### Commercial **Airplanes** 

# 747 Service Bulletin **ALERT Number: 747-28A2204**  Original Issue: December 19, 1996 Revision 3: March 11, 2010 ATA System: 2822 **SUBJECT:** FUEL - Distribution - Engine Fuel Feed System Outboard Main Tank Boost Pump Wiring Inspection 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.9E991 ECCN: 

## BOEING PROPRIETARY, CONFIDENTIAL, AND/OR TRADE SECRET Copyright © 1996 The Boeing Company Unpublished Work - All Rights Reserved Boeing claims copyright in each page of this document only to the extent that the page contains copyrightable subject matter.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.

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: December 19, 1996 747-28A2204 Revision 3: March 11, 2010 1 of 28 5.0BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: December 19, 1996 747-28A2204 Revision 3: March 11, 2010 2 of 28 **BOEING SERVICE BULLETIN 747-28A2204 ALERT**  **ALERT**

BLANK PAGE**Table of Contents** Revision Transmittal Sheet............................................ 5 Summary...................................................... 7 1. PLANNING INFORMATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 A. Effectivity. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 1. Airplanes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 2. Spares Affected. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 B. Concurrent Requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 C. Reason. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 D. Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 E. Compliance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 F. Approval. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 G. Manpower. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 H. Weight and Balance Changes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 I. Electrical Load Data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 J. References. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 1. Existing Data:. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 2. Data supplied with this Service Bulletin:. . . . . . . . . . . . . . . . . . . . . . . . . . . 23 3. Installation Drawings Used in the Preparation of this Service Bulletin:. . . . . . . . . . . 23 K. Publications Affected. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 L. Interchangeability and Intermixability of Parts. . . . . . . . . . . . . . . . . . . . . . . . . . . 23 2. MATERIAL INFORMATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 A. Material - Price and Availability. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 B. Industry Support Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 C. Parts Necessary For Each Airplane. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 1. Kits/Parts:. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 2. Parts and Materials Supplied by the Operator:. . . . . . . . . . . . . . . . . . . . . . . . 25 3. Parts Modified and Reidentified:. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 4. Parts Removed and Not Replaced:. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 D. Parts Necessary to Change Spares. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 E. Special Tooling - Price and Availability. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 F. Special Tooling Necessary to do this Service Bulletin. . . . . . . . . . . . . . . . . . . . . . . 25 3. ACCOMPLISHMENT INSTRUCTIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 A. GENERAL INFORMATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 B. WORK INSTRUCTIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 FIGURE 1: BOOST PUMP REFERENCE LOCATOR. . . . . . . . . . . . . . . . . . . . . . . . . . . 28

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: December 19, 1996 747-28A2204 Revision 3: March 11, 2010 3 of 28 **BOEING SERVICE BULLETIN 747-28A2204 ALERT**  **ALERT**BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: December 19, 1996 747-28A2204 Revision 3: March 11, 2010 4 of 28 **BOEING SERVICE BULLETIN 747-28A2204 ALERT**  **ALERT**

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### Commercial **Airplanes** 

