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Commercial Airplanes 757 Service Bulletin Number: 757-28A0079 Original Issue: July 16, 2008 Revision 1: August 24, 2010 ATA System: 2822 SUBJECT: FUEL - Engine Fuel Feed System - Fuel Pump Control Ground Fault Interrupter (GFI) Relay 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BOEING PROPRIETARY, CONFIDENTIAL, AND/OR TRADE SECRET Copyright © 2008 The Boeing Company Unpublished Work - All Rights Reserved Boeing claims copyright in each page of this document only to the extent that the page contains copyrightable subject matter. Boeing also claims copyright in this document as a compilation and/or collective work.
This document includes proprietary information owned by The Boeing Company and/or one or more third parties.
Treatment of the document and the information it contains is governed by contract with Boeing. For more information, contact The Boeing Company, P.O. Box 3707, Seattle, Washington 98124.
Boeing, the Boeing signature, the Boeing symbol, 707, 717, 727, 737, 747, 757, 767, 777, 787, Dreamliner, BBJ, DC-8, DC-9, DC-10, KC-10, KDC-10, MD-10, MD-11, MD-80, MD-88, MD-90, P-8A, Poseidon and the Boeing livery are all trademarks owned by The Boeing Company; and no trademark license is granted in connection with this document unless provided in writing by Boeing.
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Original Issue: July 16, 2008 757-28A0079Revision 1: August 24, 2010 1 of 43
4.0
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Original Issue: July 16, 2008 757-28A0079Revision 1: August 24, 2010 2 of 43 BOEING SERVICE BULLETIN 757-28A0079
BLANK PAGE
Table of Contents
Revision Transmittal Sheet5
Summary7
1. PLANNING INFORMATION9
A. Effectivity9
1. Airplanes9
2. Spares Affected ........................................ 1 0 B. Concurrent Requirements ...................................... 1 0 C. Reason ................................................ 1 0 D. Description .............................................. 1 1 E. Compliance .............................................. 1 1 F. Approval ............................................... 1 1 G. Manpower .............................................. 1 2 H. Weight and Balance Changes .................................... 1 2 I. Electrical Load Data ......................................... 1 2 J. References .............................................. 1 3
1. Existing Data: ......................................... 1 3
2. Data supplied with this Service Bulletin: ........................... 1 3
3. Installation Drawings Used in the Preparation of this Service Bulletin: ........... 1 3 K. Publications Affected ........................................ 1 3 L. Interchangeability and Intermixability of Parts ........................... 1 4
2. MATERIAL INFORMATION ........................................ 1 5 A. Material - Price and Availability ................................... 1 5 B. Industry Support Information .................................... 1 5 C. Parts Necessary For Each Airplane ................................. 1 5
1. Kits/Parts: ........................................... 1 5
2. Parts and Materials Supplied by the Operator: ........................ 1 5
3. Parts Modified and Reidentified: ............................... 1 5
4. Parts Removed and Not Replaced: .............................. 1 5 D. Parts Necessary to Change Spares ................................. 1 5 E. Special Tooling - Price and Availability ............................... 1 5 F. Special Tooling Necessary to do this Service Bulletin ....................... 1 6
3. ACCOMPLISHMENT INSTRUCTIONS .................................. 1 7 A. GENERAL INFORMATION ..................................... 1 7 B. WORK INSTRUCTIONS ....................................... 1 8 FIGURE 1: P33 PANEL PLATE 'C' - RELAY REPLACEMENT ...................... 3 5 FIGURE 2: P37 PANEL PLATE 'B' - RELAY REPLACEMENT ...................... 3 7 FIGURE 3: FUEL BOOST PUMP CONTROL GROUND FAULT INTERRUPTER (GFI) CONTROL RELAY SCHEMATIC REFERENCE .................................. 3 9 FIGURE 4: ELECTRICAL BONDING RESISTANCE CHECK FOR GROUND FAULT INTERRUPTER (GFI) RELAYS, P33 PANEL ..................................... 4 0 FIGURE 5: ELECTRICAL BONDING RESISTANCE CHECK FOR GROUND FAULT INTERRUPTER (GFI) RELAYS, P37 PANEL ..................................... 4 2
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Original Issue: July 16, 2008 757-28A0079Revision 1: August 24, 2010 3 of 43 BOEING SERVICE BULLETIN 757-28A0079
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BLANK PAGE
Commercial Airplanes 757 Service Bulletin Revision Transmittal SheetNumber: 757-28A0079Original Issue: July 16, 2008 Revision 1: August 24, 2010 ATA System: 2822 SUBJECT: FUEL - Engine Fuel Feed System - Fuel Pump Control Ground Fault Interrupter (GFI) Relay Installation This revision includes all pages of the service bulletin.
