Commercial 

Airplanes 737

Service Bulletin

Number: 737-28A1210

Original Issue: August 02, 2010

Revision 2: October 25, 2012

ATA System: 2822

SUBJECT: FUEL- Engine Fuel Feed System - Replacement of the P5-2 Fuel System Module to

Supply Low Fuel Pressure Master Caution Annunciation

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.

ECCN: 9E991

BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET

Copyright © 2010 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Unpublished Work.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, DreamlinerTM,

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with this document unless provided in writing by Boeing. BOEING is a trademark of Boeing Management

Company.

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5.0
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BOEING SERVICE BULLETIN 737-28A1210

BLANK PAGE
Table of Contents

Revision Transmittal Sheet ............................................ 5

Summary ...................................................... 7

1. PLANNING INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

A. Effectivity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

1. Airplanes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

2. Spares Affected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

B. Concurrent Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

C. Reason . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

D. Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

E. Compliance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

F. Approval . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

G. Manpower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

H. Weight and Balance Changes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

I. Electrical Load Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

J. References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

1. Existing Data: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

2. Data Supplied with this Service Bulletin: . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

3. Installation Drawings Used in the Preparation of this Service Bulletin: . . . . . . . . . . . 27

K. Publications Affected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

L. Interchangeability and Intermixability of Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

M. Software Accomplishment Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

2. MATERIAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

A. Material - Price and Availability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

B. Industry Support Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

C. Parts Necessary for Each Airplane . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

1. Kits/Parts: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

2. Parts and Materials Supplied by the Operator: . . . . . . . . . . . . . . . . . . . . . . . . 29

3. Parts Modified and Reidentified: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

4. Parts Removed and Not Replaced: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

D. Parts Necessary to Change Spares . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

E. Special Tooling - Price and Availability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

F. Special Tooling Necessary to do this Service Bulletin . . . . . . . . . . . . . . . . . . . . . . . 31

3. ACCOMPLISHMENT INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

A. GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

B. WORK INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

FIGURE 1: MASTER CAUTION SYSTEM - P5-2 FUEL SYSTEM MODULE - REPLACEMENT [Group 2]

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

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BOEING SERVICE BULLETIN 737-28A1210
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BOEING SERVICE BULLETIN 737-28A1210

BLANK PAGE
Commercial 

Airplanes 737

Service Bulletin

Revision Transmittal Sheet Number: 737-28A1210

Original Issue: August 02, 2010

Revision 2: October 25, 2012

ATA System: 2822

SUBJECT: FUEL- Engine Fuel Feed System - Replacement of the P5-2 Fuel System Module to

Supply Low Fuel Pressure Master Caution Annunciation

This revision includes all pages of the service bulletin.

COMPLIANCE INFORMATION RELATED TO THIS REVISION

No more work is necessary on the airplane(s) changed in accordance with the Original Issue or Revision 1 of

this service bulletin. However, Boeing recommends that, at the next convenient maintenance opportunity,

operators that had P5-2 Fuel System Module P/N 69-37335-129 installed and subsequently reworked by BAE

Systems Component Service Bulletin (CSB) 69-37335-28-04 at Revision 2, make sure the part number is

69-37335-2129 and not 69-37335-2126, as was given. BAE Systems Component Service Bulletin (CSB)

69-37335-28-04 gave the incorrect part number at Revision 2.

Federal Aviation Administration (FAA) Notice of Proposed Rulemaking (NPRM) 2010-NM-189-AD is related to

this service bulletin.

REASON FOR REVISION

This revision is sent because the referenced BAE Systems Component Service Bulletin (CSB) 69-37335-28-04

Revision 2 is incorrect. The part number of the reworked P5-2 Fuel System Module P/N 69-37335-129 was

incorrectly given as 69-37335-2126 in BAE Systems CSB 69-37335-28-04 Revision 2. BAE Systems CSB

69-37335-28-04 Revision 3 has been released, which gives the correct P/N 69-37335-2129 for a reworked P5-2

Fuel System Module. Thus, this service bulletin has been revised to reference the latest BAE Systems CSB

69-37335-28-04 Revision 3. Also, Boeing service bulletins 737-28A1216 and 737-28A1228, as applicable, have

been added in Concurrent Requirements. Federal Aviation Administration (FAA) Notice of Proposed Rulemaking

(NPRM) 2010-NM-189-AD is now applicable to this service bulletin and has been added at this revision.

These sections are changed:

1. In Summary, Background: Removed the reference to AD 2001-08-24.

2. In Summary, Compliance: Added FAA NPRM 2010-NM-189-AD

3. In Paragraph 1.B., Concurrent Requirements: Changed Revision and date for BAE Systems CSB.

Added concurrent Boeing service bulletins.

4. In Paragraph 1.C., Reason: Removed the reference to AD 2001-08-24.

5. In Paragraph 1.E., Compliance: Added FAA NPRM 2010-NM-189-AD.

6. In Paragraph 1.J., References: Updated.

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7. In Paragraph 1.K., Publications Affected: Added Wiring Diagram Manual.

8. Added Paragraph 1.M., Software Accomplishment Summary: New service bulletin paragraph - not

affected.

9. In Paragraph 2.A., Material - Price and Availability: Added Revision and date for BAE Systems CSB.

10. In Paragraph 2.C.2., Parts and Materials Supplied by the Operator: Changed Revision and date for

BAE Systems CSB.

