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Commercial Airplanes MD80 Service Bulletin Number: MD80-28-228 Original Issue: September 27, 2013 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Unpublished Work.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 MD80-28-228 1 of 267
4.0
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: September 27, 2013 MD80-28-228 2 of 267 BOEING SERVICE BULLETIN MD80-28-228
BLANK PAGE
Table of Contents
Summary5
1. PLANNING INFORMATION9
A. Effectivity9
1. Airplanes9
2. Spares Affected ........................................ 3 2 B. Concurrent Requirements ...................................... 3 2 C. Reason ................................................ 3 2 D. Description .............................................. 3 3 E. Compliance .............................................. 3 4 F. Approval ............................................... 3 4 G. Manpower .............................................. 3 5 H. Weight and Balance Changes .................................... 5 0 I. Electrical Load Data ......................................... 5 5 J. References .............................................. 6 2
1. Existing Data: ......................................... 6 2
2. Data Supplied with this Service Bulletin: ........................... 6 3
3. Installation Drawings Used in the Preparation of this Service Bulletin: ........... 6 3
4. Process Data: ......................................... 6 3 K. Publications Affected ........................................ 6 3 L. Interchangeability and Intermixability of Parts ........................... 6 4 M. Software Accomplishment Summary ................................ 6 4
2. MATERIAL INFORMATION ........................................ 6 5 A. Material - Price and Availability ................................... 6 5 B. Industry Support Information .................................... 6 6 C. Parts Necessary for Each Airplane ................................. 6 6
1. Kits/Parts ............................................ 6 6
2. Parts and Materials Supplied by the Operator ....................... 1 0 3
3. Parts Modified and Reidentified ............................... 1 0 3
4. Parts Removed and Not Replaced .............................. 1 0 4 D. Parts Necessary to Change Spares ................................ 1 0 4 E. Special Tooling - Price and Availability .............................. 1 0 4 F. Special Tooling Necessary to do this Service Bulletin ...................... 1 0 4
3. ACCOMPLISHMENT INSTRUCTIONS ................................. 1 0 5 A. GENERAL INFORMATION .................................... 1 0 5 B. WORK INSTRUCTIONS ...................................... 1 0 7 FIGURE 1: RELAYS R2-218, R2-219, R2-222 AND R2-223 REMOVAL - FWD CARGO COMPARTMENT, LEFT SIDE [Group 14-23, 28-30] .............................. 1 7 7 FIGURE 2: RELAYS R2-222 AND R2-223 REMOVAL - FWD CARGO COMPARTMENT, LEFT SIDE [Group 7, 27] .............................................. 1 7 9 FIGURE 3: BRACKETS AND MOD BLOCK RAILS INSTALLATION - E/E COMPARTMENT, AFT LEFT RADIO RACK ......................................... 1 8 1 FIGURE 4: TRAY AND CLIP ASSEMBLY CHANGE/INSTALLATION - E/E COMPARTMENT, AFT RIGHT RADIO RACK [Group 14-23, 28-30] ............................. 1 8 5 FIGURE 5: TRAY AND CLIP ASSEMBLY CHANGE/INSTALLATION - E/E COMPARTMENT, AFT RIGHT RADIO RACK [Group 7, 27] ................................. 1 8 9 FIGURE 6: WIRE CHANGES ....................................... 1 9 3 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: September 27, 2013 MD80-28-228 3 of 267 BOEING SERVICE BULLETIN MD80-28-228
FIGURE 7: WIRE CHANGES [Group 1-6] ................................ 1 9 7 FIGURE 8: WIRE CHANGES [Group 7-31] ................................ 1 9 9 FIGURE 9: WIRE CHANGES [Group 27-28] ............................... 2 0 1 FIGURE 10: WIRE CHANGES [Group 28] ................................. 2 0 4 FIGURE 11: WIRE CHANGES [Group 7, 14-23, 29-30] .......................... 2 0 6 FIGURE 12: WIRE CHANGES [Group 14-23, 29-30] ........................... 2 0 9 FIGURE 13: WIRE CHANGES [Group 14-23, 28-30] ........................... 2 1 1 FIGURE 14: WIRE CHANGES [Group 7, 14-23, 27-30] .......................... 2 1 8 FIGURE 15: WIRE CHANGES [Group 7, 10, 12, 17-18, 20, 23, 26, 30-31] ............... 2 2 4 FIGURE 16: WIRE CHANGES [Group 4-6, 8-9, 11, 15-16, 19, 21-22, 24-25, 27-29] .......... 2 2 7 FIGURE 17: WIRE CHANGES [Group 7] ................................. 2 3 0 FIGURE 18: WIRE CHANGES [Group 14-17, 28] ............................. 