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Commercial Airplanes MD80 Service Bulletin Number: MD80-28-228 Original Issue: September 27, 2013 Revision 1: August 27, 2015 ATA System: 2800 SUBJECT: FUEL - Fuel Systems - Install Ground Fault Interrupter Relays and Change Fuel Pump System Wiring Export of this technology is controlled under the United States Export Administration Regulations (EAR) (15 CFR 300-774). 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 © 2013 Boeing.
Unpublished Work. All Rights Reserved.
Treatment of this document and its content is governed by contract with Boeing. Rights to use this document are licensed on a per aircraft basis and such rights may not be transferable. For more information, contact The Boeing Company.
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, KC-46, KDC-10, MD-10, MD-11, MD-80, MD-88, MD-90, P-8, Poseidon and Boeing liveries 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: September 27, 2013 MD80-28-228Revision 1: August 27, 2015 1 of 298
2.0
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: September 27, 2013 MD80-28-228Revision 1: August 27, 2015 2 of 298 BOEING SERVICE BULLETIN MD80-28-228
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Table of Contents
Revision Transmittal Sheet5
S u m m a r y9
1. PLANNING INFORMATION ........................................ 1 3 A . E f f e c t i v i t y ............................................... 1 3
1. Airplanes ............................................ 1 3 2 . S p a r e s A f f e c t e d ........................................ 3 6 B. Concurrent Requirements ...................................... 3 6 C. Reason ................................................ 3 6 D. Description .............................................. 3 7 E. Compliance .............................................. 3 8 F . A p p r o v a l ............................................... 3 8 G. Manpower .............................................. 3 9 H. Weight and Balance Changes .................................... 5 4 I. Electrical Load Data ......................................... 5 9 J . R e f e r e n c e s .............................................. 6 6
1. Existing Data: ......................................... 6 6
2. Data Supplied with this Service Bulletin: ........................... 6 7
3. Installation Drawings Used in the Preparation of this Service Bulletin: ........... 6 7 4 . P r o c e s s D a t a : ......................................... 6 7 K. Publications Affected ........................................ 6 7 L. Interchangeability and Intermixability of Parts ........................... 6 8 M. Software Accomplishment Summary ................................ 6 8
2. MATERIAL INFORMATION ........................................ 6 9 A. Material - Price and Availability ................................... 6 9 B. Industry Support Information .................................... 7 0 C. Parts Necessary for Each Airplane ................................. 7 0 1 . K i t s / P a r t s ............................................ 7 0
2. Parts and Materials Supplied by the Operator ....................... 1 1 1
3. Parts Modified and Reidentified ............................... 1 1 1
4. Parts Removed and Not Replaced .............................. 1 1 2 D. Parts Necessary to Change Spares ................................ 1 1 2 E. Special Tooling - Price and Availability .............................. 1 1 3 F. Special Tooling Necessary to do this Service Bulletin ...................... 1 1 3