11. In Paragraph 2.C.3., Parts Modified and Reidentified: Changed Revision and date for BAE Systems

CSB in two locations.

12. In Paragraph 2.D., Parts Necessary to Change Spares: Changed Revision and date for BAE Systems

CSB.

13. In Paragraph 3.A., General Information: Changed Revision and date for BAE Systems CSB in two

locations.

14. In Paragraph 3.B., Work Instructions: Step 2, Note: Changed Revision and date for BAE Systems CSB.

Removed Step 6.

15. In Figure 1, Step Table: Footnote (c) - changed Revision and date for BAE Systems CSB and updated

instruction.

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

Original Issue: August 02, 2010

Revision 1: May 13, 2011

Revision 2: October 25, 2012

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BOEING SERVICE BULLETIN 737-28A1210
Commercial 

Airplanes 737

Service Bulletin

Summary Number: 737-28A1210

Original Issue: August 02, 2010

Revision 2: October 25, 2012

ATA System: 2822

SUBJECT: FUEL- Engine Fuel Feed System - Replacement of the P5-2 Fuel System Module to

Supply Low Fuel Pressure Master Caution Annunciation

CONCURRENT REQUIREMENTS

Refer to Paragraph 1.B., Concurrent Requirements.

BACKGROUND

This service bulletin is the result of fuel system safety analysis done by Boeing under Special Federal Aviation

Regulation (SFAR) 88, Fuel Tank System Fault Tolerance Evaluation Requirements. Results from the fuel

system safety analysis show that fuel boost pumps that run dry could cause an overheat condition external to

the fuel boost pump explosion resistance area, that is open to the fuel boost pump inlet. An overheat condition

in this area could possibly cause an unwanted ignition source for the fuel vapors in the fuel tank and could cause

a fire or explosion.

This service bulletin gives instructions to replace the P5-2 Fuel System Module installed in the flight deck with

a changed P5-2 Fuel System Module. The changed P5-2 Fuel System Module has new Master Caution logic

that gives the necessary indication to the flight crew so that the fuel boost pumps can be turned off and not

operate dry.

The new P5-2 Fuel System Module lets the Master Caution light come on when only one center or auxiliary tank

fuel boost pump low pressure light is on for 10 seconds. Before this change, the Master Caution light came on

when both center tank fuel boost pumps or both auxiliary tank fuel boost pumps had low pressure. All of the

equipment and wiring changes to the Master Caution System are internal to the P5-2 Fuel System Module.

Boeing Fleet Team Digest (FTD) 737 FTD 28-04003 is related to this service bulletin.

ACTION (PRR 35440-20R)

Group 1:

Operators with Group 1 airplanes should contact Boeing to get engineering and accomplishment instructions

for this change and do the instructions.

Group 2:

In the flight compartment, at the P5 overhead panel, remove the P5-2 Fuel System Module. Install a changed,

or new P5-2 Fuel System Module. Do a test to make sure that the P5-2 Fuel System Module operates correctly.

EFFECTIVITY

All 737-100/-200/-200C/-300/-400/-500 airplanes. Refer to Paragraph 1.A.1., Airplanes, for the list of affected

airplane(s).

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COMPLIANCE

Federal Aviation Administration (FAA) Notice of Proposed Rulemaking NPRM 2010-NM-189-AD is related to

this service bulletin.

Boeing recommends that the change given in this service bulletin be done within 36 months after the Original

Issue date of this service bulletin.

Group 1:

Operators with Group 1 airplanes should contact Boeing to get engineering and accomplishment instructions

for this change and do the instructions.

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

Operator Supplied Parts/Materials.

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BOEING SERVICE BULLETIN 737-28A1210

BLANK PAGE
Commercial 

Airplanes 737

Service Bulletin

Number: 737-28A1210

Original Issue: August 02, 2010

Revision 2: October 25, 2012

ATA System: 2822

SUBJECT: FUEL- Engine Fuel Feed System - Replacement of the P5-2 Fuel System Module to

Supply Low Fuel Pressure Master Caution Annunciation

1. PLANNING INFORMATION

A. Effectivity

1. Airplanes

This service bulletin is for the airplanes shown below. Refer to PRR 35440-20R for data about this

change.

Refer to Service Bulletin Index D6-19567, Part 3 for Airplane Variable Number, Line Number, and

Serial Number data.

GROUP CONFIGURATION DESCRIPTION

1 - 737-100/200/200C airplanes, line numbers 1 thru 291.

2 - 737-200/200C/300/400/500 airplanes, line numbers 292 thru 3132.