# 747 Service Bulletin **ALERT Revision Transmittal Sheet**  **Number: 747-28A2204** Original Issue: December 19, 1996 Revision 3: March 11, 2010 ATA System: 2822 **SUBJECT:** FUEL - Distribution - Engine Fuel Feed System Outboard Main Tank Boost Pump Wiring Inspection This revision includes all pages of the service bulletin. **COMPLIANCE INFORMATION RELATED TO THIS REVISION** Federal Aviation Administration (FAA) Airworthiness Directive FAA AD 97-26-07, is related to this service bulletin. No more work is necessary on airplanes inspected as shown in the revision 2 of this service bulletin. 747 airplanes line number 1317 - 1419 are added to effectivity. **REASON FOR REVISION** This revision is sent to tell operators that Compliance is revised. Operators have reported finding fuel pump wire bundle chafing of Teflon sleeving, jacket and wire installation before 30,000 flight cycles, or 60,000 flight hours. The wire bundle chafing could possibly wear away the sleeving, jacket and wire installation and expose metal conductors, which could result in electrical arcing. Boeing recommends that the operators accomplish the wiring inspection given in this service bulletin within 15,000 flight hours from the last inspection, or 6,000 flight hours from the date of this revision, whichever occurs later, but not to exceed 60,000 flight hours from the last inspection. The inspection will be required to be repeated every 15,000 flight hours from the previous inspection. Vertical lines are put on the left edge of each page, except in Paragraph 1.A., Effectivity, to show the location of important changes. Airplanes are added to effectivity. Refer to Paragraph 1.A., Effectivity. Pages with no vertical lines have no important changes. **REVISION HISTORY** December 19, 1996 Original Issue: October 30, 1997 Revision 1: September 01, 2005 Revision 2: March 11, 2010 Revision 3:

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: December 19, 1996 747-28A2204 Revision 3: March 11, 2010 5 of 28BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: December 19, 1996 747-28A2204 Revision 3: March 11, 2010 6 of 28 **BOEING SERVICE BULLETIN 747-28A2204 ALERT**  **ALERT**

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### Commercial **Airplanes** 

# 747 Service Bulletin **ALERT Summary**  **Number: 747-28A2204** Original Issue: December 19, 1996 Revision 3: March 11, 2010 ATA System: 2822 **SUBJECT:** FUEL - Distribution - Engine Fuel Feed System Outboard Main Tank Boost Pump Wiring Inspection THIS BULLETIN IS SENT TO THE OPERATORS OF RECORD OF THE AIRPLANES SHOWN IN PARAGRAPH 1.A., EFFECTIVITY. IF AN AIRPLANE HAS BEEN LEASED OR SOLD, SEND THIS SERVICE BULLETIN TO THE NEW OPERATOR. IF APPLICABLE SPARES HAVE BEEN SOLD, SEND THIS SERVICE BULLETIN TO THE NEW OWNER. **CONCURRENT REQUIREMENTS** Boeing service bulletin 747-28A2092 or 747-28A2165, is necessary to be accomplished prior to or concurrent with this service bulletin. **BACKGROUND** This inspection will make sure the number 1 and number 4 main fuel tank boost pump wiring is not chafed and will not cause arcing inside the fuel tank. The number 1 and number 4 main fuel tank boost pump wiring is installed with a double layer of Teflon sleeving in the conduit. The sleeving is installed to prevent arcing between the boost pump power wiring and the conduit caused by wire chafing. 747 airplanes cumulative line numbers 329, 348 and 356 and on had the two sleeves installed in production. All other airplanes were the subject of Alert Service Bulletin 747-28A2092 or 747-28A2165 which inspected the boost pump wiring for damage and installed the two sleeves. 747 airplanes cumulative line numbers 001-432 have aluminum conduits for the main tank boost pumps. All other 747 airplanes have stainless steel conduits. If the boost pump power wiring shorts to the conduit, it is more likely that the aluminum conduit can melt and make a hole. This could result in a fuel leak, fire or an explosion. We have not been told that chafed wires have caused any conduits to be melted through since Service Bulletin 747-28A2092 was issued. **ACTION** Remove the number 1 and number 4 main tank forward and aft boost pump cover plates. Remove the boost pump wire bundle from the conduit. Inspect the sleeving/wire bundle for damage. Install the boost pump cover plates. Do a test of the boost pumps.