3. ACCOMPLISHMENT INSTRUCTIONS ................................. 1 1 5 A. GENERAL INFORMATION .................................... 1 1 5 B. WORK INSTRUCTIONS ...................................... 1 1 7 FIGURE 1: RELAYS R2-218, R2-219, R2-222 AND R2-223 REMOVAL - FWD CARGO COMPARTMENT, LEFT SIDE [Group 14-23, 28-30] .............................. 2 0 2 FIGURE 2: RELAYS R2-222 AND R2-223 REMOVAL - FWD CARGO COMPARTMENT, LEFT SIDE [Group 7 , 2 7 ] .............................................. 2 0 4 FIGURE 3: BRACKETS AND TRACK INSTALLATION - E/E COMPARTMENT, AFT LEFT RADIO RACK ................................................. 2 0 6 FIGURE 4: TRAY AND BRACKET CHANGE/INSTALLATION - E/E COMPARTMENT, AFT RIGHT RADIO RACK [Group 14-23, 28-30] ................................. 2 1 0 FIGURE 5: TRAY AND BRACKET CHANGE/INSTALLATION - E/E COMPARTMENT, AFT RIGHT RADIO RACK [Group 7, 27] ...................................... 2 1 5 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: September 27, 2013 MD80-28-228Revision 1: August 27, 2015 3 of 298 BOEING SERVICE BULLETIN MD80-28-228
F I G U R E 6 : W I R E C H A N G E S....................................... 2 2 0 FIGURE 7: WIRE CHANGES [Group 1-6] ................................ 2 2 4 FIGURE 8: WIRE CHANGES [Group 7-31] ................................ 2 2 6 FIGURE 9: WIRE CHANGES [Group 27-28] ............................... 2 2 8 FIGURE 10: WIRE CHANGES [Group 28] ................................. 2 3 1 FIGURE 11: WIRE CHANGES [Group 7, 14-23, 29-30] .......................... 2 3 3 FIGURE 12: WIRE CHANGES [Group 14-23, 29-30] ........................... 2 3 6 FIGURE 13: WIRE CHANGES [Group 14-23, 28-30] ........................... 2 3 8 FIGURE 14: WIRE CHANGES [Group 7, 14-23, 27-30] .......................... 2 4 5 FIGURE 15: WIRE CHANGES [Group 7, 10, 12, 17-18, 20, 23, 26, 30-31] ............... 2 5 1 FIGURE 16: WIRE CHANGES [Group 4-6, 8-9, 11, 15-16, 19, 21-22, 24-25, 27-29] .......... 2 5 4 FIGURE 17: WIRE CHANGES [Group 7] ................................. 2 5 7 FIGURE 18: WIRE CHANGES [Group 14-17, 28] ............................. 2 5 9 FIGURE 19: WIRE CHANGES [Group 27] ................................. 2 6 1 FIGURE 20: WIRE CHANGES [Group 19, 29] ............................... 2 6 3 FIGURE 21: WIRE CHANGES [Group 18, 20, 30] ............................. 2 6 5 FIGURE 22: WIRE CHANGES [Group 21] ................................. 2 6 7 FIGURE 23: WIRE CHANGES [Group 22-23] ............................... 2 6 9 FIGURE 24: RELAYS AND RECEPTACLES INSTALLATION [Group 1, 4, 7-8, 18, 31] ........ 2 7 1 FIGURE 25: RELAYS AND RECEPTACLES INSTALLATION [Group 2, 5, 9-10, 15, 24, 29-30] .... 2 7 5 FIGURE 26: RELAYS AND RECEPTACLES INSTALLATION [Group 3, 6, 11-14, 16-17, 19-23, 25-28] . 279 FIGURE 27: RELAYS AND RECEPTACLES INSTALLATION [Group 14-23, 28-30] .......... 2 8 3 FIGURE 28: RELAYS AND RECEPTACLES INSTALLATION [Group 7, 27] .............. 2 8 9 APPENDIX A: ALTERNATE ALERT ENABLE TEST [Group 7, 14-23, 27-30] ............... 2 9 4 APPENDIX B: BOEING PART DEMAND INTENT ............................. 2 9 8 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
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Commercial Airplanes MD80 Service Bulletin Revision Transmittal SheetNumber: MD80-28-228Original Issue: September 27, 2013 Revision 1: August 27, 2015 ATA System: 2800 SUBJECT: FUEL - Fuel Systems - Install Ground Fault Interrupter Relays and Change Fuel Pump System Wiring This revision includes all pages of the service bulletin.
COMPLIANCE INFORMATION RELATED TO THIS REVISION Federal Aviation Administration (FAA) Airworthiness Directive AD 2012-18-05 is related to this service bulletin.
Effects of this Revision on airplanes on which Original Issue was previously done:
None.