Airplane Models:

737-100, 737-200, 737-200C, 737-300, 737-400, 737-500

Variable Number Group

PA001 - PA022 1

PA099 1

PA231 - PA232 1

PC001 - PC005 1

PG001 - PG075 1

PG199 1

PG201 - PG230 1

PG251 - PG255 1

PG271 - PG279 1

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Variable Number Group

PG301 - PG314 1

PG331 - PG332 1

PG351 - PG356 1

PG375 1

PG401 - PG403 1

PG431 - PG442 1

PG471 - PG475 1

PG501 - PG505 1

PG571 - PG583 1

PG584 - PG586 2

PG621 - PG630 1

PG651 - PG652 1

PG701 - PG705 1

PH001 2

PH011 - PH013 2

PH021 - PH024 2

PH701 - PH715 1

PH731 - PH732 1

PH741 - PH742 1

PH743 2

PJ001 - PJ002 1

PJ003 - PJ009 2

PJ031 - PJ032 1

PJ071 - PJ072 1

PJ101 - PJ104 1

PJ105 - PJ119 2

PJ201 - PJ219 2

PJ301 - PJ302 2

PJ551 - PJ561 2

PJ601 - PJ615 2

PJ811 2

PJ816 - PJ817 2

PK026 - PK029 2

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BOEING SERVICE BULLETIN 737-28A1210
Variable Number Group

PK041 - PK053 2

PK061 - PK070 2

PK081 - PK082 2

PK091 - PK099 2

PK101 - PK103 2

PK111 - PK120 2

PK141 - PK146 2

PK201 - PK204 2

PK211 - PK223 2

PK231 - PK241 2

PK251 - PK258 2

PK271 - PK274 2

PK281 - PK289 2

PK291 2

PK301 - PK318 2

PK341 2

PK351 - PK361 2

PK391 2

PK431 - PK433 2

PK451 - PK452 2

PK461 - PK469 2

PK495 2

PK501 - PK504 2

PK511 - PK515 2

PK519 2

PK521 - PK528 2

PK541 - PK565 2

PK581 2

PK591 - PK599 2

PK601 - PK617 2

PK621 - PK637 2

PK641 - PK642 2

PK661 - PK666 2

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BOEING SERVICE BULLETIN 737-28A1210
Variable Number Group

PK671 - PK681 2

PK691 - PK697 2

PK711 - PK716 2

PK731 - PK765 2

PK771 - PK779 2

PK801 - PK804 2

PK819 - PK827 2

PK830 2

PK861 - PK863 2

PK871 - PK874 2

PK881 - PK884 2

PK901 - PK938 2

PK971 - PK974 2

PL001 - PL028 2

PL061 2

PL081 2

PL101 - PL113 2

PL151 2

PL171 - PL172 2

PL201 - PL203 2

PL221 2

PL401 - PL417 2

PL421 2

PL441 2

PL451 - PL456 2

PL471 2

PL491 2

PL501 - PL506 2

PL551 - PL562 2

PL581 2

PL601 - PL603 2

PL611 2

PL621 - PL626 2

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BOEING SERVICE BULLETIN 737-28A1210
Variable Number Group

PL631 - PL632 2

PL711 - PL712 1

PL716 1

PL717 - PL747 2

PL756 2

PL758 2

PL761 - PL770 2

PL781 - PL788 2

PL793 2

PL801 - PL803 1

PM001 - PM006 2

PM016 - PM017 2

PM021 - PM023 2

PM051 - PM066 2

PM101 - PM119 2

PM141 - PM142 2

PM171 2

PM181 2

PM251 - PM255 2

PM281 - PM283 2

PM381 - PM399 2

PM401 - PM417 2

PM541 - PM564 2

PN001 - PN002 2

PN021 - PN043 2

PN081 - PN086 2

PN101 - PN117 2

PN131 - PN163 2

PN401 - PN420 2

PN431 - PN433 2

PN451 - PN456 2

PN471 - PN474 2

PN481 2

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BOEING SERVICE BULLETIN 737-28A1210
Variable Number Group

PN491 - PN493 2

PN501 - PN502 2

PN511 - PN512 2

PN521 2

PP001 - PP054 2

PP101 - PP169 2

PP181 - PP199 2

PP201 - PP205 2

PP221 2

PP231 - PP243 2

PP281 - PP286 2

PP301 - PP305 2

PP351 - PP353 2

PP376 - PP384 2

PP391 - PP393 2

PP401 - PP440 2

PP471 - PP475 2

PP501 - PP522 2

PP631 - PP634 2

PP651 - PP652 2

PP671 - PP699 2

PP701 - PP733 2

PP771 - PP779 2

PP801 - PP808 2

PP821 - PP827 2

PP831 - PP848 2

PP851 - PP852 2

PP861 - PP877 2

PP891 - PP899 2

PP901 - PP936 2

PP946 - PP948 2

PP951 - PP952 2

PP961 - PP967 2

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BOEING SERVICE BULLETIN 737-28A1210
Variable Number Group

PP981 - PP991 2

PP993 2

PQ001 - PQ016 2

PQ026 - PQ041 2

PQ051 - PQ092 2

PQ101 - PQ199 2

PQ201 - PQ202 2

PQ221 - PQ237 2

PQ241 - PQ243 2

PQ251 - PQ267 2

PQ281 - PQ299 2

PQ301 - PQ307 2

PQ331 - PQ332 2

PQ341 - PQ348 2

PQ361 - PQ373 2

PQ391 - PQ395 2

PQ401 - PQ418 2

PQ421 2

PQ431 - PQ438 2

PQ447 - PQ448 2

PQ451 2

PQ454 2

PQ471 - PQ475 2

PQ479 - PQ481 2

PQ486 - PQ487 2

PQ491 - PQ493 2

PQ771 - PQ772 2

PQ791 - PQ793 2

PQ801 - PQ805 2

PQ931 - PQ935 2

PQ951 2

PQ971 - PQ997 2

PR001 - PR017 2

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BOEING SERVICE BULLETIN 737-28A1210
Variable Number Group