COMPLIANCE INFORMATION RELATED TO THIS REVISION More work is necessary on airplanes changed in accordance with the original issue of this service bulletin. Do a General Visual Inspection of the installation screws for the GFI relays K187, K10011, K190, on Plate C of the P33 Panel and the installation screws for the GFI relays K188, K189, K10012, on Plate B of the P37 Panel to ensure the necessary grip length screw was used. More work is necessary to measure the electrical bonding resistance between the GFI Relays and the P33 Panel, Plate C, and to measure the electrical bonding resistance between the GFI Relays and the P37 Panel, Plate B.
REASON FOR REVISION This Revision 1 is sent to tell operators that the screws used to install the relays in FIGURE 1 have been changed from NAS1801-08-5 to NAS1801-08-7. Substitution information for the installation screws was added to FIGURE
2. This revision also provides a new electrical bonding resistance check of the GFI relays installed on the P33 and the P37 Panels.
These sections were changed:
1. Revised Paragraph 1.C., Reason to add the reason for Revision 01.
2. Revised Paragraph 1.D., Description to add 'More work is necessary' note and the maintenance zones table.
3. Revised Paragraph 1.J., References to add 757-300 SRM 51-40-02, 757-300 SRM 51-40-03, and added a table for installation drawings used in Paragraph 1.J.3.
4. Revised Paragraph 1.K., Publications Affected to add the Damage Tolerance Inspection note.
5. Revised Paragraph 3.A., General Information to add general notes for fastener installation and substitution.
6. Revised Paragraph 3.B., Work Instructions to add the existing work instructions to a new PART 1 and added new paragraphs 3.B.7 and 3.B.8. Added new PART 2.
7. Revised FIGURE 1 step table to add the correct the fasteners for the relay installation, and new sub-steps were added.
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8. Revised FIGURE 2 step table to add optional fastener information. New sub-steps were added.
9. Added FIGURE 4 to provide instructions for measuring the electrical bonding resistance between the GFI relays K187, K10011, K190, and the P33 Panel, Plate C.
10. Added FIGURE 5 to provide instructions for measuring the electrical bonding resistance between the GFI relays K188, K189, K10012, and the P37 Panel, Plate B.
The data given in Information Notice 757-28A0079 R00 IN01 is included in this revision.
Vertical lines are put on the left edge of each page, except in Paragraph 1.A., Effectivity, to show the location of important changes.
Pages with no vertical lines have no important changes.
REVISION HISTORY July 16, 2008Original Issue:
August 24, 2010Revision 1:
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Original Issue: July 16, 2008 757-28A0079Revision 1: August 24, 2010 6 of 43 BOEING SERVICE BULLETIN 757-28A0079
Commercial Airplanes 757 Service Bulletin SummaryNumber: 757-28A0079Original Issue: July 16, 2008 Revision 1: August 24, 2010 ATA System: 2822 SUBJECT: FUEL - Engine Fuel Feed System - Fuel Pump Control Ground Fault Interrupter (GFI) Relay Installation
CONCURRENT REQUIREMENTS None.
