNDLE W0422, W2218 WIRING CHANGE ..................... 9 5 FIGURE 23: W5112 WIRE BUNDLE ROUTING .............................. 9 7 FIGURE 24: WIRE BUNDLE W5112 WIRING CHANGE .......................... 9 9 FIGURE 25: W6210 WIRE BUNDLE ROUTING .............................. 1 0 1 FIGURE 26: WIRE BUNDLE W6210 WIRING CHANGE ......................... 1 0 3 Appendix A: ELECTRICAL BONDING ................................... 1 0 5 Appendix B: DRIVEN RIVET ELECTRICAL BOND ............................ 1 1 0 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
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Commercial Airplane Group 737 Service Bulletin ALERT Revision Transmittal SheetNumber: 737-28A1248Date: December 21, 2006 Revision 2: August 28, 2009 ATA System: 2822 SUBJECT: FUEL - Engine Fuel Feed System - Center Fuel Tank, Fuel Pumps - Power Failed ON Protection System (Un-commanded Pump ON) - Relays Installation This revision includes all pages of the service bulletin.
COMPLIANCE INFORMATION RELATED TO THIS REVISION No more work is necessary on airplanes changed as shown in the original issue or Revision 1 of this service bulletin.
Federal Aviation Administration (FAA) Notice of Proposed Rule Making FAA NPRM 2007-NM-013-AD, is related to this service bulletin.
REASON FOR REVISION This revision is sent to correct the illustrations that show the location of connectors D626 and D628. This revision also clarifies that no more work is necessary on airplanes that have accomplished the original issue of this service bulletin and adds NPRM 2007-NM-013-AD.
These sections were changed:
1. Summary, The compliance statement is clarified and NPRM 2007-NM-013-AD is added.
2. Paragraph 1.D., Description: The "More work/no more work is necessary" statement for Revision 1 of this service bulletin is changed to show that no more work is necessary on airplanes changed as shown in the original issue of this service bulletin.
3. Paragraph 1.D., Description: Maintenance zones are added.
4. Paragraph 1.E., Compliance: The compliance statement is clarified and NPRM 2007-NM-013-AD is added.
5. Paragraph 1.J., References: NPRM 2007-NM-013-AD and AMM 25-52-10 are added to the references list.
SWPM 20-30-11 and SWPM 20-10-14 are removed from the references list.
6. Paragraph 2.A., Material - Price and Availability: Rolt and price data is updated.
7. Figure 1, Sheet 4 and 5: The quantity of rivets necessary is changed from 1 to 3 in Steps 8 and 9 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
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8. Figure 2, Sheet 1: The illustration is changed to show the correct location of connector D628.
9. Figure 3, Sheet 1: The illustration is changed to show the correct location of connector D626.
10. Figure 23, Sheets 1 & 2: The illustrations are changed to clarify the routing of wire bundle W5112.
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 December 21, 2006Original Issue:
January 09, 2008Revision 1:
August 28, 2009Revision 2:
BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
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Commercial Airplane Group 737 Service Bulletin ALERT SummaryNumber: 737-28A1248Date: December 21, 2006 Revision 2: August 28, 2009 ATA System: 2822 SUBJECT: FUEL - Engine Fuel Feed System - Center Fuel Tank, Fuel Pumps - Power Failed ON Protection System (Un-commanded Pump ON) - Relays Installation
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 Boeing Service Bulletin 737-28A1206 (FUEL - Distribution - Center Fuel Tank Boost Pump Auto Shutoff and Master Caution Logic Change) released on January 11, 2006 (applicable to line number 1 through 1493), is necessary to be accomplished on airplanes line number 1 through 1493 before or concurrent with this service bulletin. Service Bulletin 737-28A1206 gives instructions to install an automatic shut off system for the fuel boost pumps in the center fuel tank. The intent of service bulletin 737-28A1206 has been incorporated during production starting with airplane line number 1494.
BACKGROUND This service bulletin gives the instructions and a kit of parts to install one additional pump control relay (secondary pump control relay) that is added to each existing center tank (Left and Right) fuel boost pump control relay (primary pump control relay). The new relays will provide the means of inhibiting the fuel pump through redundancy in turning OFF the fuel boost pumps. This system identifies when a pump is in operation and removes power to that pump if the pump switch is in the "OFF" position. The new relays are tied into the Auto Shutoff circuit, so that the new relays will also be turned off by the Auto Shutoff circuit. If a center tank fuel boost pump is left running on empty when the pump has been commanded "OFF" the center tank fuel boost pump operation with continuous low pressure could result in friction sparks or overheating in the fuel boost pump inlet, that could result in a potential ignition source in the Center Tank and consequent fire or explosion.
This service bulletin is the result of the safety assessments conducted by Boeing under SFAR 88, "Fuel Tank System Fault Tolerance Evaluation Requirements". Boeing found that in certain situations the Un-Commanded Pump ON can continue un-annunciated. If the center Tank pump is left running on empty when the pump has been commanded "OFF", the fuel boost pump operation with continuous low pressure could result in friction sparks or overheating in the fuel pump inlet. This condition has been determined to be an un-safe condition.