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: December 19, 1996 747-28A2204 Revision 3: March 11, 2010 7 of 28**EFFECTIVITY** All 747 Airplanes line number 0001-1419. Refer to Paragraph 1.A.1., Airplanes for the list of affected airplanes. **COMPLIANCE** Refer to Paragraph 1.E., Compliance. For all 747 series airplanes, certificated in any category, FAA AD 97-26-07, is related to this service bulletin and supersedes FAA AD 96-26-06, Amendment 39-9870. **INDUSTRY SUPPORT INFORMATION** Boeing warranty remedies are not available for the inspection given in this service bulletin. **MANPOWER** Total Man-hours - 4.0 for each airplane Elapsed Time - 2.0 Hours **MATERIAL INFORMATION** Operator Supplied Parts

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: December 19, 1996 747-28A2204 Revision 3: March 11, 2010 8 of 28 **BOEING SERVICE BULLETIN 747-28A2204 ALERT**  **ALERT**BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: December 19, 1996 747-28A2204 Revision 3: March 11, 2010 9 of 28 **BOEING SERVICE BULLETIN 747-28A2204 ALERT**  **ALERT**BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: December 19, 1996 747-28A2204 Revision 3: March 11, 2010 10 of 28 **BOEING SERVICE BULLETIN 747-28A2204 ALERT**  **ALERT**

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### Commercial **Airplanes** 

# 747 Service Bulletin **ALERT Number: 747-28A2204**  Original Issue: December 19, 1996 Revision 3: March 11, 2010 ATA System: 2822 **SUBJECT:** FUEL - Distribution - Engine Fuel Feed System Outboard Main Tank Boost Pump Wiring Inspection THIS BULLETIN IS SENT TO THE OPERATORS OF RECORD OF THE AIRPLANES SHOWN IN PARAGRAPH 1.A., EFFECTIVITY. IF AN AIRPLANE HAS BEEN LEASED OR SOLD, SEND THIS SERVICE BULLETIN TO THE NEW OPERATOR. IF APPLICABLE SPARES HAVE BEEN SOLD, SEND THIS SERVICE BULLETIN TO THE NEW OWNER. **1. PLANNING INFORMATION A. Effectivity**  1. Airplanes Refer to Service Bulletin Index Document D6-30300, Part 3 for Airplane Variable Number, Line Number, and Serial Number data. This service bulletin is for the airplanes shown below.
**DESCRIPTION CONFIGURATION**  **GROUP** All 747 Airplanes Line Numbers 0001-1419

- 1

Airplane Models: 747-100, 747-100B, 747-100B SUD, 747-200B, 747-200C, 747-200F, 747-300, 747-400, 747-400D, 747-400F, 747SP, 747SR **Group Variable Number** 1 RA001 - RA034 1 RA101 - RA115 1 RA161 - RA164 1 RA201 - RA203 1 RA216 - RA217

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: December 19, 1996 747-28A2204 Revision 3: March 11, 2010 11 of 28**Group Variable Number** 1 RA245 - RA246 1 RA251 - RA266 1 RA301 - RA318 1 RA351 - RA360 1 RA369 - RA373 1 RA401 - RA418 1 RA501 - RA502 1 RA521 - RA528 1 RA532 - RA548 1 RA551 - RA552 1 RA559 - RA561 1 RA581 - RA582 1 RA585 1 RA601 - RA602 1 RA631 - RA635 1 RA651 - RA652 1 RA671 - RA677 1 RA701 - RA702 1 RA721 - RA731 1 RA741 - RA745 1 RA749 - RA750 1 RA761 - RA762 1 RA781 - RA784 1 RA901 - RA916 1 RB001 - RB016 1 RB041 - RB044 1 RB071 - RB075 1 RB101 - RB102 1 RB411 - RB413 1 RB421 1 RB601 - RB607 1 RB681 - RB697 1 RB711

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: December 19, 1996 747-28A2204 Revision 3: March 11, 2010 12 of 28 **BOEING SERVICE BULLETIN 747-28A2204 ALERT**  **ALERT Group**  **Variable Number**1 RB721 - RB723 1 RB741 - RB748 1 RD001 - RD004 1 RD021 - RD022 1 RD041 - RD059 1 RD071 - RD072 1 RD081 - RD083 1 RD091 - RD092 1 RD101 - RD104 1 RD121 - RD127 1 RD131 - RD144 1 RD166 - RD167 1 RD171 - RD172 1 RD181 - RD183 1 RD201 - RD204 1 RD221 - RD227 1 RD231 - RD235 1 RD241 - RD243 1 RD251 - RD262 1 RD271 - RD272 1 RD291 - RD292 1 RD301 - RD302 1 RD311 1 RD351 - RD358 1 RD361 - RD366 1 RD381 - RD383 1 RD411 - RD414 1 RD421 - RD426 1 RD431 - RD435 1 RD441 - RD442 1 RD451 - RD456 1 RD461 1 RD471 - RD475