BACKGROUND This service bulletin gives the instructions to replace the power control relays for the fuel boost pumps and override pumps. The relays are located in the P33 and P37 equipment panels in the main equipment center.
The new relays include a ground fault interrupt (GFI) feature. The GFI feature will protect the fuel pumps from damage caused by electrical arcing. Electrical arcing could create a possible source of ignition of flammable fuel vapors in the fuel tanks. Ignition of flammable fuel vapors could cause a fire or explosion which could put the airplane in an unsafe condition.
This service bulletin is the result of the safety assessments conducted by Boeing under SFAR 88, "Fuel Tank System Fault Tolerance Evaluation Requirements".
This change affects section 9 of the Maintenance Planning Data (MPD) Document. New Airworthiness Limitations (AWL) "28-AWL-21" will be added to section 9 of the MPD to include a functional check of the ground fault interrupt (GFI) relays for the fuel boost pumps and override pumps.
The related 757-200 airplane service bulletin number is 757-28A0078.
ACTION (PRR 55000-10RS) Get access to the main equipment center. At the P33 and P37 panels, replace six relays. Check the electrical bonding resistance between the GFI relays and the P33 Panel, Plate C, and P37 Panel, Plate B. Do an operational test of the fuel boost pumps.
EFFECTIVITY See Service Bulletin Paragraph 1.A.1. for effectivity.
COMPLIANCE Boeing recommends that operators incorporate the changes shown in this service bulletin within 60 months of the date on the service bulletin.
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INDUSTRY SUPPORT INFORMATION Boeing warranty remedies are not available for the configuration changes given in this service bulletin.
MANPOWER Elapsed HoursTotal Task Hours
6.08.0
MATERIAL INFORMATION Operator Supplied Parts/Materials.
Refer to Paragraph 2.A., Material - Price and Availability.
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Original Issue: July 16, 2008 757-28A0079Revision 1: August 24, 2010 8 of 43 BOEING SERVICE BULLETIN 757-28A0079
Commercial Airplanes 757 Service Bulletin Number: 757-28A0079 Original Issue: July 16, 2008 Revision 1: August 24, 2010 ATA System: 2822 SUBJECT: FUEL - Engine Fuel Feed System - Fuel Pump Control Ground Fault Interrupter (GFI) Relay Installation
1. PLANNING INFORMATION A. Effectivity
1. Airplanes Refer to Service Bulletin Index Document D624N001 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 PRR55000-10RS for data about this change.
DESCRIPTIONCONFIGURATIONGROUP 757-300 Airplanes-1 Airplane Models:
757-300 GroupVariable Number 1NL001 - NL002 1NL006 - NL017 1NL101 - NL109 1NL141 1NL601 - NL616 1NU701 - NU705 1NU721 - NU728 1NU731 - NU732
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2. Spares Affected Examine your spares supply for the parts or components identified in Paragraph 2.C., Parts Necessary for Each Airplane. If any parts or components are found, refer to Paragraph 2.C. for the recommended use.
B. Concurrent Requirements None.
C. Reason This service bulletin gives the instructions to replace the power control relays for the fuel boost pumps and override pumps. The relays are located in the P33 and P37 equipment panels in the main equipment center. The new relays include a ground fault interrupt (GFI) feature. The GFI feature will protect the fuel pumps from damage caused by electrical arcing. Electrical arcing could create a possible source of ignition of flammable fuel vapors in the fuel tanks. Ignition of flammable fuel vapors could cause a fire or explosion which could put the airplane in an unsafe condition.
This service bulletin is the result of the safety assessments conducted by Boeing under SFAR 88, "Fuel Tank System Fault Tolerance Evaluation Requirements".
This change affects section 9 of the Maintenance Planning Data (MPD) Document. New Airworthiness Limitations (AWL) "28-AWL-21" will be added to section 9 of the MPD to include a functional check of the ground fault interrupt (GFI) relays for the fuel boost pumps and override pumps.