The installation of the automatic shut off system adds fuel pump inlet protection against friction sparks and friction overheat damage in the fuel tanks.
This change affects section 9 of the Maintenance Planning Data (MPD) Document. New Airworthiness Limitations (AWL) "28-AWL-23" will be added to section 9 of the MPD to include a functional check of the left and right center tank fuel boost pump primary and secondary control relays.
BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
December 21, 2006 737-28A1248Revision 2: August 28, 2009 7 of 112
Service Bulletin 737-28A1206 is related with this service bulletin.
ACTION (PRR 38545-80S) Install relay R962 near the P91 power distribution panel. In the P6-3 panel, position D7, install a new overlay marker labelled "FUEL AUTO S/O UCPO BST PUMP CTR TNK L AC" above circuit breaker "C1639". Remove Brady label "C1639" and install new Brady label "C1659". Change wires in J20 Junction Box. Add wires between the P5-2 panel and E2-1 electronic shelf. Add wires between E2-1 electronic shelf and J20 Junction Box. Change wires between the Left pump relay/GFI in the P91 power distribution panel and the Left pump motor to connect to the new relay R962 installed near P91 power distribution panel.
Install relay R963 near the P92 power distribution panel. In the P6-3 panel, position E7, install a new overlay marker labelled "FUEL AUTO S/O UCPO BST PUMP CTR TNK R AC" above circuit breaker C1640. Remove Brady label "C1640" and install new Brady label "C1658". Change wires in J4 Junction box. Add wires between the P5-2 panel and E4-2 electronic shelf. Add wires between E4-2 electronic shelf and J4 junction Box. Change the wires between the Left pump relay/GFI in the P92 power distribution panel and the Right pump motor to connect to the new relay installed near P92 power distribution panel.
Do a functional test of the left and right center tank fuel boost pump primary and secondary control relays. Do a pump reversal test for the left center tank fuel boost pump and right center tank fuel boost pump.
EFFECTIVITY 737-600/700/700C/800/900 Airplanes. Refer to Paragraph 1.A.1., Airplanes for the list of affected airplanes.
COMPLIANCE Federal Aviation Administration (FAA) Notice of Proposed Rule Making FAA NPRM 2007-NM-013-AD, is related to this service bulletin.
Boeing recommends that the changes given in this service bulletin be done within 60 months from the Original issue date on 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.
BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
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BOEING SERVICE BULLETIN 737-28A1248
ALERT ALERT P6-3 CIRCUIT BREAKER PANEL: J4 JUNCTION BOX INSTALL CIRCUIT BREAKER MARKERS CHANGE WO094
WIRE BUNDLE CHANGE W5160
WIRE BUNDLE CHANGE W2112, W2218 WIRE BUNDLES CHANGE W2218 AND W5160 WIRE BUNDLES INSTALL RELAY R963 NEAR P92 PANEL.
CHANGE W6210 WIRE BUNDLE P5
OVERHEAD PANEL CHANGE W5158
WIRE BUNDLE J20 JUNCTION BOX CHANGE WOO72
WIRE BUNDLE E4-2 CHANGE W5158 ELECTRONICS WIRE BUNDLE SHELF:
CHANGE WO422 CHANGE W5158 WIRE BUNDLE AND W2112 E2-1 WIRE BUNDLE INSTALL RELAY R962 ELECTRONICS NEAR P91 PANEL. SHELF:
CHANGE W5112 WIRE CHANGE WO212
BUNDLE WIRE BUNDLE U71933 December 21, 2006 Revision 2: August 28, 2009 737-28A1248 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 9 of 112
BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
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Commercial Airplane Group 737 Service Bulletin ALERT Number: 737-28A1248 Date: December 21, 2006 Revision 2: August 28, 2009 ATA System: 2822 SUBJECT: FUEL - Engine Fuel Feed System - Center Fuel Tank, Fuel Pumps - Power Failed ON Protection System (Un-commanded Pump ON) - Relays Installation
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. An equivalent change is on subsequent production airplanes. Refer to PRR 38545-80S for data about this change.
DESCRIPTIONCONFIGURATIONGROUP Airplane with wire configuration differences on J4 box-1 Airplane with wire configuration differences on J4 box-2 Airplane Models:
737-600, 737-700, 737-700C, 737-800, 737-900 GroupVariable Number 1YA001 - YA099 1YA101 - YA199 1YA201 - YA211 1YA221 1YA231 - YA242 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
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GroupVariable Number 1YA251 - YA256 1YA271 - YA272 1YA291 1YA301 - YA302 1YA311 - YA314 1YA321 - YA323 1YA336 - YA345 1YA351 1YA356 - YA357 1YA366 - YA367 1YA371 - YA377 1YA501 - YA536 1YA541 - YA552 1YA571 - YA578 1YA601 - YA615 1YA621 - YA622 1YA626 - YA631 1YA635 - YA636 1YA641 - YA642 1YA645 - YA650 1YA656 - YA659 1YA666 - YA667 1YA671 - YA672 1YA681 - YA691 1YA701 - YA710 1YA721 - YA722 1YA731 - YA734 1YA751 - YA756 1YA801 - YA803 1YA809 1YA811 - YA814 1YA831 - YA835 1YA841 - YA862 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
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