2 3 2 FIGURE 19: WIRE CHANGES [Group 27] ................................. 2 3 4 FIGURE 20: WIRE CHANGES [Group 19, 29] ............................... 2 3 6 FIGURE 21: WIRE CHANGES [Group 18, 20, 30] ............................. 2 3 8 FIGURE 22: WIRE CHANGES [Group 21] ................................. 2 4 0 FIGURE 23: WIRE CHANGES [Group 22-23] ............................... 2 4 2 FIGURE 24: RELAYS AND RECEPTACLES INSTALLATION [Group 1, 4, 7-8, 18, 31] ........ 2 4 4 FIGURE 25: RELAYS AND RECEPTACLES INSTALLATION [Group 2, 5, 9-10, 15, 24, 29-30] .... 2 4 7 FIGURE 26: RELAYS AND RECEPTACLES INSTALLATION [Group 3, 6, 11-14, 16-17, 19-23, 25-28] . 250 FIGURE 27: RELAYS AND RECEPTACLES INSTALLATION [Group 14-23, 28-30] .......... 2 5 3 FIGURE 28: RELAYS AND RECEPTACLES INSTALLATION [Group 7, 27] .............. 2 5 9 APPENDIX A: ALTERNATE ALERT ENABLE TEST [Group 7, 14-23, 27-30] ............... 2 6 4 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: September 27, 2013 MD80-28-228 4 of 267 BOEING SERVICE BULLETIN MD80-28-228
Commercial Airplanes MD80 Service Bulletin SummaryNumber: MD80-28-228Original Issue: September 27, 2013 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) MD-80 FTD 28-03001 is related to this service bulletin.
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.
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: September 27, 2013 MD80-28-228 5 of 267
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 MD80-28-228 6 of 267 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 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished MD80-28-228 Work - See page 1 for details. 7 of 267
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: September 27, 2013 MD80-28-228 8 of 267 BOEING SERVICE BULLETIN MD80-28-228
BLANK PAGE
Commercial Airplanes MD80 Service Bulletin Number: MD80-28-228 Original Issue: September 27, 2013 ATA System: 2800 SUBJECT: FUEL - Fuel Systems - Install Ground Fault Interrupter Relays and Change Fuel Pump System Wiring
1. PLANNING INFORMATION A. Effectivity
1. Airplanes
DESCRIPTIONCONFIGURATIONGROUP Airplanes that install GFI relays for center fuel tank boost pumps which are affected by SR09280101-7001, SR09280104-7001, SR09280105-7001 and -7023 drawing configurations.
-1 Airplanes that install GFI relays for center fuel tank boost pumps which are affected by SR09280101-7001, SR09280104-7001, SR09280105-7001 and -7025 drawing configurations.
-2 Airplanes that install GFI relays for center fuel tank boost pumps which are affected by SR09280101-7001, SR09280104-7001, SR09280105-7001 and -7027 drawing configurations.
-3 Airplanes that install GFI relays for center fuel tank boost pumps which are affected by SR09280101-7003, SR09280104-7001, SR09280105-7003 and -7023 drawing configurations.
-4 Airplanes that install GFI relays for center fuel tank boost pumps which are affected by SR09280101-7003, SR09280104-7001, SR09280105-7003 and -7025 drawing configurations.
-5 Airplanes that install GFI relays for center fuel tank boost pumps which are affected by SR09280101-7003, SR09280104-7001, SR09280105-7003 and -7027 drawing configurations.
-6 Airplanes that install GFI relays for center fuel tank and aft auxiliary fuel tank boost pumps which are affected by SR09280101-7011, SR09280104-7005, SR09280105-7005 and -7023 drawing configurations.
-7 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: September 27, 2013 MD80-28-228 9 of 267
DESCRIPTIONCONFIGURATIONGROUP Airplanes that install GFI relays for center fuel tank boost pumps which are affected by SR09280101-7007, SR09280104-7001, SR09280105-7007 and -7023 drawing configurations.
-8 Airplanes that install GFI relays for center fuel tank boost pumps which are affected by SR09280101-7007, SR09280104-7001, SR09280105-7007 and -7025 drawing configurations.
-9 Airplanes that install GFI relays for center fuel tank boost pumps which are affected by SR09280101-7009, SR09280104-7001, SR09280105-7007 and -7025 drawing configurations.
-10 Airplanes that install GFI relays for center fuel tank boost pumps which are affected by SR09280101-7007, SR09280104-7001, SR09280105-7007 and -7027 drawing configurations.
-11 Airplanes that install GFI relays for center fuel tank boost pumps which are affected by SR09280101-7009, SR09280104-7001, SR09280105-7007 and -7027 drawing configurations.
-12 Airplanes that install GFI relays for center fuel tank boost pumps which are affected by SR09280101-7005, SR09280104-7001, SR09280105-7009 and -7027 drawing configurations.