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: December 19, 1996 747-28A2204 Revision 3: March 11, 2010 13 of 28 **BOEING SERVICE BULLETIN 747-28A2204 ALERT**  **ALERT Group**  **Variable Number**1 RD513 - RD519 1 RD531 - RD533 1 RD551 1 RD561 1 RD571 1 RD581 - RD583 1 RD591 - RD593 1 RD601 - RD607 1 RD621 - RD623 1 RD641 - RD649 1 RD651 - RD659 1 RD661 1 RD671 1 RD681 - RD682 1 RD691 - RD692 1 RD701 - RD702 1 RD721 - RD722 1 RD741 - RD742 1 RD751 - RD755 1 RD761 1 RD771 - RD775 1 RD781 - RD783 1 RD791 - RD792 1 RE001 1 RF001 - RF006 1 RG001 - RG009 1 RG091 1 RG095 1 RG101 - RG104 1 RG121 - RG126 1 RG141 - RG142 1 RG161 - RG164 1 RG171 - RG174

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: December 19, 1996 747-28A2204 Revision 3: March 11, 2010 14 of 28 **BOEING SERVICE BULLETIN 747-28A2204 ALERT**  **ALERT Group**  **Variable Number**1 RG191 - RG193 1 RG211 - RG213 1 RG221 - RG222 1 RH101 - RH102 1 RH111 - RH112 1 RH121 - RH122 1 RJ131 - RJ133 1 RJ151 - RJ152 1 RJ301 - RJ303 1 RJ321 - RJ322 1 RJ331 - RJ333 1 RL401 - RL403 1 RL411 - RL436 1 RL451 - RL456 1 RL461 - RL462 1 RL471 - RL481 1 RL491 - RL492 1 RL501 - RL502 1 RL511 - RL516 1 RL521 - RL522 1 RL531 - RL534 1 RL551 1 RL561 - RL568 1 RL571 - RL572 1 RL576 - RL577 1 RL579 1 RL581 - RL586 1 RL651 - RL655 1 RL671 - RL675 1 RL681 - RL684 1 RL751 - RL752 1 RM001 - RM007 1 RM010 - RM013

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: December 19, 1996 747-28A2204 Revision 3: March 11, 2010 15 of 28 **BOEING SERVICE BULLETIN 747-28A2204 ALERT**  **ALERT Group**  **Variable Number**1 RM021 - RM024 1 RM026 - RM030 1 RM036 - RM045 1 RM051 - RM053 1 RM071 1 RM081 - RM084 1 RM091 1 RM096 - RM097 1 RM116 - RM117 1 RM126 - RM132 1 RM136 - RM147 1 RM156 - RM158 1 RM166 - RM177 1 RM191 - RM192 1 RM231 - RM233 1 RM241 - RM246 1 RM261 - RM264 1 RM316 - RM318 1 RM331 - RM333 1 RM341 1 RM351 - RM355 1 RM366 - RM367 1 RM401 - RM403 1 RM426 1 RM431 1 RM441 - RM443 1 RM445 1 RM801 - RM803 1 RM811 - RM813 1 RM851 - RM859 1 RM861 - RM863 1 RM871 - RM899 1 RM901 - RM906