REASON FOR REVISION This revision is sent to incorporate engineering released after the original issue of this service bulletin to address the no work conditions due to Ground Fault Interrupter (GFI) panel washers, wires in wire assembly too short, GFI panel mounting holes too small, wire assembly routing and process issues encountered during validation of the original issue of this service bulletin.
The data given in Information Notice MD80-28-228 IN 01 is included in this revision.
As a part of a service bulletin validation program, this installation was completed on airplane fuselage number 1683 by Service Bulletin MD80-28-228 Original Issue before the release of Revision 1 of this service bulletin.
The installation completed on airplane fuselage number 1683 by Service Bulletin MD80-28-228 Original Issue is equivalent to the release of Revision 1 of this service bulletin. Airplane fuselage number 1683 has the configuration of a Group 11 airplane.
These sections were changed:
1. In Background, added Boeing Fleet Team Digest (FTD) statement.
2. In Background, added Summary Evaluation Table.
3. In Paragraph 1.C., Reason, added statements.
4. In Paragraph 1.D., Description, added Compliance statement.
5. In Paragraph 1.G., Manpower, updated Manpower.
6. In Paragraph 1.H., Weight and Balance Changes, updated Group 1 through Group 31 information.
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: September 27, 2013 MD80-28-228Revision 1: August 27, 2015 5 of 298
7. In Paragraph 1.J.1., Existing Data, added additional references.
8. In Paragraph 1.J.2.a., Drawings: changed drawings revision.
9. In Paragraph 1.J.3., Installation Drawings Used in the preparation of this Service Bulletin: changed drawings revision.
10. In Paragraph 1.K.1., Publications:, updated information.
11. In Paragraph 2.A., Material - Price and Availability, added survey information.
12. In Paragraph 2.C.1., Kits/Parts, Group 1 through Group 31, updated information.
13. In Paragraph 2.C.1., Kits/Parts, [Split Across Subdocument], Wire Kit Table, Kit Number SB09280228-110, Part Number D2426-1C-20NM, changed wire length to 57 Feet.
14. In Paragraph 2.C.1., Kits/Parts, Wire Kit Table, Kit Number SB09280228-111, Part Number D2426-1C-20NM, changed wire length to 57 Feet.
15. In Paragraph 2.C.2., Parts and Materials Supplied by the Operator, added part information.
16. In Paragraph 2.C.3., Parts Modified and Reidentified, Group 1 through Group 31: added new Tables and information.
17. In Paragraph 3.A., General Information, Note: added new note.
18. In Paragraph 3.B., Work Instructions, Group 1 through 31: added instructions.
19. In Figure 4, changed title, changed view A and added view B.
20. In Figure 4, changed table and added footnotes (g) and (h).
21. In Figure 5, changed title and changed view A and added view B.
22. In Figure 5, changed table and added footnote (g) and (h).
23. In Figure 6 through Figure 23, added reference.
24. In Figure 13, updated figure.
25. In Figure 15, changed wires length to 225 Inches.
26. In Figure 16, changed wires length to 225 Inches.
27. In Figure 24, changed view A, view B and added View C.
28. In Figure 24, changed table and added footnotes (b), (c), (d) and (e).
29. In Figure 25, changed view A, view B and added View C.
30. In Figure 25, changed table and added footnotes (b), (c), (d) and (e).
31. In Figure 26, changed view A, view B and added View C.
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
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32. In Figure 26, changed table and added footnotes (b), (c), (d) and (e).
33. Appendix A, updated information.
34. Added Appendix B.
Vertical lines are put on the left edge of each page, except in Paragraph 1.A., Effectivity and format changes, to show the location of all content changes.
Pages with no vertical lines have no changes.
