# Boeing Alert Service Bulletin 737-28A1248: Revision 2

- Rights: © The Boeing Company. Filed by the FAA in regulations.gov docket FAA-2007-28661; AD 2011-18-03 incorporates this document by reference. Not covered by OpenAirDocs’ CC0 dedication.
- Document: [Boeing Alert Service Bulletin 737-28A1248](https://openairdocs.org/service-documents/boeing/737-28a1248.md)
- Title as filed: U.S. DOT/FAA - Service Bulletin
- Pages: 112
- PDF: https://openairdocs.org/files/sha256/ae/d8/aed8ec180bffddc689b33787f80213e2ff4c6027322c31abed566be5f555cc31
- Page: https://openairdocs.org/service-documents/boeing/737-28a1248/file/aed8ec180bff

## Text

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### Page 1

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Unpublished Work - All Rights Reserved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.
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December 21, 2006
737-28A1248Revision 2: August 28, 2009
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Table of Contents
Revision Transmittal Sheet ............................................ 5
Summary ...................................................... 7
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
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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
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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
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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:
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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.
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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.
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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
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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
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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
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GroupVariable Number
1YA881 - YA882
1YA891 - YA892
1YA961 - YA977
1YB001 - YB006
1YB101 - YB132
1YB151 - YB153
1YB156 - YB158
1YB161 - YB164
1YB171 - YB172
1YB181 - YB184
1YB201 - YB208
1YB271
1YB276
1YB301 - YB310
1YB371 - YB390
1YB501 - YB502
1YB521 - YB526
1YB541 - YB544
1YB551
1YB561 - YB579
1YB581 - YB596
1YB601 - YB632
1YB651
1YB656
1YB851 - YB863
1YB871 - YB874
1YB881 - YB890
1YB901 - YB903
1YB911
1YB961 - YB964
1YC001 - YC030
1YC051 - YC083
1YC091 - YC094
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GroupVariable Number
1YC101 - YC104
1YC111 - YC113
1YC121
1YC126 - YC127
1YC136 - YC141
1YC146 - YC147
1YC151 - YC156
1YC166 - YC171
1YC176 - YC178
1YC186 - YC189
1YC201 - YC203
1YC206 - YC207
1YC301 - YC305
1YC321 - YC387
1YC391 - YC394
1YC396
1YC401 - YC417
1YC421 - YC422
1YC426 - YC428
1YC436 - YC437
1YC441 - YC448
1YC451 - YC455
1YC459
1YC461 - YC467
1YC471 - YC499
1YC501 - YC526
1YC571 - YC583
1YC587 - YC589
1YC591 - YC593
1YC601 - YC655
1YC681 - YC696
1YC701 - YC715
1YC720 - YC725
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GroupVariable Number
1YC727 - YC741
2YC742
1YC751 - YC752
1YC761 - YC770
1YC781 - YC793
1YC801 - YC892
1YC901 - YC907
1YC921 - YC922
1YC931 - YC932
1YC941 - YC951
1YC971 - YC978
1YC981 - YC983
1YD001 - YD007
1YD021 - YD025
1YD041 - YD057
1YD081 - YD084
1YD101 - YD110
1YD121 - YD126
1YD151 - YD159
1YD171 - YD172
1YD201 - YD203
1YD206 - YD209
1YD216 - YD219
1YD251 - YD254
1YD256 - YD257
1YD261
1YD301 - YD334
1YD391
1YD401 - YD410
1YD412 - YD414
1YD481 - YD485
1YD491 - YD494
1YD501 - YD512
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GroupVariable Number
1YD531 - YD535
1YD541 - YD547
1YD561 - YD564
1YD571 - YD572
1YD591 - YD595
1YD601 - YD612
1YD651 - YD655
1YE001 - YE020
1YE051
1YE101 - YE109
1YE151 - YE157
1YE171 - YE172
1YE201 - YE206
1YE301 - YE305
1YE321 - YE326
1YE371 - YE378
1YG001 - YG044
1YG061 - YG064
1YG066 - YG089
1YG091 - YG096
1YG101
1YG201 - YG204
1YG211 - YG212
1YG501 - YG506
2YG507 - YG509
2YG601 - YG602
1YJ001 - YJ005
1YJ011 - YJ013
1YJ021
1YJ471 - YJ480
1YJ501 - YJ517
1YJ531 - YJ552
1YJ591 - YJ594
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GroupVariable Number
1YJ631 - YJ632
1YJ671 - YJ685
1YJ690 - YJ692
1YJ801 - YJ867
1YJ871
1YJ901 - YJ902
1YJ911 - YJ928
1YJ931 - YJ936
1YJ941 - YJ947
1YK001 - YK007
1YK101 - YK104
1YK111 - YK112
1YK121 - YK122
1YK131 - YK132
1YK136 - YK137
1YK141 - YK142
1YK146 - YK147
1YK151 - YK154
1YK301 - YK305
1YK321 - YK331
1YK361 - YK369
2YK401 - YK402
1YK403
2YK404 - YK406
1YK426 - YK427
1YK431 - YK435
1YK456 - YK460
1YK476
1YK480 - YK484
1YK511 - YK514
1YK551 - YK559
1YK571
1YK601 - YK602
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GroupVariable Number
1YK611 - YK613
1YK621
1YK631
1YK641 - YK642
1YK701 - YK707
1YK721
1YK801 - YK818
1YK901 - YK906
1YK941
1YL001 - YL003
1YL011
1YM101 - YM103
1YM201 - YM210
1YM251 - YM290
1YM471
1YM481 - YM484
1YM501 - YM507
1YM521 - YM522
1YM541
1YM551 - YM553
1YM571 - YM572
1YM591
1YN001 - YN005
1YN061
1YN101 - YN104
2. Spares Affected
None.
B. 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.
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C. Reason
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.
Service Bulletin 737-28A1206 is related with this service bulletin.
Revision 1 was sent to include the following changes:
1. Deleted the word "override" throughout the service bulletin.
2. In Summary page, Concurrent Requirements paragraph and Planning Information, Paragraph
1.B., Concurrent Requirements - Added additional information related to service bulletin
737-28A1206 that has to be accomplished prior to or in same time with this service bulletin.
3. In Summary Page, Action paragraph and Planning Information, Paragraph 1.D., Description -
Removed the instructions related to the wire change in P6-3 Circuit Breaker Panel.
4. In Summary page, Effectivity paragraph - Added the airplanes line numbers range for the service
bulletin effectivity.
5. In Summary page, Summary Figure - Removed the instructions for changing wires W0040 and
W0044.
6. In Planning Information, Paragraph 1.A., Effectivity - Removed airplanes YC743, YC744, YC745,
YC746, YC747, YC748 from this service bulletin effectivity.
7. In Planning Information, Paragraph 1.C., Reason - Added the list of all changes included in this
revision.
8. In Planning Information, Paragraph 1.G., Manpower - Changed the task hours and elapsed hours
for some tasks.
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9. In Material Section, Paragraph 2.A., Material - Price And Availability - Changed the ROLT, Price,
and Date for Top Kit 012A0054-1.
10. In Material Section, Paragraph 2.C.1, Parts Necessary For Each airplane - Removed kit