PR021 - PR034 2

PR041 - PR045 2

PR061 - PR072 2

PR077 - PR082 2

PR091 - PR092 2

PR096 2

PR101 2

PR121 - PR122 2

PR131 - PR132 2

PR141 - PR143 2

PR161 - PR172 2

PR181 2

PS601 - PS631 2

PS636 - PS638 2

PS641 - PS644 2

PS651 - PS657 2

PS666 - PS669 2

PS691 - PS692 2

PS701 - PS706 2

PS751 - PS799 2

PS811 2

PS836 - PS837 2

PS841 - PS846 2

PS851 - PS852 2

PS856 2

PS861 - PS863 2

PS866 - PS868 2

PS871 - PS874 2

PS896 - PS897 2

PS901 - PS941 2

PS956 - PS957 2

PS961 - PS963 2

PS971 - PS978 2

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BOEING SERVICE BULLETIN 737-28A1210
Variable Number Group

PT001 - PT015 2

PT021 - PT031 2

PT041 - PT064 2

PT101 - PT105 2

PT121 - PT138 2

PT146 - PT148 2

PT161 - PT170 2

PT181 - PT188 2

PT211 - PT220 2

PT295 2

PT301 - PT309 2

PT331 - PT360 2

PT381 - PT399 2

PT401 - PT438 2

PT501 - PT517 2

PT561 - PT565 2

PT581 - PT586 2

PT611 - PT621 2

PT641 - PT644 2

PT651 - PT656 2

PT671 - PT672 2

PT681 - PT685 2

PT701 - PT703 2

PT716 - PT717 2

PT721 - PT725 2

PT801 - PT834 2

PT851 - PT854 2

PT871 - PT886 2

PT901 - PT930 2

PT971 - PT973 2

PT981 - PT985 2

PT996 2

PU001 - PU025 2

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BOEING SERVICE BULLETIN 737-28A1210
Variable Number Group

PU301 2

PU311 - PU313 2

PV001 - PV055 2

PV201 - PV209 2

PV226 - PV229 2

PV231 - PV237 2

PV271 - PV272 2

PV281 - PV287 2

PV296 2

PV301 - PV302 2

PV351 2

PV356 - PV357 2

PW001 - PW054 2

PW061 - PW068 2

PW072 2

PW086 - PW088 2

PW091 - PW094 2

PW101 - PW102 2

PW106 2

PW111 - PW120 2

PW156 - PW157 2

PW161 - PW171 2

PW201 - PW252 2

PW261 - PW268 2

PW271 - PW276 2

PW278 2

PW281 - PW293 2

PW296 2

PW301 - PW327 2

PW401 - PW408 2

PW411 - PW418 2

PW421 - PW424 2

PW431 - PW435 2

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BOEING SERVICE BULLETIN 737-28A1210
Variable Number Group

PW441 - PW450 2

PW461 - PW467 2

PW501 - PW504 2

PW511 - PW522 2

PW524 - PW550 2

PW556 - PW557 2

PW561 - PW564 2

PW571 - PW576 2

PW591 - PW596 2

PW611 - PW622 2

PW631 - PW637 2

PW661 - PW662 2

PW681 - PW683 2

PW701 - PW702 2

PW711 - PW717 2

PW741 - PW742 2

PW761 2

PW771 2

PW831 2

PW851 - PW856 2

PX071 1

PX701 1

PY001 - PY008 1

PY021 1

PY022 2

PY031 1

PY036 - PY037 2

PY046 - PY048 2

PY051 - PY053 2

PY056 - PY057 2

PY101 - PY103 2

PY111 - PY113 2

PY131 - PY135 2

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Variable Number Group

PY141 - PY143 2

PY151 - PY154 2

PY156 - PY157 2

PY161 - PY162 2

PY166 2

PY191 2

PY201 2

PY221 - PY222 2

PY231 2

PY241 - PY244 2

PY270 - PY275 2

PY281 2

PY286 2

PY301 - PY304 1

PY321 - PY323 1

PY341 - PY346 1

PY361 - PY362 1

PY381 1

PY401 2

PY409 - PY411 2

PY421 - PY422 2

PY441 2

PY451 2

PY461 - PY463 2

PY591 - PY595 2

PY611 - PY612 2

PY621 2

PY631 2

PY651 2

PY671 - PY672 2

PY721 2

PY741 2

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BOEING SERVICE BULLETIN 737-28A1210
2. Spares Affected

None.

B. Concurrent Requirements

Group 1:

Operators with Group 1 airplanes should contact Boeing to get engineering and accomplishment

instructions for this change and do the instructions.

The service bulletin(s) listed below must be done before or at the same time as this service bulletin:

Group 2:

Company Component Service Bulletin Description

Gives instructions to install a printed circuit

assembly in the P5-2 fuel system module

assembly for fuel system master caution

warning.

69-37335-28-04, Revision 3, dated March

31, 2011 (a)

BAE Systems

(a) If operators choose to rework the existing P5-2 Fuel System Module, do this service bulletin before or at

the same time.

Group 2:

Company Service Bulletin Description

Installation of the Auto Shutoff Protection for

the Center and Auxiliary Fuel Tank Boost

Pumps.