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: December 19, 1996 747-28A2204 Revision 3: March 11, 2010 16 of 28 **BOEING SERVICE BULLETIN 747-28A2204 ALERT**  **ALERT Group**  **Variable Number**1 RM911 1 RR001 - RR005 1 RR021 - RR025 1 RR031 1 RR201 - RR206 1 RR221 - RR226 1 RR261 - RR267 1 RR301 - RR310 1 RR331 - RR332 1 RR336 1 RR341 - RR345 1 RR361 - RR362 1 RR421 - RR422 1 RR431 - RR432 1 RR441 - RR442 1 RR451 1 RR501 - RR504 1 RR521 - RR522 1 RR526 1 RR531 1 RR551 - RR556 1 RR561 1 RR566 1 RR701 1 RR721 - RR724 1 RR746 - RR748 1 RR851 - RR856 1 RR861 - RR862 1 RR951 - RR952 1 RS001 - RS002 1 RS201 1 RS211 - RS212 1 RS221 - RS222

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: December 19, 1996 747-28A2204 Revision 3: March 11, 2010 17 of 28 **BOEING SERVICE BULLETIN 747-28A2204 ALERT**  **ALERT Group**  **Variable Number**1 RS231 - RS241 1 RS251 - RS259 1 RS263 1 RS265 - RS268 1 RS271 - RS276 1 RS291 - RS292 1 RS301 - RS306 1 RS311 - RS320 1 RS331 - RS333 1 RS341 - RS342 1 RS699 1 RS701 - RS703 1 RS711 - RS713 1 RS721 - RS722 1 RS731 - RS732 1 RS741 - RS743 1 RS751 - RS752 1 RS761 - RS762 1 RS771 1 RS781 - RS782 1 RS786 1 RT001 - RT014 1 RT021 - RT022 1 RT031 - RT035 1 RT041 - RT047 1 RT061 1 RT071 - RT075 1 RT101 - RT103 1 RT121 1 RT131 - RT137 1 RT151 - RT152 1 RT161 - RT168 1 RT401 - RT412

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: December 19, 1996 747-28A2204 Revision 3: March 11, 2010 18 of 28 **BOEING SERVICE BULLETIN 747-28A2204 ALERT**  **ALERT Group**  **Variable Number**1 RT431 - RT447 1 RT451 - RT469 1 RT471 - RT499 1 RT501 - RT535 1 RT551 - RT568 1 RT571 - RT591 1 RT601 - RT657 1 RT671 - RT673 1 RT681 - RT682 1 RT691 - RT699 1 RT701 - RT704 1 RT711 - RT717 1 RT741 - RT757 1 RT776 - RT777 1 RT781 - RT784 1 RT801 - RT803 1 RT811 - RT814 1 RT831 - RT837 1 RT861 - RT864 1 RT876 - RT880 1 RT931 - RT932 1 RT945 - RT949 1 RT951 - RT955 1 RT966 - RT967 1 RU001 - RU006 1 RU016 - RU017 1 RU031 - RU032 1 RU051 - RU052 1 RU059 - RU062 1 RU081 - RU083 1 RU101 - RU102 1 RU121 - RU132 1 RU801 - RU809