280A3134-101 and all parts that belonged to kit 280A3134-101 and added flag note (a) in each
affected table.
11. In Material Section, Paragraph 2.C.2, Parts and Materials Supplied by Operator - Added a socket
contact and a note.
12. In Accomplishment Instructions, Paragraph 3.B., Work Instructions, PART 1 - Added to Step 5 the
reference documents for removing the floor panels, changed step instructions 11.b. and 11.c.,
deleted step instructions 12., 13., 14., and 15 and renumbered the remaining step instructions,
and added step 20 that provides instructions to install the floor panels removed in step 5.
13. In Accomplishment Instructions, Paragraph 3.B., Work Instructions, PART 1 - Added additional
data to Step 18 and 19.
14. In Accomplishment Instructions, Paragraph 3.B., Work Instructions, PART 2 - Added more data
to Step 1, added more data to Step 33, and in Step 11 corrected a terminal number from "C3" to
"C2".
15. In Accomplishment Instructions, Paragraph 3.B., Work Instructions, PART 3 - Added more data
to Step 1.
16. In Accomplishment Instructions, Paragraph 3.B., Figure 1 - Added instructions to remove and
install floor panels in order to install the R962 and R963 relays.
17. In Accomplishment Instructions, Paragraph 3.B. - Deleted Figure 5.
18. In Accomplishment Instructions, Paragraph 3.B. - Changed Figure 6 to show that wire
W0040-6402-14 does not have to be re-identified, wire W0040-6403-14 does not have to be
deleted, and wires W0040-6409-14 and W0040-6439-14 do not have to be installed.
19. In Accomplishment Instructions, Paragraph 3.B., Figure 16 and Figure 18 - Added new socket
contact and corrected existing socket contact part number.
20. In Accomplishment Instructions, Paragraph 3.B. - Changed quantity of contact pins for step 2 and
step 3 in Figure 22.
Revision 2 is sent to correct the illustrations that show the location of connectors D626 and D628.
Revision 2 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.
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4. Paragraph 1.E., 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
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.
D. Description
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.
NOTE: Service Bulletin 737-28A1206 has similar access requirements as this service bulletin.
Revision 1 - No more work is necessary on airplanes changed as shown in the original issue of this
service bulletin.
Revision 2 - No more work is necessary on airplanes changed as shown in the original issue or Revision
1 of this service bulletin.
The work in this service bulletin is done in the maintenance zone(s) given below.
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Group 1:
Affected Maintenance Zones
ZoneModel
113, 114, 117, 118, 123, 124, 211, 212737-600, 737-700, 737-700C,
737-800, 737-900
Group 2:
Affected Maintenance Zones
ZoneModel
113, 114, 117, 118, 123, 124, 211, 212737-700C, 737-800
E. 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 operators do the changes given this service bulletin within 60 months from
the Original issue date on this Service Bulletin.
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 change 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:
This estimate does not include the task-hour data given in the service bulletins in Paragraph 1.B.,
Concurrent Requirements.
— Time to adjust to the workplace
— Time to schedule the work
— Time to examine the work
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— Time to cure the materials
— Time to make the parts
— Time to find the tools.
Group 1:
Elapsed HoursTask-HoursNumber of
Persons
Task
1.002.002Open Access
1.503.002Figure 1
1.402.802Figure 2 and Figure 22
1.352.702Figure 3 and Figure 20
0.300.301Figure 4 and Figure 6
1.603.202Figure 7 and Figure 8
1.603.202Figure 9 and Figure 10
7.6515.302Figure 13 and Figure 14
1.352.702Figure 15 and Figure 16
2.004.002Figure 19 and Figure 20
2.104.202Figure 21 and Figure 22
4.158.302Figure 23 and Figure 24
6.1512.302Figure 25 and Figure 26
0.501.002Test - Part 2
0.250.502Test - Part 3
1.002.002Close Access
33.9067.50TOTAL FOR EACH
AIRPLANE
Group 2:
Elapsed HoursTask-HoursNumber of
Persons
Task
1.002.002Open Access
1.503.001Figure 1
1.402.802Figure 2 and Figure 22
1.352.702Figure 3 and Figure 20
0.300.301Figure 4 and Figure 6
1.603.202Figure 7 and Figure 8
1.603.202Figure 11 and Figure 12
7.6515.302Figure 13 and Figure 14
1.352.702Figure 17 and Figure 18
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Group 2:
Elapsed HoursTask-HoursNumber of
Persons
Task
2.004.002Figure 19 and Figure 20
2.104.202Figure 21 and Figure 22
4.158.302Figure 23 and Figure 24
6.1512.302Figure 25 and Figure 26
0.501.002Test - Part 2
0.250.502Test - Part 3
1.002.002Close Access
33.9067.50TOTAL FOR EACH
AIRPLANE
H. Weight and Balance Changes
Change in Moment
(Pound-Inches)
Change in Weight
(Pounds)
Airplane
+970.0+3.2737-600 Airplanes
+800.0+3.2737-700 Airplanes
+420.0+3.2737-800 Airplanes
+220.0+3.2737-900 Airplanes
I. Electrical Load Data
1. Direct Current (DC) Loads
BusAmperesCircuit BreakersAirplanes
28 VDC Bus 1 Sect 2No ChangeC1637All Airplanes
28 VDC Bus 2 Sect 2No ChangeC1638All Airplanes
2. Alternating Current (AC) Loads
BusPhaseVolt-Ampere-Reactive
(VARs)
WattsCircuit
Breakers
Airplanes
115 VAC Transfer Bus 1
Sect 2
C6.3 increaseC1659All Airplanes
115 VAC Transfer Bus 2
Sect 2
C6.3 increaseC1658All Airplanes
3. Type
Continuous
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J. References
1. Existing Data:
a. Engineering Change Memo PRR 38545-80S
b. Boeing Parts Standards Document D-590
c. Boeing Service Bulletin 737-28A1206
d. Federal Aviation Administration (FAA) Notice of Proposed Rule Making 2007-NM-013-AD
e. Standard Overhaul Practices Manual (SOPM) 20-11-03, 20-43-03, 20-50-05, 20-50-10,
20-50-19, 20-60-02
f. Standard Wiring Practices Manual (SWPM) 20-10-11, 20-10-12, 20-10-19, 20-20-00, 20-31-12,
20-60-11, 20-61-11, 20-74-11, 20-81-12, 20-90-15.
g. 737-600/700/800/900 Aircraft Maintenance Manual (AMM) 06-41-00, 24-22-00, 24-31-11,
25-52-10, 28-26-00
h. 737-600 Structural Repair Manual (SRM) 51-40-02, 51-40-05, 53-10-54
i. 737-700 Structural Repair Manual (SRM) 51-40-02, 51-40-05, 53-10-54
j. 737-700CONV Structural Repair Manual (SRM) 51-40-02, 51-40-05, 53-10-54
k. 737-800 Structural Repair Manual (SRM) 51-40-02, 51-40-05, 53-10-54, 53-10-54
l. 737-900 Structural Repair Manual (SRM) 51-40-02, 51-40-05, 53-10-54
2. Data supplied with this Service Bulletin:
None.
3. Installation Drawings Used in the Preparation of this Service Bulletin:
TitleDrawing Number
WIRE BUNDLE INSTALLATION - RIGHT E/E BAY, SIDEWALL288A4121
WIRE BUNDLE INSTL - LEFT E/E BAY SIDEWALL288A4131
WIRE BUNDLE INSTL - E/E BAY FLOOR BEAMS288A4141
WIRE BUNDLE INSTL E2, E3, AND E4, TRANSVERSE RACK288A4360
WIRE BUNDLE INSTL - FLIGHT DECK SIDEWALLS288A4101