The related 757-200 airplane service bulletin number is 757-28A0078.
This Revision 01 is sent to tell operators that the screws used to the install the relays in FIGURE 1 have been changed from NAS1801-08-5 to NAS1801-08-7. Substitution information for the installation screws was added to FIGURE 2. This revision also provides a new electrical bonding resistance check of the GFI relays replaced on both the P33 and P37 Panels.
These sections were changed:
1. Revised Paragraph 1.C., Reason to add the reason for Revision 01.
2. Revised Paragraph 1.D., Description to add 'More work is necessary' note and the maintenance zones table.
3. Revised Paragraph 1.J., References to add 757-300 SRM 51-40-02, 757-300 SRM 51-40-03, and added a table for installation drawings used... in Paragraph 1.J.3.
4. Revised Paragraph 1.K., Publications Affected to add the Damage Tolerance Inspection note.
5. Revised Paragraph 3.A., General Information to add general notes for fastener installation and substitution.
6. Revised Paragraph 3.B., Work Instructions to add the existing work instructions to a new PART 1 and new paragraphs 3.B.PART 1.7 and 8. Also added new PART 2.
7. Revised FIGURE 1 step table to add the correct the fasteners for the relay installation. New sub-steps were added.
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Original Issue: July 16, 2008 757-28A0079Revision 1: August 24, 2010 10 of 43 BOEING SERVICE BULLETIN 757-28A0079
8. Revised FIGURE 2 step table to add optional fastener information. New sub-steps were added.
9. Added FIGURE 4 to show where to take electrical bonding resistance check readings for the GFI relays K187, K10011, K190, on the P33 Panel, Plate C.
10. Added FIGURE 5 to show where to take electrical bonding resistance check readings for the GFI relays K188, K189, K10012, on the P37 Panel, Plate B.
The data given in Information Notice 757-28A0079 IN 01 is included in this revision.
D. Description Get access to the main equipment center. At the P33 and P37 panels, replace six relays. Check the electrical bonding resistance of the GFI relays for the P33 and P37 Panels. Do an operational test of the fuel boost pumps.
Revision 1: More work is necessary on airplanes changed in accordance with the original issue of this service bulletin. Do a General Visual Inspection of the installation screws for the GFI relays K187, K10011, K190, on Plate C of the P33 Panel and the installation screws for the GFI relays K188, K189, K10012, on Plate B of the P37 Panel to ensure the necessary grip length screw was used. More work is necessary to measure the electrical bonding resistance between the GFI Relays and the P33 Panel, Plate C and measure the electrical bonding resistance between the GFI Relays and the P37 Panel, Plate B.
The work in this service bulletin is done in the maintenance zone(s) given below.
Affected Maintenance Zones ZoneModel 119757-300 E. Compliance Boeing recommends that operators incorporate the changes shown in this service bulletin within 60 months of the date on the 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.
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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:
— Time to adjust to the workplace — Time to schedule the work — Time to examine the work — Time to cure the materials — Time to make the parts — Time to find the tools.
Elapsed HoursTask-HoursNumber of Persons Task
0.750.751Open Access
2.52.51Change
0.750.751Close Access
2.04.02Test
6.08.0TOTAL FOR EACH AIRPLANE H. Weight and Balance Changes Change in Moment (Pound-Inches) Change in Weight (Pounds) Airplane + 380.0+ 1.6757-300 I. Electrical Load Data
1. Direct Current (DC) Loads None.
2. Alternating Current (AC) Loads BusPhaseVolt-Ampere- Reactive (VARs) WattsAirplanes 115V AC BUS LEFT - SECTION 1C0.52- 0.53757-300 115V AC BUS LEFT - SECTION 3C1.04- 1.06757-300 115V RIGHT AC TRANSFER BUSC0.52- 0.53757-300 115V AC GROUND SERVICE BUSC0.52- 0.53757-300
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