-13 Airplanes that install GFI relays for center fuel tank, forward auxiliary fuel tank and aft auxiliary fuel tank boost pumps which are affected by SR09280101-7013, SR09280104-7003, SR09280105-7011 and -7027 drawing configurations.
-14 Airplanes that install GFI relays for center fuel tank, forward auxiliary fuel tank and aft auxiliary fuel tank boost pumps which are affected by SR09280101-7015, SR09280104-7003, SR09280105-7013 and -7025 drawing configurations.
-15 Airplanes that install GFI relays for center fuel tank, forward auxiliary fuel tank and aft auxiliary fuel tank boost pumps which are affected by SR09280101-7015, SR09280104-7003, SR09280105-7013 and -7027 drawing configurations.
-16 Airplanes that install GFI relays for center fuel tank, forward auxiliary fuel tank and aft auxiliary fuel tank boost pumps which are affected by SR09280101-7017, SR09280104-7003, SR09280105-7013 and -7027 drawing configurations.
-17 Airplanes that install GFI relays for center fuel tank, forward auxiliary fuel tank and aft auxiliary fuel tank boost pumps which are affected by SR09280101-7021, SR09280104-7003, SR09280105-7015 and -7023 drawing configurations.
-18 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: September 27, 2013 MD80-28-228 10 of 267 BOEING SERVICE BULLETIN MD80-28-228
DESCRIPTIONCONFIGURATIONGROUP Airplanes that install GFI relays for center fuel tank, forward auxiliary fuel tank and aft auxiliary fuel tank boost pumps which are affected by SR09280101-7019, SR09280104-7003, SR09280105-7015 and -7027 drawing configurations.
-19 Airplanes that install GFI relays for center fuel tank, forward auxiliary fuel tank and aft auxiliary fuel tank boost pumps which are affected by SR09280101-7021, SR09280104-7003, SR09280105-7015 and -7027 drawing configurations.
-20 Airplanes that install GFI relays for center fuel tank, forward auxiliary fuel tank and aft auxiliary fuel tank boost pumps which are affected by SR09280101-7023, SR09280104-7003, SR09280105-7015 and -7027 drawing configurations.
-21 Airplanes that install GFI relays for center fuel tank, forward auxiliary fuel tank and aft auxiliary fuel tank boost pumps which are affected by SR09280101-7025, SR09280104-7003, SR09280105-7015 and -7027 drawing configurations.
-22 Airplanes that install GFI relays for center fuel tank, forward auxiliary fuel tank and aft auxiliary fuel tank boost pumps which are affected by SR09280101-7027, SR09280104-7003, SR09280105-7029 and -7027 drawing configurations.
-23 Airplanes that install GFI relays for center fuel tank boost pumps which are affected by SR09280101-7029, SR09280104-7001, SR09280105-7017 and -7025 drawing configurations.
-24 Airplanes that install GFI relays for center fuel tank boost pumps which are affected by SR09280101-7029, SR09280104-7001, SR09280105-7017 and -7027 drawing configurations.
-25 Airplanes that install GFI relays for center fuel tank boost pumps which are affected by SR09280101-7031, SR09280104-7001, SR09280105-7017 and -7027 drawing configurations.
-26 Airplanes that install GFI relays for center fuel tank and aft auxiliary fuel tank boost pumps which are affected by SR09280101-7033, SR09280104-7005, SR09280105-7019 and -7027 drawing configurations.
-27 Airplanes that install GFI relays for center fuel tank, forward auxiliary fuel tank and aft auxiliary fuel tank boost pumps which are affected by SR09280101-7035, SR09280104-7003, SR09280105-7021 and -7027 drawing configurations.
-28 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: September 27, 2013 MD80-28-228 11 of 267 BOEING SERVICE BULLETIN MD80-28-228
DESCRIPTIONCONFIGURATIONGROUP Airplanes that install GFI relays for center fuel tank, forward auxiliary fuel tank and aft auxiliary fuel tank boost pumps which are affected by SR09280101-7019, SR09280104-7003, SR09280105-7015 and -7025 drawing configurations.
-29 Airplanes that install GFI relays for center fuel tank, forward auxiliary fuel tank and aft auxiliary fuel tank boost pumps which are affected by SR09280101-7021, SR09280104-7003, SR09280105-7015 and -7025 drawing configurations.
-30 Airplanes that install GFI relays for center fuel tank boost pumps which are affected by SR09280101-7009, SR09280104-7001, SR09280105-7007 and -7023 drawing configurations.
-31 Airplane Models:
DC-9-81 (MD-81), DC-9-82 (MD-82), DC-9-83 (MD-83), DC-9-87 (MD-87), MD-88 GroupFuselage Number 3938 3941 3944 1948 3950 1952 - 953 3957 1962 3966 1967 1969 1970 3971 3973 1978 3981 3986 1988 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: September 27, 2013 MD80-28-228 12 of 267 BOEING SERVICE BULLETIN MD80-28-228