737-28A1228, Original Issue or Revision 1,

applicable to 737-100/200/200C airplanes.

or

Boeing

737-28A1216, Original Issue, Revision 1, or

Revision 2, applicable to 737-300/400/500

airplanes.

C. Reason

This service bulletin is the result of fuel system safety analysis done by Boeing under Special Federal

Aviation Regulation (SFAR) 88, Fuel Tank System Fault Tolerance Evaluation Requirements. Results

from the fuel system safety analysis show that fuel boost pumps that run dry could cause an overheat

condition external to the fuel boost pump explosion resistance area, that is open to the fuel boost pump

inlet. An overheat condition in this area could possibly cause an unwanted ignition source for the fuel

vapors in the fuel tank and could cause a fire or explosion.

This service bulletin gives instructions to replace the P5-2 Fuel System Module installed in the flight

deck with a changed P5-2 Fuel System Module. The changed P5-2 Fuel System Module has new

Master Caution logic that gives the necessary indication to the flight crew so that the fuel boost pumps

can be turned off and not operate dry.

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The new P5-2 Fuel System Module lets the Master Caution light come on when only one center or

auxiliary tank fuel boost pump low pressure light is on for 10 seconds. Before this change, the Master

Caution light came on when both center tank fuel boost pumps or both auxiliary tank fuel boost pumps

had low pressure. All of the equipment and wiring changes to the Master Caution System are internal

to the P5-2 Fuel System Module.

Boeing Fleet Team Digest (FTD) 737 FTD 28-04003 is related to this service bulletin.

Revision 1 put airplanes from Groups 3 thru 28 together into Group 2, of the service bulletin effectivity,

to resolve interchangeability problems. Airplanes line numbers 1 thru 291 stay in Group 1 and are not

affected by this revision. Groups in the original issue were based on the P5-2 Fuel System Module

dash number, delivered on each airplane. But new P5-2 Fuel System Module dash numbers were

created, after the airplanes were delivered, that are interchangeable with older P5-2 Fuel System

Modules. As a result, some operators, that installed P5-2 Fuel System Module part numbers

interchangeable with the ones delivered on their airplane, may not be able to accomplish the original

issue. Reference to Federal Aviation Administration (FAA) Airworthiness Directive AD 2001-08-24 and

Boeing Fleet Team Digest (FTD) 737 FTD 28-04003 are also added.

The data given in Information Notice 737-28A1210 IN 01 and 737-28A1210 IN 02 was included in

Revision 1.

Revision 2 is sent because the referenced BAE Systems Component Service Bulletin (CSB)

69-37335-28-04 Revision 2 is incorrect. The part number of the reworked P5-2 Fuel System Module

P/N 69-37335-129 was incorrectly given as 69-37335-2126 in BAE Systems CSB 69-37335-28-04

Revision 2. BAE Systems CSB 69-37335-28-04 Revision 3 has been released, which gives the correct

P/N 69-37335-2129 for a reworked P5-2 Fuel System Module. Thus, this service bulletin has been

revised to reference the latest BAE Systems CSB 69-37335-28-04 Revision 3. Also, Boeing service

bulletins 737-28A1216 and 737-28A1228, as applicable, have been added in Concurrent Requirements.

Federal Aviation Administration (FAA) Notice of Proposed Rulemaking (NPRM) 2010-NM-189-AD is

now applicable to this service bulletin and has been added at this revision.

D. Description

Group 1:

Operators with Group 1 airplanes should contact Boeing to get engineering and accomplishment

instructions for this change and do the instructions.

Group 2:

In the flight compartment, at the P5 overhead panel, remove the P5-2 Fuel System Module. Install a

changed, or new P5-2 Fuel System Module. Do a test to make sure that the P5-2 Fuel System Module

operates correctly.

Revision 1 - No more work is necessary on the airplane(s) changed in accordance with the original

issue of this service bulletin.

Revision 2 - No more work is necessary on the airplane(s) changed in accordance with the Original

Issue or Revision 1 of this service bulletin. However, Boeing recommends that, at the next convenient

maintenance opportunity, operators that had P5-2 Fuel System Module P/N 69-37335-129 installed

and subsequently reworked by BAE Systems Component Service Bulletin (CSB) 69-37335-28-04 at

Revision 2, make sure the part number is 69-37335-2129 and not 69-37335-2126, as was given. BAE

Systems Component Service Bulletin (CSB) 69-37335-28-04 gave the incorrect part number at Revision

2.

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The work in this service bulletin is done in the maintenance zone(s) given below.

Group 1:

Affected Maintenance Zones

Model Zone

737-100, 737-200, 737-200C 1-1

Group 2:

Affected Maintenance Zones

Model Zone

737-200, 737-200C 1-1

Group 2:

Affected Maintenance Zones

Model Zone

737-300, 737-400, 737-500 101

E. Compliance

Federal Aviation Administration (FAA) Notice of Proposed Rulemaking NPRM 2010-NM-189-AD is

related to this service bulletin.

Boeing recommends that the change given in this service bulletin be done within 36 months after the

Original Issue date of this service bulletin.

Group 1:

Operators with Group 1 airplanes should contact Boeing to get engineering and accomplishment

instructions for this change and do the instructions.

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 man-hours necessary to do this service bulletin for each

airplane. This estimate is for direct labor only, done by an experienced crew. Adjust the estimate with

operator man-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 inspect the work

— Time to find the tools.

