Boeing ASB 777-28A0047: Boeing - Service Bulletin, text

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Commercial Airplanes 777 Service Bulletin Number: 777-28A0047 Original Issue: April 13, 2007 Revision 5: September 20, 2010 ATA System: 2831 SUBJECT: FUEL - Fuel Jettison System - Center Override/Jettison Fuel Pumps and Main Jettison Fuel Pumps - Change to Give Redundant Control of the Pumps Export of this technology is controlled under the United States Export Administration Regulations (EAR) (15 CFR 730-774). An export license may be required before it is used for development, production or use by foreign persons from specific countries. The controller of this data has the individual responsibility to abide by all export laws.

9E991ECCN:

BOEING PROPRIETARY, CONFIDENTIAL, AND/OR TRADE SECRET Copyright © 2007 The Boeing Company Unpublished Work - All Rights Reserved Boeing claims copyright in each page of this document only to the extent that the page contains copyrightable subject matter.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.

Original Issue: April 13, 2007 777-28A0047Revision 5: September 20, 2010 1 of 124

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Original Issue: April 13, 2007 777-28A0047Revision 5: September 20, 2010 2 of 124 BOEING SERVICE BULLETIN 777-28A0047

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Table of Contents

Revision Transmittal Sheet5

Summary7

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

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

2. Spares Affected ........................................ 1 2 B. Concurrent Requirements ...................................... 1 3 C. Reason ................................................ 1 3 D. Description .............................................. 1 4 E. Compliance .............................................. 1 5 F. Approval ............................................... 1 6 G. Manpower .............................................. 1 6 H. Weight and Balance Changes .................................... 1 8 I. Electrical Load Data ......................................... 1 8 J. References .............................................. 2 0

1. Existing Data: ......................................... 2 0

2. Data supplied with this Service Bulletin: ........................... 2 0

3. Installation Drawings Used in the Preparation of this Service Bulletin: ........... 2 0 K. Publications Affected ........................................ 2 1 L. Interchangeability and Intermixability of Parts ........................... 2 1

2. MATERIAL INFORMATION ........................................ 2 3 A. Material - Price and Availability ................................... 2 3 B. Industry Support Information .................................... 2 4 C. Parts Necessary For Each Airplane ................................. 2 4

1. Kits/Parts: ........................................... 2 4

2. Parts and Materials Supplied by the Operator: ........................ 3 1

3. Parts Modified and Reidentified: ............................... 3 1

4. Parts Removed and Not Replaced: .............................. 3 1 D. Parts Necessary to Change Spares ................................. 3 1 E. Special Tooling - Price and Availability ............................... 3 1 F. Special Tooling Necessary to do this Service Bulletin ....................... 3 1

3. ACCOMPLISHMENT INSTRUCTIONS .................................. 3 3 A. GENERAL INFORMATION ..................................... 3 3 B. WORK INSTRUCTIONS ....................................... 3 4 FIGURE 1: MAIN EQUIPMENT CENTER - INSTALLATION OF THE P301 PANEL [Group 1-2, Configuration 2 ] ................................................ 5 1 FIGURE 2: MAIN EQUIPMENT CENTER - INSTALLATION OF THE P302 PANEL [Group 1-2, Configuration 2 ] ................................................ 5 7 FIGURE 3: LEFT JETTISON FUEL PUMP - WIRING CHANGE [Group 1-2, Configuration 2] ..... 6 3 FIGURE 4: CENTER LEFT OVERRIDE FUEL PUMP - WIRING CHANGE [Group 1-2, Configuration 2] . 68 FIGURE 5: LEFT JETTISON NOZZLE VALVE - WIRING CHANGE [Group 1, Configuration 2] .... 7 1 FIGURE 6: LEFT JETTISON NOZZLE VALVE- WIRING CHANGE [Group 2, Configuration 2] .... 7 3 FIGURE 7: MAIN EQUIPMENT CENTER - AIRPLANE WIRE ROUTING [Group 1-2, Configuration 2] . 75 FIGURE 8: LEFT JETTISON NOZZLE VALVE - WIRING CHANGE [Group 1, Configuration 2] .... 9 9 FIGURE 9: LEFT JETTISON NOZZLE VALVE - WIRING CHANGE [Group 2, Configuration 2] . . . 101