WIRE BUNDLE - FORWARD, OVERHEAD INSTRUMENT PANEL288A4156
WIRE BUNDLE INSTL - AFT OVERHEAD INSTRUMENT PANEL288A4157
TOP KIT - RELAY INSTL - CENTER FUEL TANK, UNCOMMANDED PUMP ON012A0054
KIT - RELAY, CENTER FUEL TANK, UN-COMMANDED PUMP ON284A9822
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TitleDrawing Number
SUB - KIT - C/B INSTL233A5001
WIRE KIT - SFAR 88: CENTER FUEL TANK UN-COMMANDED PUMP ON (UCPO)280A3134
These drawings were used to prepare this service bulletin. These drawings are not necessary to
make the specified changes, and are not supplied with this service bulletin. These drawings may
not be applicable to all airplane configurations or operators.
K. Publications Affected
Chapter-SectionPublication
28737 Aircraft Maintenance Manual
28737 Wiring Diagram Manual
28737 Fault Isolation Manual
28737 Illustrated Parts Catalog
Section 9Maintenance Planning Data
28737 Schematic Diagram Manual
L. Interchangeability and Intermixability of Parts
Accomplishment of this service bulletin does not affect interchangeability or intermixability of parts.
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2.    MATERIAL INFORMATION
A. Material - Price and Availability
Boeing can supply the kit shown in Paragraph 2.C., Parts Necessary for Each Airplane shown below.
If there is a limit in the quantity (QTY) of available kits/parts, a supply sequence is given by Spares.
More kits/parts become available as shown in the Reorder Lead Time (ROLT). ROLT is calculated
from the date Boeing gets the purchase order.
Unit Price thru
April 30, 2009
Rolt
(Weeks)
NamePart umber
$3,274.0078TOP KIT - RELAY INSTL -
CENTER FUEL TANK,
UNCOMMANDED PUMP ON
012A0054-1
The kits/parts are subject to the terms and conditions of the Boeing standard purchase order
acknowledgment. After the Unit Price date, new price and ROLT data is applicable. Prices are in United
States dollars. Terms: Net 30 days.
Reference this service bulletin and submit your purchase order by one of the methods that follow:
1. Order on-line via ATA Spec 2000 or Boeing Part Page
2. Fax to (206) 662-7145
3. Mail to:
Spares Customer Support - MC 36-65
Boeing Spares Department
P.O. Box 3707
Seattle, Washington 98124-2207 USA
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/parts shown below, refer to Paragraph 2.A., Material - Price and Availability.
NOTE: One top kit and the items shown in Paragraph 2.C.2., Parts and Materials Supplied by
the Operator Paragraph, are necessary for each airplane.
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Kit 012A0054
NotesExisting Part
Number
NameQTYNew Part Number
-1
TOP KIT - RELAY INSTL - CENTER
FUEL TANK, UNCOMMANDED PUMP
ON
-012A0054-1
SUB-KIT - C/B INSTL1233A5001-37
WIRE KIT - SFAR 88: CENTER FUEL
TANK UN-COMMANDED PUMP ON
(UCPO)
1280A3134-1
KIT - RELAY, CENTER FUEL TANK,
UN-COMMANDED PUMP ON
1284A9822-1
Kit 233A5001
NotesExisting Part
Number
NameQTYNew Part Number
-37
SUB-KIT - C/B INSTL-233A5001-37
MARKER1BAC27DCC3564
MARKER1BAC27DCC3565
(a)TAPE, ID3BACT19J4
(a) There are more parts than are necessary.
Kit 280A3134 (a)
NotesExisting Part
Number
NameQTYNew Part Number
-1
WIRE KIT - SFAR 88: CENTER FUEL
TANK UN-COMMANDED PUMP ON
(UCPO)
-280A3134-1
LACING TAPE1280A2001-1
ASSY -102 (W0072)1280A3134-102
ASSY -103 (W0094)1280A3134-103
ASSY -104 (W5158)1280A3134-104
ASSY -105 (W5160)1280A3134-105
ASSY -106 (W0212, W2112)1280A3134-106
ASSY -107 (W0422, W2218)1280A3134-107
ASSY -108 (W5112)1280A3134-108
ASSY -109 (W6210)1280A3134-109
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Kit 280A3134 (a)
NotesExisting Part
Number
NameQTYNew Part Number
-1
(a) Wire Kit 280A3134-101 and all parts contained in this wire kit have been removed from
280A3134-1 kit. Operators that received the 280A3134-101 wire kit as part of 280A3134-1
kit should discard it. The 280A3134-101 wire kit is not necessary, wire bundle W0040 does
not have to be changed.
Kit 284A9822
NotesExisting Part
Number
NameQTYNew Part Number
-1
KIT - RELAY, CENTER FUEL TANK,
UN-COMMANDED PUMP ON
-284A9822-1
BRACKET ASSY2284A3839-66
DECAL, VINYL1BAC27DEX7194
DECAL, VINYL1BAC27DEX7195
BONDING JUMPER1BACJ40A20-4
NUT2BACN10YR3CD
(a)RIVET3BACR15BB5AD5C
(a)RIVET3BACR15BB5AD6C
(a)BOLT8BACS12HN08-8
(a)BOLT1BACS12HN3-8
(a)BOLT1BACS12HN3-9
RELAY2MS27418-2A
WASHER6NAS1149D0316H
WASHER8NAS1149DN832J
(a) If grip length shown is not available at Boeing, fasteners supplied in kits may be one 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. Boeing Parts Standards Document
D-590 and Boeing Drawing 65-88700 are used to determine the part numbers used as substitutes.
Kit 280A3134 (a) (b)
NotesExisting Part
Number
NameQTYNew Part Number
-102-103-104-105-106
ASSY -102 (W0072)-....280A3134-102
ASSY -103 (W0094).-...280A3134-103
ASSY -104 (W5158)..-..280A3134-104
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Kit 280A3134 (a) (b)
NotesExisting Part
Number
NameQTYNew Part Number
-102-103-104-105-106
ASSY -105 (W5160)...-.280A3134-105
ASSY -106 (W0212,
W2112)
....-280A3134-106
ASSY -102 WIRE
LIST
1....280A3134-102W
ASSY -103 WIRE
LIST
.1...280A3134-103W
ASSY -104 WIRE
LIST
..1..280A3134-104W
ASSY -105 WIRE
LIST
...1.280A3134-105W
ASSY -106 WIRE
LIST
....1280A3134-106W
ASSY -102 I.D.
SLEEVE "SM603"
1....280A3134-10201
ASSY -103 I.D.
SLEEVE "SM503"
.1...280A3134-10301
CONTACT, PIN44...BACC47CN1A
CONTACT..443BACC47CP1T
CONTACT,
SOCKET
44...BACC47DJ1
CONTACT,
SOCKET, SIZE 20
....2CTA-0165
CONTACT, PIN,
SIZE 20
....4CTA-0166
SPLICE22...D-436-37
CONTACT...44M39029/57-358
CONTACT..4..M39029/58-364
CONTACT, PIN,
SIZE 20
....2S280W555-920
(a) Wire Kit 280A3134-101 and all parts contained in this wire kit have been removed from 280A3134-1 kit.
Operators that received the 280A3134-101 wire kit as part of 280A3134-1 kit should discard it. The
280A3134-101 wire kit is not necessary, wire bundle W0040 does not have to be changed.
(b) There are more parts than are necessary.
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Kit 280A3134 (a) (b)
NotesExisting Part
Number
NameQTYNew Part Number
-107-108-109-102W-103W
ASSY -107 (W0422,
W2218)
-....280A3134-107
ASSY -108 (W5112).-...280A3134-108
ASSY -109 (W6210)..-..280A3134-109
ASSY -102 WIRE
LIST
...-.280A3134-102W
ASSY -103 WIRE
LIST
....-280A3134-103W
ASSY -107 WIRE
LIST
1....280A3134-107W
ASSY -108 WIRE
LIST
.1...280A3134-108W
ASSY -109 WIRE
LIST
..1..280A3134-109W
PIN CONTACT.44..BACC47CN2A
CONTACT3....BACC47CP1T
TERMINAL.33..BACT12AR183
TERMINAL.77..BACT12AR184
WIRE...11BMS13-48T10C01G020
CONTACT,
SOCKET, SIZE 20
266..CTA-0165
CONTACT, PIN,
SIZE 20
5....CTA-0166
CONTACT4....M39029/58-364
CONTACT, PIN,
SIZE 20
2....S280W555-920
(a) Wire Kit 280A3134-101 and all parts contained in this wire kit have been removed from 280A3134-1 kit.
Operators that received the 280A3134-101 wire kit as part of 280A3134-1 kit should discard it. The