Group 1:

Operators with Group 1 airplanes should contact Boeing to get engineering and accomplishment

instructions for this change and do the instructions.

Group 2:

Elapsed Time

(Hours)

Number of Task-Hours

Persons

Task

FIGURE 1 1 0.50 0.50

Do Functional Test 1 0.50 0.50

TOTAL FOR EACH AIRPLANE 1.0 1.0

H. Weight and Balance Changes

None.

I. Electrical Load Data

Not applicable.

J. References

1. Existing Data:

a. Engineering Change Memo PRR 35440-20R.

b. Boeing Service Bulletin 737-28A1216, 737-28A1228.

c. Federal Aviation Administration (FAA) Notice of Proposed Rule Making (NPRM)

2010-NM-189-AD.

d. Service Bulletin Index D6-19567.

e. 737 Fleet Team Digest (FTD) 28-04003.

f. 737-100/200 Aircraft Maintenance Manual (AMM) 24-22-00, 28-22-122, 28-42-00.

g. 737-300/400/500 Aircraft Maintenance Manual (AMM) 24-22-00, 28-22-43, 28-42-00.

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BOEING SERVICE BULLETIN 737-28A1210
h. BAE Systems Component Service Bulletin 69-37335-28-04, Revision 3, dated March 31,

2011.

i. Special Federal Aviation Regulation (SFAR) 88.

2. Data Supplied with this Service Bulletin:

None.

3. Installation Drawings Used in the Preparation of this Service Bulletin:

Drawing Number Title

MODULE INSTALLATION-OVERHEAD,

ELECTRONICS, AND AUXILIARY

65-46991

MODULE INSTALLATION-OVERHEAD,

ELECTRONICS, AND AUXILIARY

65C46991

These drawings were used to prepare this service bulletin. These drawings are not necessary to

make the specified changes, and are not supplied with this service bulletin. These drawings may

not be applicable to all airplane configurations or operators.

K. Publications Affected

1. Publications:

Publication Chapter-Section

737-100/200/300/400/500 FAA Approved (a)

Airplane Flight Manual

11-30, 28-11, 28-41, 28-42,

31-11, and 73-00

737-100/200/300/400/500 Illustrated Parts

Catalog

737-100/200/300/400/500 Aircraft Mainte- 28-22

nance Manual

Chapter 12, Normal Procedures (NP), Non-Normal

Checklist (NNC)

737-100/200/300/400/500 Flight Crew Operations Manual

737-100/200/300/400/500 Wiring Diagram Equipment List

Manual

(a) This Change affects Section 1 and 3 of the FAA Approved Airplane Flight

Manual. Operators will receive applicable data.

2. Damage Tolerance Based Structural Inspections:

Boeing has evaluated this service bulletin for effects on Fatigue Critical Structure (FCS) and for

changes to Damage Tolerance Inspections (DTI) required in the Maintenance Program. This

service bulletin does not affect FCS, therefore DTIs are not necessary.

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L. Interchangeability and Intermixability of Parts

Refer to Paragraph 2.C., Parts Necessary for Each Airplane, for interchangeability and intermixability

information.

M. Software Accomplishment Summary

Not affected.

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2. MATERIAL INFORMATION

A. Material - Price and Availability

The operator can supply the parts and materials shown in Paragraph 2.C., Parts Necessary for Each

Airplane and Paragraph 2.D., Parts Necessary to Change Spares. Refer to BAE Systems Component

Service Bulletin 69-37335-28-04, Revision 3, dated March 31, 2011.

B. Industry Support Information

Boeing warranty remedies are not available for the configuration changes given in this service bulletin.

C. Parts Necessary for Each Airplane

1. Kits/Parts:

None.

2. Parts and Materials Supplied by the Operator:

Group 1:

Operators with Group 1 airplanes should contact Boeing to get engineering and accomplishment

instructions for this change and do the instructions.

Group 2:

Existing Part Notes

Number

Part Number / QTY Name

Specification

69-37335-2031 1 P5-2 Fuel System Module Assembly 69-37335-31 (a) (b)

69-37335-2032 1 P5-2 Fuel System Module Assembly 69-37335-32 (a) (b)

69-37335-2039 1 P5-2 Fuel System Module Assembly 69-37335-39 (a) (b)

69-37335-2043 1 P5-2 Fuel System Module Assembly 69-37335-43 (a) (b)

69-37335-2045 1 P5-2 Fuel System Module Assembly 69-37335-45 (a) (b)

69-37335-2051 1 P5-2 Fuel System Module Assembly 69-37335-51 (a) (b)

69-37335-2058 1 P5-2 Fuel System Module Assembly 69-37335-58 (a) (b) (c)

69-37335-2066 1 P5-2 Fuel System Module Assembly 69-37335-66 (a) (b)

69-37335-2067 1 P5-2 Fuel System Module Assembly 69-37335-67 (a) (b)

69-37335-2068 1 P5-2 Fuel System Module Assembly 69-37335-68 (a) (b)

69-37335-2071 1 P5-2 Fuel System Module Assembly 69-37335-71 (a) (b) (c)

69-37335-2072 1 P5-2 Fuel System Module Assembly 69-37335-72 (a) (b) (c)