Original Issue: April 13, 2007 777-28A0047Revision 5: September 20, 2010 3 of 124 BOEING SERVICE BULLETIN 777-28A0047

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FIGURE 10: MAIN EQUIPMENT CENTER - P301 PANEL - INSTALLATION OF RELAY SOCKETS AND RELAYS [Group 1-2, Configuration 2] ............................ 1 0 3 FIGURE 11: MAIN EQUIPMENT CENTER - P301 PANEL - INSTALLATION OF THE PANEL COVER [Group 1-2, Configuration 2] ..................................... 1 0 5 FIGURE 12: RIGHT FUEL JETTISON PUMP - WIRING CHANGE [Group 1-2, Configuration 2] .... 1 0 7 FIGURE 13: RIGHT JETTISON NOZZLE VALVE - WIRING CHANGE [Group 1-2, Configuration 2] . 110 FIGURE 14: CENTER RIGHT OVERRIDE FUEL PUMP - WIRING CHANGE [Group 1-2, Configuration 2] ................................................. 1 1 2 FIGURE 15: DEFUEL VALVE - WIRING CHANGE [Group 1-2, Configuration 2] ............ 1 1 5 FIGURE 16: RIGHT JETTISON NOZZLE VALVE - WIRING CHANGE [Group 1-2, Configuration 2] . 116 FIGURE 17: MAIN EQUIPMENT CENTER - P302 PANEL - INSTALLATION OF RELAY SOCKETS AND RELAYS [Group 1-2, Configuration 2] ............................ 1 1 7 FIGURE 18: MAIN EQUIPMENT CENTER - P302 PANEL - INSTALLATION OF THE PANEL COVER [Group 1-2, Configuration 2] ..................................... 1 1 9 FIGURE 19: MORE WORK - BOND MEASUREMENT - P301 PANEL [Group 1-2, Configuration 1] . . 121 FIGURE 20: MORE WORK - BOND MEASUREMENT - P302 PANEL [Group 1-2, Configuration 1] . . 123

Original Issue: April 13, 2007 777-28A0047Revision 5: September 20, 2010 4 of 124 BOEING SERVICE BULLETIN 777-28A0047

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Commercial Airplanes 777 Service Bulletin Revision Transmittal SheetNumber: 777-28A0047Original Issue: April 13, 2007 Revision 5: September 20, 2010 ATA System: 2831 SUBJECT: FUEL - Fuel Jettison System - Center Override/Jettison Fuel Pumps and Main Jettison Fuel Pumps - Change to Give Redundant Control of the Pumps This revision includes all pages of the service bulletin.

COMPLIANCE INFORMATION RELATED TO THIS REVISION More work is necessary on airplanes changed as shown in the Original Issue, Revision 1, or Revision 2 of this service bulletin. The resistance of the bond between the terminal lugs on the ground stud GD41243 and the P301 panel structure must be measured to make sure the resistance is not more than 0.001 ohms. Also, the resistance of the bond between the terminal lugs on the ground stud GD41236 and the P302 panel structure must be measured to make sure the resistance is not more than 0.001 ohms No more work is necessary on airplanes changed in accordance with Revision 3, or Revision 4 of this service bulletin.

REASON FOR REVISION This revision is sent to change the functional test for the center right override/jettison fuel pump. An operator reported a difference between the functional test for the center right override/jettison fuel pump and the functional test for the center left override/jettison fuel pump. The functional test for the center right override/jettison fuel pump did not have a step to make sure the power to the center right override/jettison pump goes off approximately 30 seconds after the pump switch is turned to the ON position with the plug DM28203 disconnected. This step in the test is not required to make sure the system is functional, but it is one way to check that the system performs its intended function.