REVISION HISTORY September 27, 2013Original Issue:
August 27, 2015Revision 1:
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: September 27, 2013 MD80-28-228Revision 1: August 27, 2015 7 of 298 BOEING SERVICE BULLETIN MD80-28-228
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
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Commercial Airplanes MD80 Service Bulletin SummaryNumber: MD80-28-228Original Issue: September 27, 2013 Revision 1: August 27, 2015 ATA System: 2800 SUBJECT: FUEL - Fuel Systems - Install Ground Fault Interrupter Relays and Change Fuel Pump System Wiring
CONCURRENT REQUIREMENTS Refer to Paragraph 1.B., Concurrent Requirements.
BACKGROUND Frictional heating or sparking may develop from fuel pump failure, wear of fuel pump rotating components, or ingestion of debris by the pump. Electrical faults in a fuel pump may result in electrical arc burn through of a fuel pump. Frictional heating or sparking and electrical arc burn through in fuel pump inlets or priming system outlets exposed (i.e. not covered by fuel) to the tank ullage in combination with the ullage being flammable, may result in a fuel tank ignition event. A fuel tank ignition event could develop with a pump running in an empty tank if the normal shutoff command is delayed or as a result of control system failures that keep the pump in a latent uncommanded running condition. Center wing and auxiliary fuel tanks may be subject to this condition since they are normally pumped dry over the course of a flight. If not corrected frictional heating or sparking, electrical arc burn through, or a fuel tank pump running in an empty fuel tank may result in a fuel tank ignition event.
This service bulletin is the result of the safety assessments conducted by Boeing under a Special Federal Aviation Regulation (SFAR) 88, Fuel Tank System Fault Tolerance Evaluation Requirements.
Boeing Fleet Team Digest (FTD) MD80 FTD 28-03001 and MD80 FTD 28-12003 are related to this service bulletin.
This table is provided to operators for planning purposes only. Refer to the applicable sections for more information.
ReferenceAffectedPlanning Data Paragraph 1.A.2., Spares AffectedNoSpares Affected Paragraph 1.E., Compliance and Paragraph
1.F., Approval YesAD Related Paragraph 1.H., Weight and Balance ChangesYesWeight and Balance Change Paragraph 1.I., Electrical Load DataYesElectrical Load Changed Paragraph 1.K., Publications AffectedYesPublications Affected Paragraph 1.K., Publications AffectedYesAirplane Flight Operations Affected (Flight Crew Operations Manual and/or FAA Approved Airplane Flight Manual) Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
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ReferenceAffectedPlanning Data Paragraph 2.C.1., Kits/PartsYesKits/Parts Required Paragraph 2.C.2., Parts and Materials Supplied by the Operator YesOperator Supplied Parts/Material Paragraph 2.F., Special Tooling Necessary to do this Service Bulletin NoSpecial Tooling Required ACTION This service bulletin installs Ground Fault Interrupter (GFI) relays and cuts/coils/stows wires to center wing and auxiliary fuel tank pump motor neutral circuits.
EFFECTIVITY All DC-9-81 (MD-81), DC-9-82 (MD-82), DC-9-83 (MD-83), DC-9-87 (MD-87) and MD-88 Airplanes. Refer to Paragraph 1.A.1., Airplanes, for the list of affected airplanes.
COMPLIANCE Federal Aviation Administration (FAA) Airworthiness Directive AD 2012-18-05 is related to this service bulletin.
Boeing recommends that the change given in this service bulletin be done within 60 months after the effective date of AD 2012-18-05.
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.
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: September 27, 2013 MD80-28-228Revision 1: August 27, 2015 10 of 298 BOEING SERVICE BULLETIN MD80-28-228
BOEING SERVICE BULLETIN MD80-28-228 .....
INSTALL GROUND FAULT INTERRUPTER RELAYS
AND CHANGE FUEL PUMP SYSTEM WIRING 1946126 Original Issue: September 27, 2013 Revision 1: August 27, 2015 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished MD80-28-228 Work - See page 1 for details. 11 of 298
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: September 27, 2013 MD80-28-228Revision 1: August 27, 2015 12 of 298 BOEING SERVICE BULLETIN MD80-28-228