69-37335-2079 1 P5-2 Fuel System Module Assembly 69-37335-79 (a) (b) (c)

69-37335-2087 1 P5-2 Fuel System Module Assembly 69-37335-87 (a) (b) (c)

69-37335-2088 1 P5-2 Fuel System Module Assembly 69-37335-88 (a) (b)

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Group 2:

Existing Part Notes

Number

Part Number / QTY Name

Specification

69-37335-2093 1 P5-2 Fuel System Module Assembly 69-37335-93 (a) (b)

69-37335-2095 1 P5-2 Fuel System Module Assembly 69-37335-95 (a) (b)

69-37335-2096 1 P5-2 Fuel System Module Assembly 69-37335-96 (a) (b)

69-37335-2098 1 P5-2 Fuel System Module Assembly 69-37335-98 (a) (b) (c)

69-37335-2100 1 P5-2 Fuel System Module Assembly 69-37335-100 (a) (b) (c)

69-37335-2105 1 P5-2 Fuel System Module Assembly 69-37335-105 (a) (b) (c)

69-37335-2111 1 P5-2 Fuel System Module Assembly 69-37335-111 (a) (b)

69-37335-2112 1 P5-2 Fuel System Module Assembly 69-37335-112 (a) (b)

69-37335-2115 1 P5-2 Fuel System Module Assembly 69-37335-115 (a) (b)

69-37335-2117 1 P5-2 Fuel System Module Assembly 69-37335-117 (a) (b)

69-37335-2118 1 P5-2 Fuel System Module Assembly 69-37335-118 (a) (b) (c)

69-37335-2119 1 P5-2 Fuel System Module Assembly 69-37335-119 (a) (b) (c)

69-37335-2123 1 P5-2 Fuel System Module Assembly 69-37335-123 (a) (b)

69-37335-2124 1 P5-2 Fuel System Module Assembly 69-37335-124 (a) (b)

69-37335-2125 1 P5-2 Fuel System Module Assembly 69-37335-125 (a) (b)

69-37335-2126 1 P5-2 Fuel System Module Assembly 69-37335-126 (a) (b)

69-37335-2127 1 P5-2 Fuel System Module Assembly 69-37335-127 (a) (b)

69-37335-2128 1 P5-2 Fuel System Module Assembly 69-37335-128 (a) (b) (c)

69-37335-2129 1 P5-2 Fuel System Module Assembly 69-37335-129 (a) (b)

69-37335-2130 1 P5-2 Fuel System Module Assembly 69-37335-130 (a) (b)

69-37335-2131 1 P5-2 Fuel System Module Assembly 69-37335-131 (a) (b) (c)

69-37335-2132 1 P5-2 Fuel System Module Assembly 69-37335-132 (a) (b)

69-37335-2133 1 P5-2 Fuel System Module Assembly 69-37335-133 (a) (b)

69-37335-2134 1 P5-2 Fuel System Module Assembly 69-37335-134 (a) (b)

69-37335-2135 1 P5-2 Fuel System Module Assembly 69-37335-135 (a) (b)

69-37335-2136 1 P5-2 Fuel System Module Assembly 69-37335-136 (a) (b)

69-37335-2137 1 P5-2 Fuel System Module Assembly 69-37335-137 (a) (b)

69-37335-2138 1 P5-2 Fuel System Module Assembly 69-37335-138 (a) (b) (c)

69-37335-2139 1 P5-2 Fuel System Module Assembly 69-37335-139 (a) (b)

69-37335-2140 1 P5-2 Fuel System Module Assembly 69-37335-140 (a) (b) (c)

69-37335-2143 1 P5-2 Fuel System Module Assembly 69-37335-143 (a) (b)

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Group 2:

Existing Part Notes

Number

Part Number / QTY Name

Specification

(a) Refer to BAE Systems Component Service Bulletin 69-37335-28-04, Revision 3, dated March

31, 2011 for more data about changes to P5-2 Fuel System Module.

(b) This part is not used in production.

(c) This part is for airplanes with an auxiliary fuel tank.

3. Parts Modified and Reidentified:

Group 1:

Operators with Group 1 airplanes should contact Boeing to get engineering and accomplishment

instructions for this change and do the instructions.

Group 2:

Existing Part QTY Name New Part Number Notes

Number

P5-2 Fuel System Mod- 69-37335-( ) (a) (b)

ule Assembly

69-37335-( ) 1

(a) Make the change in accordance with BAE Systems Component Service Bulletin 69-37335-

28-04, Revision 3, dated March 31, 2011.

(b) Refer to BAE Systems Component Service Bulletin 69-37335-28-04, Revision 3, dated

March 31, 2011 for the part number to use after the change has been done.

4. Parts Removed and Not Replaced:

None.

D. Parts Necessary to Change Spares

Group 1:

Operators with Group 1 airplanes should contact Boeing to get engineering and accomplishment

instructions for this change and do the instructions.

Group 2:

Refer to BAE Systems Component Service Bulletin 69-37335-28-04, Revision 3, dated March 31, 2011.

E. Special Tooling - Price and Availability

None.

F. Special Tooling Necessary to do this Service Bulletin

No special tools or equipment are necessary to do the change in this service bulletin. But, maintenance

and overhaul tools in the manuals given in Paragraph 1.J., References, can be necessary. Examine

operator tool supply to make sure all necessary tools are available.