These sections were changed:

1. In Accomplishment Instructions, Paragraph 3.B., changed the functional test for the center right override/jettison fuel pump to make sure the power to the center right override/jettison pump shuts off.

2. In Figure 4, corrected the quantity of contacts for flag note 4 and 5.

The data given in Information Notice 777-28A0047 IN 06 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.

Original Issue: April 13, 2007 777-28A0047Revision 5: September 20, 2010 5 of 124

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REVISION HISTORY April 13, 2007Original Issue:

April 03, 2008Revision 1:

October 09, 2008Revision 2:

June 11, 2009Revision 3:

May 20, 2010Revision 4:

September 20, 2010Revision 5:

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Commercial Airplanes 777 Service Bulletin SummaryNumber: 777-28A0047Original Issue: April 13, 2007 Revision 5: September 20, 2010 ATA System: 2831 SUBJECT: FUEL - Fuel Jettison System - Center Override/Jettison Fuel Pumps and Main Jettison Fuel Pumps - Change to Give Redundant Control of the Pumps

CONCURRENT REQUIREMENTS You cannot make the changes given in this service bulletin unless the changes given in these service bulletins are made:

Service Bulletin 777-28A0040 Original Issue or Revision 1. Service Bulletin 777-28A0040 gives procedures to install Electrical Load Management System (ELMS) software changes for redundant control of the jettison fuel pumps.

Boeing service bulletin 777-31-0097 Original Issue, Revision 1, Revision 2, or Revision 3. Service bulletin 777-31-0097 gives the procedures to install necessary software changes for the Airplane Information Management System (AIMS) to give status messages to Engine Indicating and Crew Alerting (EICAS) that relate to the fuel pumps.

GE Aviation service bulletin 5000ELM-28-456 Revision 1. Service bulletin 5000ELM-28-456 gives the procedure to make wiring changes to the P110 panel for the redundant control of the left center override/jettison fuel pump by the jettison nozzle valve switch.

GE Aviation service bulletin 6000ELM-28-457 Revision 1. Service bulletin 6000ELM-28-457 gives the procedure to make wiring changes to the P210 panel for the redundant control of the right center override/jettison fuel pump by the jettison nozzle valve switch.

BACKGROUND Accomplishment of the changes in this service bulletin will help prevent an ignition source in a fuel tank as a result of a center override/jettison fuel pump or a main jettison fuel pump that continues to run after it has been commanded OFF. An ignition source in a fuel tank could result in a fire or an explosion.

A safety assessment conducted by Boeing indicates that there is a small risk of an ignition source in a fuel tank if a center override/jettison fuel pump or a main jettison fuel pump continues to run for an extended time after fuel level goes below the pump inlet. Normally the pump is commanded OFF when a low fuel pressure is indicated. If a single failure in the pump control circuitry occurs, a pump can continue to run after it is commanded OFF. When a pump runs after the fuel level goes below the pump inlet, there is a small risk that the pump can cause an ignition source in the fuel tank from an overheat condition, electrical arcs or frictional sparks.

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This service bulletin gives the instructions to install new relays and contactors in the circuitry for the center override/jettison fuel pumps and the main jettison fuel pumps. The new relays and contactors for the center override/jettison fuel pumps allow ELMS to remove power from these pumps when the inputs to ELMS show that the pumps continue to run after the pumps have been commanded OFF. The new relays for the main jettison fuel pumps give redundant control of these pumps with the jettison nozzle valve switches. These changes help make sure that the risk of an ignition source in a fuel tank is kept to a minimum. The changes are identical to the changes to airplanes in production.

This service bulletin is the result of the safety assessments conducted by Boeing under SFAR 88, "Fuel Tank System Fault Tolerance Evaluation Requirements".