280A3134-101 wire kit is not necessary, wire bundle W0040 does not have to be changed.
(b) There are more parts than are necessary.
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Kit 280A3134
NotesExisting
Part
Number
NameQTYNew Part Number
-104W-105W-106W-107W-108W-109W
ASSY -104
WIRE LIST
-.....280A3134-104W
ASSY -105
WIRE LIST
.-....280A3134-105W
ASSY -106
WIRE LIST
..-...280A3134-106W
ASSY -107
WIRE LIST
...-..280A3134-107W
ASSY -108
WIRE LIST
....-.280A3134-108W
ASSY -109
WIRE LIST
.....-280A3134-109W
WIRE RMS
5454011752
..1...BMS13-58T1C1G20
WIRE111111BMS13-48T10C01G020
WIRE....11BMS13-48T10C03G018
Kit 280A3134 (a)
NotesExisting Part
Number
NameQTYNew Part Number
-10201-10301
ASSY -102 I.D. SLEEVE
"SM603"
-.280A3134-10201
ASSY -103 I.D. SLEEVE
"SM503"
.-280A3134-10301
ESCO;VERSABU375S
HEAT SHRINKABLE
SLEEVE
..N0001025
MARKER SLEEVE11TMSSCE14-2-4
(a) Wire Kit 280A3134-101 and all parts contained in this wire kit have been removed
from 280A3134-1 kit. Operators that received the 280A3134-101 wire kit as part of
280A3134-1 kit should discard it. The 280A3134-101 wire kit is not necessary, wire
bundle W0040 does not have to be changed.
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2. Parts and Materials Supplied by the Operator:
NotesNameQTYPart Number /
Specification
(a) (b)Chemical Conversion Coating2 ouncesALODINE 1200
(MIL-C-5541, BAC5719,
Type II, Class A)
(a)Primer2 ouncesBMS 10-11, Type I
(a)White Gloss Enamel2 ouncesBMS 10-11, Type II
For General Cleaning (a)WipersAs
Necessary
BMS 15-5, Class A or B
Methyl Propyl Ketone (a)Solvent8 ouncesBMS 11-9, Grade 1 or
Grade 2 or
Methyl Ethyl KetoneTT-M-261 or
Isopropyl AlcoholTT-I-735, Grade A
Aliphatic NaphthaTT-N-95 (BMS 3-2)
Abrasive Paper 180 GritAbrasivesAs
Necessary
P-P-121
Abrasive Cloth, Aluminum
Oxide
P-C-451
Aluminum OxideAbrasive Blast Grit,
100-325 Grit
Abrasive Pad-Scotch
Brite
(c)Socket Contact, size 201CTA-0165
(a) See the Qualified Products List at the end of the Boeing Material Specification (BMS) for supplier
data.
(b) Refer to the Boeing Standard Overhaul Practices Manual 20-43-03 or 737 Structural Repair Manual,
chapter 51, for material sources.
(c) You can use one CTA-0165 socket contact from 280A3134-106 kit. There are two socket contacts
in 280A3134-106 kit and only one is need for wire W2112 installation.
3. Parts Modified and Reidentified:
None.
4. Parts Removed and Not Replaced:
None.
D. Parts Necessary to Change Spares
None.
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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.
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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. The work instructions are divided into three Parts, Part 1, Part 2, and Part 3. Task
Hours and Elapsed Hours for each package are given in Paragraph 1.G., Manpower.
You can do each "Part" independently.
4. 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.
— Tolerance on rivet and bolt edge margin is plus or minus 0.05 inch
— Hole dimensions for standard solid rivets are given in Structural Repair Manual,
Chapter 51
— Torque limits to tighten nuts and bolts are given in Structural Repair Manual,
Chapter 51.
5. For approved fastener and process material substitutions, refer to Structural Repair
Manual, Chapter 51, Alternate fasteners are given in Structural Repair Manual Chapter
51 and Boeing Drawing 65-88700.
6. Refer to the Boeing Standard Wiring Practices Manuals SWPM 20-10-11 and SWPM
20-10-12 for the wire installation procedures.
7. If the length of fasteners specified in this service bulletin do not meet the installation
standards, fasteners of the same specification, or an approved substitute, one grip
length longer or shorter may be used.
8. These work instructions refer to procedures included on 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 "as
given in" are included in the instruction, the procedure in the Boeing document must
be used.
BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
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B. WORK INSTRUCTIONS
PART 1 - INSTALL SECONDARY CONTROL RELAYS R962 AND R963, CHANGE WIRE BUNDLES
W2218, W2112, W0040, W0044, W0072, W0094, W5158, W5160, W0212, W0422, W5112, AND
W6210
1. Remove the electrical power from the airplane. Refer to 737-600/700/800/900 AMM 24-22-00 as
an accepted procedure.
WARNING: DO THE DEACTIVATION PROCEDURE FOR THE SPOILERS OR MOVE ALL PERSONS
AND EQUIPMENT AWAY FROM THE SPOILERS. THE SPOILERS CAN RETRACT
QUICKLY AND CAUSE INJURY TO THE PERSONS OR DAMAGE TO EQUIPMENT.
WARNING: IF THE EXTERNAL POWER SUPPLY HAS AN EARTH GROUNDED NEUTRAL, THERE
MUST NOT BE AN OPEN OR FLOATING GROUND IN THE NEUTRAL CIRCUIT WIRING
OF THE SUPPLY OR THE AIRPLANE. IF AN OPEN OR FLOATING GROUND IS
PRESENT, THE AIRPLANE CAN BE PUT AT AN ELECTRICAL POTENTIAL ABOVE
EARTH GROUND. THIS ELECTRICAL POTENTIAL CAN RESULT IN ELECTRIC SHOCK
WITH POSSIBLE SEVERE INJURY TO PERSONNEL WHO TOUCH THE AIRPLANE.
WARNING: REMOVE THE ELECTRICAL POWER FROM THE EXTERNAL POWER CABLE BEFORE
YOU CONNECT THE CABLE TO THE AIRPLANE. INJURY TO PERSONS CAN BE
CAUSED BY AN ELECTRICAL SHOCK.
2. Disconnect the battery connectors from the batteries. Refer to 737-600/700/800/900 AMM 24-31-11
as an accepted procedure.
3. Remove access panels 113BW, 114AW, and 114BW in the nose landing gear wheel well area to
get access to the J4 and J20 junction boxes and related wiring. Refer to 737-600/700/800/900
AMM 06-41-00.
4. Remove the Electronic Equipment access door 117A. Get access to Electronic Equipment bay.
5. Remove the floor panels as given in FIGURE 1. Refer to 737-600 SRM 53-10-54, 737-700 SRM
53-10-54, 737-700CONV SRM 53-10-54, 737-800 SRM 53-10-54, 737-900 SRM 53-10-54 and
737-600/700/800/900 AMM 25-52-10 as accepted procedures.
6. Install the new relay R962 on the left side on the frame, approximately underneath the P91 panel,
as given in FIGURE 1.
7. Install the new relay R963 on the right side, on the frame, approximately underneath the P92 panel
as given in FIGURE 1.
8. Get access to the flight compartment.
9. Add new wire in wire W2218 between connector D628 on P5-2 Fuel Control Panel and Connector
D40540P on E4-2 Electronic Rack as given in FIGURE 2 and FIGURE 22.
10. Add new wire in wire bundle W2112 between connector D626 on P5-2 Fuel Control Panel and
Connector D40598P on E2-1 Electronic Rack as given in FIGURE 3 and FIGURE 20.
11. On P6-3 Circuit Breaker Panel:
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a. Install two new markers in the P6-3 panel position D7 and position E7 as given in FIGURE 4.
b. Remove the Brady label above circuit breaker C1639 and install a new Brady Label marked
C1659, on P6-3 Circuit Breaker panel as given in FIGURE 4 and FIGURE 6.
NOTE: There is no change of wires W0040. FIGURE 6 shows the changes of the wire
diagrams after the circuit breakers are re-identified.