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BLANK PAGE
3. ACCOMPLISHMENT INSTRUCTIONS

A. GENERAL INFORMATION

CAUTION: KEEP THE WORK AREA, WIRES AND ELECTRICAL BUNDLES CLEAN OF METAL

PARTICLES OR CONTAMINATION WHEN YOU USE TOOLS. UNWANTED MATERIAL,

METAL PARTICLES OR CONTAMINATION CAUGHT IN WIRE BUNDLES CAN CAUSE

DAMAGE TO THE BUNDLES. DAMAGED WIRE BUNDLES CAN CAUSE SPARKS OR

OTHER ELECTRICAL DAMAGE.

NOTE: 1. Manual titles are referred to by acronyms. Refer to Paragraph 1.J., References, for

definition of the acronyms.

2. Obey all of the warnings and cautions given in the specified manual sections.

3. Use the approved fastener and process material substitutions in accordance with

737 SRM, Chapter 51.

4. These work instructions refer to procedures included in other Boeing documents.

When the words "refer to" are used and the operator has an accepted alternative

procedure, the accepted alternative procedure can be used. When the words "in

accordance with" are included in the instruction, the procedure in the Boeing document

must be used.

5. The instructions in Paragraph 3.B., Work Instructions and the figures can include

operation of tools or test equipment. Boeing Engineering Tool Drawings, the Illustrated

Tool and Equipment Manual, and the Special Tool and Ground Handling Drawing

Index contain data on versions of the tools or test equipment that you can use. It is

permitted to use replaced tools. It is not permitted to use superseded tools.

6. This service bulletin includes functional test procedures for the systems changed by

this service bulletin. More functional tests can possibly be necessary in accordance

with standard maintenance practices because of interruption to other airplane systems.

7. Refer to BAE Systems Component Service Bulletin 69-37335-28-04 Revision 3,

dated March 31, 2011, for the component part number changes of the P5-2 Fuel

System Module. BAE Systems Component Service Bulletin 69-37335-28-04 Revision

3, dated March 31, 2011, gives the procedures to change the equipment and wire

connections in the P5-2 Fuel System Modules.

B. WORK INSTRUCTIONS

Group 1:

Operators with Group 1 airplanes should contact Boeing to get engineering and accomplishment

instructions for this change and do the instructions.

Group 2:

1. Remove electrical power from the airplane. Refer to 737-100/200 AMM 24-22-00 or 737-300/400/500

AMM 24-22-00 as an accepted procedure.

2. In the flight compartment, at the P5 forward overhead panel, replace the P5-2 Fuel System Module

in accordance with FIGURE 1.

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BOEING SERVICE BULLETIN 737-28A1210
NOTE: Operators can choose to install a new P5-2 Fuel System Module as a replacement, or

do the work in accordance with BAE Systems Component Service Bulletin 69-37335-28-04,

Revision 3, dated March 31, 2011 to change the removed P5-2 Fuel System Module.

Refer to Paragraph 2.C.2., Parts and Materials Supplied by the Operator for replacement

part numbers for the existing P5-2 Fuel System Module.

3. Supply electrical power to the airplane. Refer to 737-100/200 AMM 24-22-00 or 737-300/400/500

AMM 24-22-00 as an accepted procedure.

4. Do the Master Caution Timing Test and Operational Test of the Fuel System Module. Refer to

737-100/200 AMM 28-22-122 or 737-300/400/500 AMM 28-22-43 as an accepted procedure.

5. Do the Fuel Feed Low Pressure Indicating Test. Refer to 737-100/200 AMM 28-42-00 or

737-300/400/500 AMM 28-42-00 as an accepted procedure.

6. Put the airplane back to a serviceable condition.

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This Figure applies only to: Group 2.

FIGURE 1: MASTER CAUTION SYSTEM - P5-2 FUEL SYSTEM MODULE - REPLACEMENT

(SHEET 1 OF 2)

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The step numbers shown below agree with the numbers shown in the circle symbols in the figure. The QTY

numbers shown below are the numbers of parts necessary for one airplane.

STEP TASK NAME IDENTIFICATION QTY MORE DATA

From the P5 forward

overhead panel. (a)

P5-2 Fuel System 69-37335-( ) 1

Module

1 Remove / Keep

In the P5 forward

overhead panel. (a)

(c)

P5-2 Fuel System 69-37335-( ) 1

Module

2 Install (Changed)

In the P5 forward

overhead panel. (a)

(b)

P5-2 Fuel System 69-37335-( ) 1

Module

Install (New)

(a) Refer to 737-100/200 AMM 28-22-122 or 737-300/400/500 AMM 28-22-43 as an accepted procedure.

(b) For the new P5-2 Fuel System Module part number(s) that can replace the existing P5-2 Fuel System

Module (as applicable), refer to Paragraph 2.C.2., Parts and Materials Supplied by the Operator.

(c) The P5-2 Fuel System Module can be changed in accordance with BAE Systems Component Service

Bulletin 69-37335-28-04, Revision 3, dated March 31, 2011. As an option, operators can install a new

P5-2 Fuel System Module.

FIGURE 1: MASTER CAUTION SYSTEM - P5-2 FUEL SYSTEM MODULE - REPLACEMENT

(SHEET 2 OF 2)

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