ACTION (PRR 61998-7) Group 1-2, Configuration 2:

Get access to the main equipment center. Install the new P301 panel on the left side of the airplane. Install the new P302 panel on the right side of the airplane. Change the airplane wiring. Change the wiring in the P110 and P210 panels as given in the Smiths service bulletins 5000ELM-28-456 and 6000ELM-28-457. Change the ELMS software as given in the Boeing service bulletin 777-28A0040. Make sure that Boeing service bulletin 777-31-0097 is accomplished. Do a functional test. Close access.

Group 1-2, Configuration 1:

More work is necessary. Get access to the main equipment center. Measure the resistance of the bond between the terminal lugs on the ground stud GD41243 and the P301 panel structure. Measure the resistance of the bond between the terminal lugs on the ground stud GD41236 and the P302 panel structure. Close access.

For airplanes with ELMS-1, the hardware and wiring are installed by a different service bulletin.

EFFECTIVITY 777-200/300/300ER 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 this service bulletin be incorporated within 3 years after 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.

Original Issue: April 13, 2007 777-28A0047Revision 5: September 20, 2010 8 of 124 BOEING SERVICE BULLETIN 777-28A0047

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BOEING SERVICE BULLETIN 777-28A0047 P200

INSTALL NEW P302 PANEL • - P210 AE0232 P110

ROUTE NEW WIRING ' P1 00 TO P200, P210, INSTALL P205, PANELS AND TO P100, P110, ROUTE NEW WIRING WIRING IN CHANGE AE0231 CHANGE THE NEW P301 PANEL AE0231 BRACKET P105, PANELS AND THE P205 WIRING IN AE0232 BRACKET PANEL THE P105 PANEL U46894 Original Issue: April 13, 2007 Revision 5: September 20, 2010 777-28A0047 Copyright © Unpublished Work - See page 1 for details. BOEING PROPRIETARY - 9 of 124

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Original Issue: April 13, 2007 777-28A0047Revision 5: September 20, 2010 10 of 124 BOEING SERVICE BULLETIN 777-28A0047

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1. PLANNING INFORMATION A. Effectivity

1. Airplanes This service bulletin is for the airplanes shown below. An equivalent change is on subsequent production airplanes. Refer to PRR 61998-7 for data about this change.

Refer to Service Bulletin Index Document D624W001 Part 3 for Airplane Variable Number, Line Number, and Serial Number data.

DESCRIPTIONCONFIGURATIONGROUP 777-300/300ER airplanes with ELMS-2-1 777-300/300ER airplanes with ELMS-2 that have accomplished the Original Issue, Revision 1 or Revision 2 of this bulletin 1 777-300/300ER airplanes with ELMS-2 that have not accomplished the Original Issue, Revision 1 or Revision 2 of this bulletin 2 777-200 airplanes with ELMS-2-2 777-200 airplanes with ELMS-2 that have accomplished the Original Issue, Revision 1 or Revision 2 of this bulletin 1 777-200 airplanes with ELMS-2 that have not accomplished the Original Issue, Revision 1 or Revision 2 of this bulletin 2 Airplane Models:

777-200, 777-300, 777-300ER GroupVariable Number 2WA282

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GroupVariable Number 2WA301 - WA304 2WB140 - WB141 2WB176 - WB177 2WB193 - WB194 2WB215 2WB368 2WB438 1WB508 - WB511 1WB596 - WB597 1WB619 - WB622 2WC115 - WC117 2WC287 - WC290 2WC303 - WC308 2WC363 - WC364 2WC373 - WC374 2WC381 - WC391 2WC441 2WC446 - WC448 2WC456 - WC458 2WC486 - WC489 2WC521 1WD501 - WD504 1WD521 - WD532 1WD561 - WD563 1WD581 - WD586 1WD606 1WD621 - WD625 1WD651 - WD652 1WD671 - WD675

2. Spares Affected None.

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