c. Remove the Brady label above circuit breaker C1640 and install a new Brady label marked
C1658, on P6-3 Circuit Breaker panel as given in FIGURE 4 and FIGURE 6.
NOTE: There is no change of wires W0040. FIGURE 6 shows the changes of the wire
diagrams after the circuit breakers are re-identified.
12. Change wire bundle W0072 in the J20 Junction Box as given in FIGURE 7 and FIGURE 8.
13. Change wire bundle W0094 in the J4 Junction Box:
a. Group 1:
As given in FIGURE 9 and FIGURE 10.
b. Group 2:
As given in FIGURE 11 and FIGURE 12.
14. Add new wires in wire bundle W5158 between connector D40428P on E2-1 Electronic Shelf and
connector D40858P on J20 Junction Box as given in FIGURE 13 and FIGURE 14.
15. Add new wires in wire bundle W5160 between connector D40658P on J4 junction Box and D40472P
connector on E4-2 Electronic Shelf:
a. Group 1:
As given in FIGURE 15 and FIGURE 16.
b. Group 2:
As given in FIGURE 17 and FIGURE 18.
16. Add new wires in wire bundle W0212 between D40428J connector and D40598J, and between
D40428J connector and D49996J connector on E2-1 Electronic Shelf as given in FIGURE 19 and
FIGURE 20.
17. Add new wires in wire bundle W0422 between connector D40472J and connector D40540J, and
between D40472J connector and D40938J connector, on E4-2 Electronic Shelf as given in FIGURE
21 and FIGURE 22.
18. Change wire bundle W5112 as given in FIGURE 23 and FIGURE 24. Add new wire bundle W5112
between connector D49996P on E2-1 Electronic Shelf and R962 Relay (Secondary Boost Pump
CTR Tank L Relay), and between R962 Relay and D11434 connector on P91 as given in FIGURE
23 and FIGURE 24.
19. Change wire bundle W6210 as given in FIGURE 25 and FIGURE 26. Add new wire bundle W6210
between connector D40938P on E4-2 Electronic Shelf and R963 Relay (Secondary Boost Pump
CTR Tank R Relay), and between R963 Relay and D11738 connector on P92 as given in FIGURE
25 and FIGURE 26.
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20. Install the floor panels as given in FIGURE 1. Refer to 737-600 SRM 53-10-54, 737-700 SRM
53-10-54, 737-700CONV SRM 53-10-54, 737-800 SRM 53-10-54, 737-900 SRM 53-10-54 and
737-600/700/800/900 AMM 25-52-10 as accepted procedures.
21. Connect the battery cable connector to the batteries. Refer to 737-600/700/800/900 AMM 24-31-11
as an accepted procedure.
22. Restore the electrical power to the airplane. Refer to 737-600/700/800/900 AMM 24-22-00 as an
accepted procedure.
23. Do the Test for "Left and Right Center Tank Fuel Boost Pump Primary Control Relays" and "Left
and Right Center Tank Fuel Boost Pump Secondary Control Relays as given in PART 2.
24. Do the Pump Reversal Test for Left Center Tank Fuel Boost Pump and the Pump Reversal Test
for Right Center Tank Fuel Boost Pump as given in PART 3.
PART 2 - TEST - LEFT AND RIGHT CENTER TANK FUEL BOOST PUMP PRIMARY CONTROL
RELAYS AND LEFT AND RIGHT CENTER TANK FUEL BOOST PUMP SECONDARY CONTROL
RELAYS
1. Make sure there is a minimum fuel quantity of 3,000 pounds (1,364 Kilograms) in the center fuel
tank, and not more than 7,000 (3,182 kilograms) pounds of fuel in the left main tank, and not more
than 7,000 (3,182 kilograms) pounds of fuel in the right main tank. There must be an operator in
the flight compartment to monitor the fuel quantity and the low pressure indication in the fuel tank,
so that the pumps do not run dry.
2. Open the circuit breakers shown below and attach DO-NOT-CLOSE" tags:
Circuit BreakerNamePanel / Location
C845FUEL BOOST PUMP CTR TANK LEFTP91/ D6
C846FUEL BOOST PUMP CTR TANK RIGHTP92/ D6
C1637BOOST PUMP CTR TNK L AUTO SHUT OFF - DCP6-3/C3
C1638BOOST PUMP CTR TNK R AUTO SHUT OFF - DCP6-3/C7
C313INDICATOR MASTER DIM SECT 1P6-3/E11
C318INDICATOR MASTER DIM SECT 6P6-3/F12
C1658FUEL AT S-O/UCPO BST PMP CTR TNK R ACP6-3/E7
C1659FUEL AT S-O/UCPO BST PMP CTR TNK L ACP6-3/D7
3. Make sure that all fuel pump switches on the P5-2 fuel management control panel are OFF.
4. Remove the "DO-NOT-CLOSE" tags and close the circuit breakers shown below:
Circuit BreakerNamePanel / Location
C1637BOOST PUMP CTR TNK L AUTO SHUT OFF - DCP6-3/C3
C318INDICATOR MASTER DIM SECT 6P6-3/F12
C1659FUEL AT S-O/UCPO BST PMP CTR TNK L ACP6-3/D7
BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
December 21, 2006
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Circuit BreakerNamePanel / Location
C845FUEL BOOST PUMP CTR TANK LEFTP91/ D6
5. Push the L FUEL CTR PUMPS switch on the Fuel Management Control on the P5-2 panel to the
ON position.
6. Make sure that the Left Center Tank low pressure light illuminates momentarily, and then
extinguishes.
7. Get access to the secondary relay R962 installed in the Electronic Bay underneath the floor panel
at the P91 power distribution panel.
8. Measure the voltage between each terminal A1, A2, B1, B2, C1, and C2 of R962 secondary relay,
and the floor structure. Make sure that the voltage measured is 115+/- 10 VAC.
9. Push the L FUEL CTR PUMPS switch on the P5 panel to the OFF position.
10. Measure the voltage between each terminal A1, A2, B1, B2, C1, and C2 of R962 secondary relay,
and the floor structure. Make sure that the voltage measured is less than 10 VAC.
NOTE: It is recommended that you use an analog Volt-Ohm-Milliammeter (VOM) such as the
Simpson 260, Tripplett 630 or equivalent to minimize AC voltage noise pickup in this open
circuit test.
11. Measure the resistance between each terminal pair: A1 and A2, B1 and B2, and C1 and C2. Verify
that the resistance measured between terminals A1 and A2, and B1 and B2, and C1 and C2 is
greater than 1.0 Meg-Ohm (1,000,000 Ohms).
12. Push the L FUEL CTR PUMPS switch of the Fuel on the P5 panel to the ON position.
13. Make sure that the Left Center Tank low pressure light illuminates momentarily, and then
extinguishes.
14. Push and Hold the Left Auto Shutoff test switch on the P61-8 panel until the Left Center Tank low
pressure light illuminates after approximately 15 seconds, than release the switch.
15. Measure the voltage between each terminal A1, A2, B1, B2, C1, and C2 of the R962 relay and
the floor structure. Verify that the voltage measured is less than 10 VAC.
16. Measure the resistance between each terminal pair A1 and A2, B1 and B2, and C1 and C2. Verify
that the resistance measured between each terminals pair: A1 and A2, B1and B2, and C1 and
C2,is greater than 1.0 Meg-Ohm (1,000,000 Ohms).
17. Push the L FUEL CTR PUMPS switch in the fuel management control panel in the overhead panel
P5 to the OFF position, then to the ON position. Verify that the left center tank low pressure light
illuminates momentarily and then extinguishes.
18. Push the L FUEL CTR PUMPS switch to the OFF position.
19. Open the circuit breakers shown below and attach "DO-NOT-CLOSE" tags:
BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
December 21, 2006
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### Page 40

