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Commercial Airplanes 777 Service Bulletin Number: 777-28A0037 Original Issue: June 13, 2008 Revision 2: September 20, 2010 ATA System: 2831 2822 SUBJECT: FUEL - Fuel Jettison System - Center Tank Override/Jettison Pumps and Main Tank Jettison Pump Ground Fault Protection and Uncommanded On Protection Change 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BOEING PROPRIETARY, CONFIDENTIAL, AND/OR TRADE SECRET Copyright © 2008 The Boeing Company Unpublished Work - All Rights Reserved Boeing claims copyright in each page of this document only to the extent that the page contains copyrightable subject matter.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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4.0
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Original Issue: June 13, 2008 777-28A0037Revision 2: September 20, 2010 2 of 110 BOEING SERVICE BULLETIN 777-28A0037
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Table of Contents
Revision Transmittal Sheet5
Summary9
1. PLANNING INFORMATION ........................................ 1 3 A. Effectivity ............................................... 1 3
1. Airplanes ............................................ 1 3
2. Spares Affected ........................................ 1 5 B. Concurrent Requirements ...................................... 1 5 C. Reason ................................................ 1 6 D. Description .............................................. 1 8 E. Compliance .............................................. 1 9 F. Approval ............................................... 1 9 G. Manpower .............................................. 1 9 H. Weight and Balance Changes .................................... 2 1 I. Electrical Load Data ......................................... 2 1 J. References .............................................. 2 2
1. Existing Data: ......................................... 2 2
2. Data supplied with this Service Bulletin: ........................... 2 2
3. Installation Drawings Used in the Preparation of this Service Bulletin: ........... 2 2 K. Publications Affected ........................................ 2 2 L. Interchangeability and Intermixability of Parts ........................... 2 3
2. MATERIAL INFORMATION ........................................ 2 5 A. Material - Price and Availability ................................... 2 5 B. Industry Support Information .................................... 2 6 C. Parts Necessary For Each Airplane ................................. 2 7
1. Kits/Parts: ........................................... 2 7
2. Parts and Materials Supplied by the Operator: ........................ 3 4
3. Parts Modified and Reidentified: ............................... 3 5
4. Parts Removed and Not Replaced: .............................. 3 5 D. Parts Necessary to Change Spares ................................. 3 5 E. Special Tooling - Price and Availability ............................... 3 5 F. Special Tooling Necessary to do this Service Bulletin ....................... 3 5
3. ACCOMPLISHMENT INSTRUCTIONS .................................. 3 7 A. GENERAL INFORMATION ..................................... 3 7 B. WORK INSTRUCTIONS ....................................... 3 8 FIGURE 1: P301 PANEL INSTALLATION [Group 1-2, Configuration 2] ................. 5 4 FIGURE 2: P302 RELAY PANEL ASSEMBLY INSTALLATION [Group 1-2, Configuration 2] ..... 5 9 FIGURE 3: LEFT MAIN TANK JETTISON PUMP WIRING CHANGE [Group 1-2, Configuration 2] . . 64 FIGURE 4: CENTER TANK LEFT OVERRIDE/JETTISON PUMP WIRING CHANGE [Group 1-2, Configuration 2 ] ................................................ 6 9 FIGURE 5: LEFT MAIN TANK JETTISON NOZZLE VALVE WIRING CHANGE [Group 1, Configuration 2] .................................................. 7 2 FIGURE 6: LEFT MAIN TANK JETTISON NOZZLE VALVE WIRING CHANGE [Group 2, Configuration 2] .................................................. 7 5 FIGURE 7: RIGHT MAIN TANK JETTISON PUMP WIRING CHANGE [Group 1-2, Configuration 2] . 78 FIGURE 8: CENTER TANK RIGHT OVERRIDE/JETTISON PUMP WIRING CHANGE [Group 1-2, Configuration 2] ......................................... 8 1
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FIGURE 9: RIGHT MAIN TANK JETTISON NOZZLE VALVE WIRING CHANGE [Group 1-2, Configuration 2 ] ................................................ 8 4 FIGURE 10: DEFUEL VALVE WIRING CHANGE [Group 1-2, Configuration 2] .............. 8 6 FIGURE 11: WIRING INSTALLATION [Group 1-2, Configuration 2] .................... 8 7 FIGURE 12: P301 RELAY INSTALLATION [Group 1-2, Configuration 2] ................ 1 0 0 FIGURE 13: P302 PANEL RELAY INSTALLATION [Group 1-2, Configuration 2] ............ 1 0 3 FIGURE 14: P110 AND P210 PANEL CHANGE [Group 1-2, Configuration 2] .............. 1 0 6 FIGURE 15: P301 PANEL - MORE WORK - BOND RESISTANCE MEASUREMENT [Group 1-2, Configuration 1 ] ................................................ 1 0 7 FIGURE 16: P302 PANEL - MORE WORK - BOND RESISTANCE MEASUREMENT [Group 1-2, Configuration 1 ] ................................................ 1 0 9
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Commercial Airplanes 777 Service Bulletin Revision Transmittal SheetNumber: 777-28A0037Original Issue: June 13, 2008 Revision 2: September 20, 2010 ATA System: 2831 2822 SUBJECT: FUEL - Fuel Jettison System - Center Tank Override/Jettison Pumps and Main Tank Jettison Pump Ground Fault Protection and Uncommanded On Protection Change 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 or Revision 1 of this service bulletin. The resistance of the bond between each ground wire terminal lug on the ground studs GD41253-DC, GD41254-DC and the ground bracket assembly must be measured to make sure the resistance is not more than 0.001 ohm.
REASON FOR REVISION This revision is sent to correct discrepancies and typographical errors found in this service bulletin. Also, a new top kit has been added for Group 2 airplanes. The Group 2 top kit 005W3256-3 contains the same parts as the Group 1 top kit 005W3256-2.
Terminology has been changed in the Work Instructions to agree with the terminology defined in Paragraph
3.A., General Information - Notes.
These sections were changed:
1. In Summary, Action and Paragraph 1.D., Description, added the more work necessary data.
2. In Paragraph 1.C., Reason, added Information Notice data.
3. In Paragraph 1.D., Description, added Affected Maintenance Zones tables.
4. In Paragraph 1.G., Manpower, added manpower table for more work necessary.
5. In Paragraph 1.H., Weight and Balance Changes, changed weight and balance data.
6. In Paragraph 1.j.1., Existing Data, added Standard Wiring Practices Manual (SWPM) references.
7. In Paragraph 2.A., Material - Price and Availability, added top kit pricing data.
8. In Paragraph 2.C., Parts Necessary for Each Airplane:
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Original Issue: June 13, 2008 777-28A0037Revision 2: September 20, 2010 5 of 110
a. Added Group 2 top kit 005W3256-3.
b. Top kit 005W3256-2, added optional retainer part numbers.
c. Top kit 005W3256-2, added screw, cap part number.
d. Sub kit 280W3256-113, changed terminal, lug part number.
e. Sub kit 280W3256-118, added optional contact part numbers.
9. In Paragraph 3.B., Work Instructions:
a. Steps 17.a.(4).(a).1), 17.a.(4).(a).2), 17.a.(4).(b) and 17.a.(11).(b), changed fuel quantity data.
b. Steps 17.b.(10).(b), 17.b.(13).(b), 17.b.(17).(c).2), 17.c.(4).(d).5.a).{2} and 17.c.(5).(h).1).b), changed voltage data.
c. Steps 17.b.(14).(f).2) and 17.b.(15).(b), changed fuel jettison switch name.
d. Step 17.b.(19), added Engine Indication and Crew Alerting System (EICAS) status message data.
e. Step 17.c.(5).(k).9), changed center pumps switch name.
f. Step 17.c.(5).(t), changed Fuel Management maintenance page data.
g. Added steps to do the more work necessary.
10. In Figure 1:
a. Sheet 2 and step table, removed steps 15 and 16.
b. Step table, steps 8 and 9, added optional retainer part numbers.
11. In Figure 2:
a. Sheet 1, changed incorrect location of panel P302 and stringer references.
b. Sheet 2 and step table, removed steps 15 and 16.
c. Sheet 3, changed incorrect stringer reference.
d. Step table, steps 8 and 9, added optional retainer part numbers and a note.
12. In Figure 3, sheet 1, changed incorrect wire identification number.
13. In Figure 4:
a. Sheet 1, changed incorrect flag note reference.
b. Flag note table, flag notes 3 and 4, changed contact quantity.
14. In Figure 5:
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a. Sheet 1, changed flag note 2 data.
b. Sheet 1 and flag note table, added flag note 11.
c. Flag note table, flag note 2, changed contact quantity.
15. In Figure 11:
a. Sheet 1, added wire bundle data.
b. Sheets 3 and 7, added circle notes 14 thru 16.
c. Step table, steps 3, 6 and 13, added a note.
d. Step table, added steps 14 thru 16.
e. Extra parts table, added screw, cap BACS12GU3K70 and a note.
16. In Figures 3 thru 10, added SWPM references.
17. Added new Figures 15 and 16 to do bond resistance measurements.
The data given in Information Notice 777-28A0037 IN02 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 June 13, 2008Original Issue:
June 15, 2009Revision 1:
September 20, 2010Revision 2:
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Commercial Airplanes 777 Service Bulletin SummaryNumber: 777-28A0037Original Issue: June 13, 2008 Revision 2: September 20, 2010 ATA System: 2831 2822 SUBJECT: FUEL - Fuel Jettison System - Center Tank Override/Jettison Pumps and Main Tank Jettison Pump Ground Fault Protection and Uncommanded On Protection Change
CONCURRENT REQUIREMENTS Refer to Paragraph 1.B., Concurrent Requirements.