Circuit BreakerNamePanel / Location
C1637BOOST PUMP CTR TNK L AUTO SHUT OFF - DCP6-3/C3
C318INDICATOR MASTER DIM SECT 6P6-3/F12
C1659FUEL S-O/UCPO BST PMP CTR TNK LEFTP6-3/D7
C845FUEL BOOST PUMP CTR TANK LEFTP91/ D6
20. Remove the "DO-NOT-CLOSE" tags and close the circuit breakers shown below:
Circuit BreakerNamePanel / Location
C1638BOOST PUMP CTR TNK R AUTO SHUT OFF - DCP6-3/C7
C313INDICATOR MASTER DIM SECT 1P6-3/E11
C1658FUEL AT S-O/UCPO BST PMP CTR TNK R ACP6-3/E7
C846FUEL BOOST PUMP CTR TANK RIGHTP92/ D6
21. Push the R FUEL CTR PUMPS switch on the P5 overhead panel to the ON position.
22. Make sure that the Right Center Tank low pressure light illuminates momentarily, and then
extinguishes.
23. Get access to the secondary relay R963 installed in the Electronic Bay underneath the floor panel
at the P92 power distribution panel.
24. Measure the voltage between each terminal A1, A2, B1, B2, C1, and C2 of R963 relay, and the
floor structure. Make sure that the voltage measured is 115+/- 10 VAC.
25. Push the R FUEL CTR PUMPS switch on the P5 panel to the OFF position.
26. Measure the voltage between each terminal A1, A2, B1, B2, C1, and C2 of the R963 relay, and
the floor structure. Make sure that the voltage measured is less than 10 VAC.
27. Measure the resistance between each terminals pair: A1 and A2, B1 and B2, and C1 and C2 of
the R963 relay terminals. Make sure that the resistance measured between terminals is greater
than 1.0 Meg-Ohm (1,000,000 Ohms).
28. Push the R FUEL CTR PUMPS switch on the P5 panel to the ON position.
29. Make sure that the Center Tank low pressure light illuminates momentarily, and then extinguishes.
30. Push and Hold the Right Auto Shutoff test switch on the P61-8 panel until the Right Center Tank
low pressure light illuminates after approximately 15 seconds, then release the switch.
31. Measure the voltage between each pair: A1, A2, B1, B2, C1, and C2 of the R963 relay, and the
floor structure. Make sure that the voltage measured is less than 10 VAC.
32. Measure the resistance between each terminal pair: A1 and A2, B1 and B2, and C1 and C2. Make
sure that the resistance measured between terminals A1 and A2, B1 and B2, and C1 and C2 is
greater than 1.0 Meg-Ohm (1,000,000 Ohms).
BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
December 21, 2006
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33. Push the R FUEL CTR PUMPS switch of the fuel management control panel on the P5 overhead
panel to the OFF position, then to the ON position. Make sure that the right center tank low pressure
light on the switch illuminates temporarily, and then extinguishes.
34. Push the R FUEL CTR PUMPS switch to the OFF position.
35. Put the airplane back to a serviceable condition.
PART 3- TEST - PUMP REVERSAL FOR LEFT CENTER TANK FUEL BOOST PUMP AND RIGHT
CENTER TANK FUEL BOOST PUMP
1. Make sure there is a minimum fuel quantity of 3,000 pounds (1,364 Kilograms) in the center fuel
tank and no more than 7,000 pounds (3,182 kilograms) of fuel in the left main tank, and no more
than 7,000 pounds (3,182 kilograms) of fuel in the right main tank. There must be an operator in
the flight compartment to monitor the fuel quantity and the low pressure indication in the fuel tank,
so that the pumps do not run dry.
2. Close the circuit breakers shown below if they are not already closed:
Circuit BreakerNamePanel / Location
C1637BOOST PUMP CTR TNK L AUTO SHUT OFF - DCP6-3/C3
C318INDICATOR MASTER DIM SECT 6P6-3/F12
C1659FUEL AT S-O/UCPO BST PMP CTR TNK L ACP6-3/D7
C845FUEL BOOST PUMP CTR TANK LEFTP91/ D6
C1638BOOST PUMP CTR TNK R AUTO SHUT OFF - DCP6-3/C7
C313INDICATOR MASTER DIM SECT 1P6-3/E11
C1658FUEL AT S-O/UCPO BST PMP CTR TNK R ACP6-3/E7
C846FUEL BOOST PUMP CTR TANK RIGHTP92/ D6
C397FUEL QTY 1P6-3/A6
C1441FUEL FUELING INDP6-3/A4
C398FUEL QTY 2P6-3/A5
C1373DISPLAY CTR LOWERP6-1/E12
C1362DISPLAY DEU 2 HOLDUPP6-1/D9
C1360DISPLAY DEU 2 PRIP6-1/D11
C1372DISPLAY CTR UPRP18-2/D2
C1359DISPLAY DEU 1 PRIP18-2/D5
C1361DISPLAY DEU 1 HOLDUPP6-1/D10
3. Make sure that all fuel pump switches on the P5-2 fuel management control panel are initially OFF.
4. Record in Table 1 the present fuel reading as the initial fuel quantity for the center tank quantity
(Ctr Tnk Qty 1).
BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
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5. Do the set-up for Tank-to Tank Fuel Transfer from the center tank to the left main tank with the
left center tank fuel pump as given in 737-600/700/800/900 AMM 28-26-00.
6. Push the L FUEL CTR PUMPS switch on the P5-2 fuel panel to ON position for a period of two
minutes.
7. After the two minutes, push the L FUEL CTR PUMPS switch on the P5-2 fuel panel to OFF position.
8. Record in Table 1 the final center tank fuel quantity as center tank quantity (Ctr Tnk Qty 2).
9. Calculate in Table 1 the amount of fuel that was transferred from the center tank to the left main
tank (the difference equal to [(Ctr Tnk Qty 1) minus (Ctr Tnk Qty 2)].
10. Make sure that the difference is more than, or equal to 400 pounds (182 kilograms). If the difference
is less than 400 pounds, check the phase relationship of the wiring to R962 relay.
TABLE 1
CTR TNK QTY TRANSFERED = (CTR TNK QTY 1 -
CTR TNK QTY 2)
CTR TNK QTY 2 -
Center Tank Fuel
Quantity - Final
Reading
CTR TNK QTY 1 -
Center Tank Fuel
Quantity - Initial
Reading SMALLER THAN 400POUNDS (182
kILOGRAMS)
LARGER THAN OR
EQUAL TO 400 POUNDS
(182 kILOGRAMS)
.
11. Record in Table 2 the present fuel reading as the initial fuel quantity for the center tank quantity
(Ctr Tnk Qty 3).
12. Do the set-up for Tank to Tank Fuel Transfer from the center tank to the right main tank with the
right center fuel pump as given in 737-600/700/800/900 AMM 28-26-00.
13. Push the R FUEL CTR PUMPS switch on the P5-2 fuel panel to ON position for a period of two
minutes.
14. After the two minutes, push the R FUEL CTR PUMPS switch on the P5-2 fuel panel to OFF position.
15. Record in Table 2 the final center tank fuel quantity as center tank quantity (Ctr Tnk Qty 4).
16. Calculate in Table 2 the amount of fuel that was transferred from the center tank to the right main
tank (the difference equal to [(Ctr Tnk Qty 3) minus (Ctr Tnk Qty 4)].
17. Make sure that the difference is more than, or equal to, 400 pounds (182 kilograms). If the difference
is less than 400 pounds, check the phase relationship of the wiring to R963 relay.
BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
December 21, 2006
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TABLE 2
CTR TNK QTY TRANSFERED = (CTR TNK QTY 3 -
CTR TNK QTY 4)
CTR TNK QTY 4 -
Center Tank Fuel
Quantity - Final
Reading
CTR TNK QTY 3 -
Center Tank Fuel
Quantity - Present
Reading SMALLER THAN 400POUNDS (182
kILOGRAMS)
LARGER THAN OR
EQUAL TO 400 POUNDS
(182 kILOGRAMS)
.
18. Put the airplane back to a serviceable condition.
BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
December 21, 2006
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### Page 44 (OCR)

BOEING SERVICE BULLETIN 737-28A1248
ALERT  ALERT
E2 ELECTRONICS SHELF
00
E4 ELECTRONICS SHELF
STA
400
• R962
RELAY
PANEL
- BL
PANEL
•R963
RELAY
TYPICAL FLOOR STRUCTURE
(SOME AIRPLANES HAVE DIFFERENT  U78148
FLOOR STRUCTURE)
FIGURE 1: R962, R963 RELAY INSTALLATION
(SHEET 1 OF 7)
December 21, 2006
Revision 2 August 28, 2009  737-28A1248
BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.  44 of 112

### Page 45 (OCR)

BOEING SERVICE BULLETIN 737-28A1248
ALERT  ALERT
STA
360.91  20) MARKER
BRACKET
208
WL
165.62  2.65
O
RELAY 17)18  R963
9.86
→FWD
A-A
LBL
34.92
-2.73-  19) MARKER
WL
165.62
BRACKET
409  > INBD  (18) R962  RELAY
B-B  U78650
FIGURE 1: R962, R963 RELAY INSTALLATION
(SHEET 2 OF 7)
December 21, 2006
Revision 2 August 28, 2009  737-28A1248
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### Page 46 (OCR)

BOEING SERVICE BULLETIN 737-28A1248
ALERT  ALERT
1213 14 1516  0.84
0.68
INBD
C-C
→1.30
12 13 14 15 16
0.985
FWDE
INBD
D-D
•NUT
WASHERS
JUMPER
BOLT
TYPICAL  U81111
FIGURE 1: R962, R963 RELAY INSTALLATION
(SHEET 3 OF 7)
December 21, 2006
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### Page 47

The step numbers shown below agree with the numbers shown in the circle symbols in the figure. The QTY
numbers shown below are the number of parts necessary for this figure.
NOTE: This figure shows a typical floor structure between STA 355 and STA 371. On some airplanes the floor
support structure is different inboard of R962 Relay location. The dimensions given in this figure for
the installation of R962 and R963 Relays are applicable for all airplanes and are not affected by the
various floor structure inboard of R962 Relay location.
MORE DATAQTYIDENTIFICATIONNAMETASKSTEP
Refer to 737-600 SRM 53-10-54,
737-700 SRM 53-10-54,
737-700CONV SRM 53-10-54,
737-800 SRM 53-10-54, 737-900
SRM 53-10-54and
737-600/700/800/900 AMM
25-52-10 as accepted procedures.
284A6813-( ) LH
286A6813-( ) RH
PanelRemove1
1284A3839-66BracketPut/Hold2
for 5/32 inch diameter universal
head rivets as given in 737-600
SRM 51-40-05, 737-700 SRM
51-40-05, 737-700CONV SRM
51-40-05, 737-800 SRM 51-40-05
or 737-900 SRM 51-40-05.
3-HolesDrill3
1284A3839-66BracketPut/Hold4
for 5/32 inch diameter universal
head rivets as given in 737-600
SRM 51-40-05, 737-700 SRM
51-40-05, 737-700CONV SRM
51-40-05, 737-800 SRM 51-40-05
or 737-900 SRM 51-40-05.
3-HolesDrill5
from the floor support structure.2284A3839-66BracketRemove6
in the brackets and floor support
structure.
12-HolesDeburr7
Refer to 737-600 SRM 51-40-02,
737-700 SRM 51-40-02,
737-700CONV SRM 51-40-02,
737-800 SRM 51-40-02 or 737-900
SRM 51-40-02 as an accepted
procedure for fastener installation
data.(a) (b) (d)
1284A3839-66BracketInstall8
3BACR15BB5AD6CRivet
-BMS 5-95, Class BSealant
FIGURE 1: R962, R963 RELAY INSTALLATION
(SHEET 4 OF 7)
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ALERTALERT

### Page 48

MORE DATAQTYIDENTIFICATIONNAMETASKSTEP
Refer to 737-600 SRM 51-40-02,
737-700 SRM 51-40-02,
737-700CONV SRM 51-40-02,
737-800 SRM 51-40-02 or 737-900
SRM 51-40-02 as an accepted
procedure for fastener installation
data.(a) (b) (d)
1284A3839-66BracketInstall9
3BACR15BB5AD5CRivet
-BMS 5-95, Class BSealant
Between bracket and the floor
support structure as given in
APPENDIX B, section 4.B.
Maximum resistance permitted
between the bracket and the floor
support structure is 0.0005 Ohm
(0.5 milliohms).
--ResistanceMeasure10
Between bracket and the floor
support structure as given in
APPENDIX B, section 4.B.
Maximum resistance permitted
between the bracket and the floor
support structure is 0.0005 Ohm
(0.5 milliohms).
--ResistanceMeasure11
as given in 737-600 SRM 51-40-05,
737-700 SRM 51-40-05,
737-700CONV SRM 51-40-05,
737-800 SRM 51-40-05 or 737-900
SRM 51-40-05.
20.218-0.229 InchHolesDrill12
2-HolesDeburr13
as given in SOPM 20-11-03. (c) (e)
(f)
1BACJ40A20-4Bonding JumperInstall14
2BACS12HN3-9Bolt
6NAS1149D0316HWasher
2BACN10YR3CDNut
as given in APPENDIX A Section
5.B., between the Jumper Lug and
the structure adjacent to the lug.
Make sure that the maximum
resistance between the Jumper Lug
and the structure is 0.0005 Ohm
(0.5 milliohms). (g)
ResistanceMeasure15
on the fastener head and mating
component. (h)
-BMS 5-95, Class B
or BMS 5-142, Class
B
SealantApply16
FIGURE 1: R962, R963 RELAY INSTALLATION
(SHEET 5 OF 7)
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December 21, 2006
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BOEING SERVICE BULLETIN 737-28A1248
ALERTALERT