BACKGROUND This service bulletin will add an extra layer of protection to prevent possible sources of ignition in a fuel tank caused by electrical faults or uncommanded dry operation of the center tank override/jettison pumps or main tank jettison pumps. An ignition source in the fuel tank could result in a fire or an explosion.
This service bulletin is the result of the safety assessments conducted by Boeing under Special Federal Aviation Regulation 88 (SFAR 88), "Fuel Tank System Fault Tolerance Evaluation Requirements". The safety assessments indicate that wiring deterioration or damage in the center tank override/jettison pumps or main tank jettison pumps can result in electrical faults. Internal electrical faults in the center tank override/jettison pumps or main tank jettison pumps could cause an ignition source in the fuel tank from an overheat condition or electrical arcs.
There is also a safety concern that these pumps may continue to operate dry for an extended period of time due to electrical faults or a single failure in the pump switch or the Electrical Load Control Unit (ELCU). The extended dry operation of the pump could cause an overheat, electrical arcs or frictional sparks in the fuel tank.
This service bulletin provides instructions to modify the pump control circuit to include new Ground Fault Interrupt (GFI) relays between the pumps and their ELCU. New GFI relays provide ground fault protection and changes in the control circuit and ELMS software provide the necessary redundancy that allows the system to remove the power to prevent uncommanded operation of the pump.
This change affected Section 9 of the Maintenance Planning Data (MPD) Document. New Airworthiness Limitation (AWL) 28-AWL-18 will be added to Section 9 of the MPD to include the GFI operational check of the center tank override/jettison pumps and main tank jettison pumps.
ACTION (PRR 61998-1) Group 1-2, Configuration 2:
Install the new P301 panel on the left side frame in the main equipment center. Install the new P302 panel on the right side frame in the main equipment center. Do a wiring change. Install new GFI relays in P301 and P302 panels. Install new ELMS software in accordance with Boeing Service Bulletin 777-28A0039. Do the functional test.
Group 1-2, Configuration 1:
More work is necessary. Get access to the main equipment center. Measure the resistance of the bond between each terminal lug on the ground studs GD41253-DC, GD41254-DC and the ground bracket assembly.
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Original Issue: June 13, 2008 777-28A0037Revision 2: September 20, 2010 9 of 110
EFFECTIVITY 777-200, 777-300 Airplanes. Refer to Paragraph 1.A.1 Airplanes, for the list of affected airplanes.
COMPLIANCE The Federal Aviation Administration (FAA) will possibly release an Airworthiness Directive related to this service bulletin. The Airworthiness Directive will make the compliance tasks and times given in this service bulletin mandatory.
Boeing recommends that the change given in this service bulletin be done within 36 months after the original issue date of this service bulletin.
INDUSTRY SUPPORT INFORMATION Boeing warranty remedies are not available for the configuration changes given in this service bulletin.
MANPOWER Group 1-2, Configuration 2:
Elapsed HoursTotal Task HoursAirplanes
45.5064.00All Group 1-2, Configuration 2:
The time to make the change to the ELMS panels in accordance with the GE Aviation service bulletins is not included.
Group 1-2, Configuration 1:
Elapsed HoursTotal Task HoursAirplanes
1.101.10More Work
MATERIAL INFORMATION Boeing Supplied Kits/Parts.
Refer to Paragraph 2.A., Material - Price and Availability.
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Original Issue: June 13, 2008 777-28A0037Revision 2: September 20, 2010 10 of 110 BOEING SERVICE BULLETIN 777-28A0037
BOEING SERVICE BULLETIN 777-28A0037
MAKE A WIRING CHANGE IN THE P210 PANEL AS
GIVEN IN THE GE
AVIATION SERVICE MAKE A WIRING
BULLETIN CHANGE
MAKE A WIRING CHANGE IN THE P110 PANEL AS P200
GIVEN IN THE GE
INSTALL NEW AVIATION SERVICE P302 PANEL BULLETIN
AND RELAYS AE0232
MAKE A WIRING
CHANGE IN THE P205 PANEL AE0231 P100 MAKE A WIRING INSTALL NEW P301
CHANGE IN THE PANEL AND RELAYS P105 PANEL MAIN EQUIPMENT CENTER 1327972 Original Issue: June 13, 2008 Revision 2: September 20, 2010 777-28A0037
BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 11 of 110
BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: June 13, 2008 777-28A0037Revision 2: September 20, 2010 12 of 110 BOEING SERVICE BULLETIN 777-28A0037