### Page 49

MORE DATAQTYIDENTIFICATIONNAMETASKSTEP
Refer to 737-600 SRM 51-40-02,
737-700 SRM 51-40-02,
737-700CONV SRM 51-40-02,
737-800 SRM 51-40-02 or 737-900
SRM 51-40-02 as an accepted
procedure for fasteners installation.
Install relay R962 such that the
screw heads on terminals are
positioned facing forward and
upward direction. Install relay R963
such that the screws on the
terminals are positioned inboard
and upward direction.
2MS27418-2ARelayInstall17
8BACS12HN08-8Bolt
8NAS1149DN832JWasher
Between the relay and bracket
284A3839-66. Maximum resistance
permitted between the relay and
the bracket is 0.0005 Ohm (0.5
milliohms). (i)
--ResistanceMeasure18
as given in SOPM 20-50-05.1BAC27DEX7194DecalInstall19
as given in SOPM 20-50-05.1BAC27DEX7195DecalInstall20
Refer to 737-600 SRM 53-10-54,
737-700 SRM 53-10-54,
737-700CONV SRM 53-10-54,
737-800 SRM 53-10-54, 737-900
SRM 53-10-54 and
737-600/700/800/900 AMM
25-52-10 as accepted procedures.
284A6813-( ) LH
286A6813-( ) RH
PanelInstall21
(a) Apply a corrosion protection faying surface seal with BMS 5-95, between brackets and the floor support
structure.
(b) Prepare the rivet holes as given in APPENDIX B for electrically driven bond rivets.
(c) Install the fasteners wet with sealant as given in SOPM 20-50-19, Corrosion Protection Sealing, Method
2.
(d) Fillet seal the manufactured head and the hand driven head of the rivet as given in SOPM 20-50-19,
Corrosion Protection Sealing, Paragraph 15.D.(2), Method 3.
(e) In general use solvent clean (CM3) First, as given in SOPM 20-11-03. But if there is paint or finish over
the metal, you may need to use abrasive clean by hand (CM1) procedure. Also, if you can not get
necessary electrical conductivity after using the solvent clean procedure, then you can use the abrasive
clean by hand procedure. Be careful when you use the abrasive clean by hand procedure that you do
not make the surface uneven.
(f) Install the nut on the same side as the terminal on the bonding jumper.
(g) If the maximum resistance of 0.0005 Ohm (0.5 milliohms) is exceeded, disassemble the bonding jumper.
Clean the bonding surfaces again. Reassemble the bonding jumper. Repeat resistance measurement.
FIGURE 1: R962, R963 RELAY INSTALLATION
(SHEET 6 OF 7)
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December 21, 2006
737-28A1248Revision 2 August 28, 2009
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BOEING SERVICE BULLETIN 737-28A1248
ALERTALERT

### Page 50

MORE DATAQTYIDENTIFICATIONNAMETASKSTEP
(h) Seal the electrical installation as given in SOPM 20-50-19, Electrical Sealing, Paragraph 16.B. and
FIGURE 15 (sealing ground studs).
(i) If the maximum resistance of 0.0005 Ohm (0.5 milliohms) is exceeded, disassemble the relay. Clean the
bonding surfaces with solvent (CM3) as given in SOPM 20-11-03. Do again Step 16 and 17.
FIGURE 1: R962, R963 RELAY INSTALLATION
(SHEET 7 OF 7)
BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
December 21, 2006
737-28A1248Revision 2 August 28, 2009
50 of 112
BOEING SERVICE BULLETIN 737-28A1248
ALERTALERT

### Page 51 (OCR)

BOEING SERVICE BULLETIN 737-28A1248
ALERT  ALERT
W2218
• W2218
FWD
P5-2 FUEL
D628
CONTROL PANEL
FIGURE 2: W2218 WIRE BUNDLE ROUTING
(SHEET 1 OF 5)
December 21, 2006
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### Page 52 (OCR)

BOEING SERVICE BULLETIN 737-28A1248
ALERT  ALERT
STA
260
W2218
STA
260
W2218
GD264-AC
GROUND BLOCK
FWD  U72319
FIGURE 2: W2218 WIRE BUNDLE ROUTING
(SHEET 2 OF 5)
December 21, 2006
Revision 2 August 28, 2009  737-28A1248
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### Page 53 (OCR)

BOEING SERVICE BULLETIN 737-28A1248
ALERT  ALERT
STA
277
W2218
FWD
U78673
FIGURE 2: W2218 WIRE BUNDLE ROUTING
(SHEET 3 OF 5)
December 21, 2006
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### Page 54 (OCR)

BOEING SERVICE BULLETIN 737-28A1248
ALERT  ALERT
W2218
STA
294.5
STA  W2218
420
→ FWD
RIGHT SIDE FLOOR BEAMS  U78674
STA 294.5 - STA 420
FIGURE 2: W2218 WIRE BUNDLE ROUTING
(SHEET 4 OF 5)
December 21, 2006
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### Page 55 (OCR)

BOEING SERVICE BULLETIN 737-28A1248
ALERT  ALERT
W2218
D40540P
POS 32
E4-2 ELECTRONICS SHELF
> FWD  U78675
E4 ELECTRONICS RACK
FIGURE 2: W2218 WIRE BUNDLE ROUTING
(SHEET 5 OF 5)
December 21, 2006
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### Page 56 (OCR)

BOEING SERVICE BULLETIN 737-28A1248
ALERT  ALERT
- W2112
W2112
FWD
P5-2 FUEL
D626
CONTROL PANEL
FIGURE 3: W2112 WIRE BUNDLE ROUTING
(SHEET 1 OF 5)
December 21, 2006
Revision 2 August 28, 2009  737-28A1248
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### Page 57 (OCR)

BOEING SERVICE BULLETIN 737-28A1248
ALERT  ALERT
S-SR
STA
260
W2112
W2112
GD261-AC
GROUND BLOCK
→ FWD  U78683
FIGURE 3: W2112 WIRE BUNDLE ROUTING
(SHEET 2 OF 5)
December 21, 2006
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### Page 58 (OCR)

BOEING SERVICE BULLETIN 737-28A1248
ALERT  ALERT
STA
277
STA  W2112
294
> FWD
FIGURE 3: W2112 WIRE BUNDLE ROUTING
(SHEET 3 OF 5)
December 21, 2006
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### Page 59 (OCR)

BOEING SERVICE BULLETIN 737-28A1248
ALERT  ALERT
LBL
/ 55
STA
295.5
STA
312
W2112
• STA
360
W2112
STA
400
IND FWD  U79012
FIGURE 3: W2112 WIRE BUNDLE ROUTING
(SHEET 4 OF 5)
December 21, 2006
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### Page 60 (OCR)

BOEING SERVICE BULLETIN 737-28A1248
ALERT  ALERT
AE0201A DISCONNECT PANEL
(E2-1 ELECTRONICS SHELF)
D40598P
POS 10
FUD INED
W2112
U79017
FIGURE 3: W2112 WIRE BUNDLE ROUTING
(SHEET 5 OF 5)
December 21, 2006
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