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: December 19, 1996 747-28A2204 Revision 3: March 11, 2010 19 of 28 **BOEING SERVICE BULLETIN 747-28A2204 ALERT**  **ALERT Group**  **Variable Number**1 RU831 - RU841 2. Spares Affected None. **B. Concurrent Requirements** Boeing service bulletin 747-28A2092 or 747-28A2165, is necessary to be accomplished prior to or concurrent with this service bulletin. **C. Reason** This inspection will make sure the number 1 and number 4 main fuel tank boost pump wiring is not chafed and will not cause arcing inside the fuel tank. The number 1 and number 4 main fuel tank boost pump wiring is installed with a double layer of teflon sleeving in the conduit. The sleeving is installed to prevent arcing between the boost pump power wiring and the conduit caused by wire chafing. 747 airplanes cumulative line numbers 329, 348 and 356 and on had the two sleeves installed in production. All other airplanes were the subject of Alert Service Bulletin 747-28A2092 or 747-28A2165 which inspected the boost pump wiring for damage and installed the two sleeves. 747 airplanes cumulative line numbers 001-432 have aluminum conduits for the main tank boost pumps. All other 747 airplanes have stainless steel conduits. If the boost pump power wiring shorts to the conduit, it is more likely that the aluminum conduit can melt and make a hole. This could result in a fuel leak, fire or an explosion. We have not been told that chafed wires have caused any conduits to be melted through since Service Bulletin 747-28A2092 or 747-28A2165 was issued. Revision 1 is sent to add airplanes delivered after line number 432. A repeat inspection is added for all 747 airplanes. Revision 2 is sent to tell operators that airplanes line number 1121-1316 were added to the effectivity. Also, steps have been added to the referenced airplane maintenance manual sections to amplify and clarify the expected inspection procedures. Revision 3 is sent to tell operators that Compliance is revised. Operators have reported finding fuel pump wire bundle chafing before 30,000 flight cycles, or 60,000 flight hours. The wire bundle chafing could possibly wear away the sleeving, jacket and wire installation and expose metal conductors, which could result in electrical arcing. Boeing recommends that the operators accomplish the wiring inspection given in this service bulletin within 15,000 flight hours from the last inspection, or 6,000 flight hours from the date of this revision, whichever occurs later, but not to exceed 60,000 flight hours from the last inspection. The inspection will be required to be repeated every 15,000 flight hours from the previous inspection.

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: December 19, 1996 747-28A2204 Revision 3: March 11, 2010 20 of 28 **BOEING SERVICE BULLETIN 747-28A2204 ALERT**  **ALERT D. Description**  The number 1 and number 4 main tank forward and aft boost pump cover plates are removed. The boost pump wire bundle is removed from the conduit. The sleeving/wire bundle is inspected for damage. The boost pump cover plates are installed. A test of the boost pumps is done. Revision 1 - No more work is necessary on airplanes changed as shown in the initial release of this service bulletin. This inspection assumes that service bulletin 747-28A2092 or 747-28A2165 has been incorporated. Revision 2 - No more work is necessary on airplanes changed as shown in the initial release and the Revision 1 of this service bulletin. Revision 3 - No more work is necessary on airplanes inspected as shown in revision 2 of this service bulletin. PLEASE SEND A REPORT OF YOUR INSPECTION PROGRAM. ALSO, SEND THE INSPECTION RESULTS WHEN EACH INSPECTION IS COMPLETE. SEND TO: BOEING COMMERCIAL AIRPLANE GROUP ATTENTION: MANAGER, AIRLINE SUPPORT The work in this service bulletin is done in the maintenance zone(s) given below.
**Affected Maintenance Zones Zone**  **Model** 544, 545, 644, 645 747-100, 747-100B, 747-100B SUD, 747-200B, 747-200C, 747-200F, 747-300, 747-400, 747-400D, 747-400F, 747SP, 747SR **E. Compliance** For all 747 series airplanes, certificated in any category, FAA AD 97-26-07, Amendment 39-10250, is related to this service bulletin and supersedes FAA AD 96-26-06, Amendment 39-9870. Boeing recommends that the operators accomplish the wiring inspection given in this service bulletin within 15,000 flight hours from the last inspection, or 6,000 flight hours from the date of this revision, whichever occurs later, but not to exceed 60,000 flight hours from the last inspection. The inspection will be required to be repeated every 15,000 flight hours from the previous inspection. **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 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.

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: December 19, 1996 747-28A2204 Revision 3: March 11, 2010 21 of 28 **BOEING SERVICE BULLETIN 747-28A2204 ALERT**  **ALERT**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. This service bulletin has been approved by the FAA. In addition, the Manager of the FAA Seattle Aircraft Certification Office approves the inspection and the replacement, as required, of the wire bundle and sleeves of the boost pumps of the numbers 1 and 4 main fuel tanks, and of the auxiliary tank jettison pumps (if installed), as described in this service bulletin, as an alternative method of compliance with the requirements of paragraphs (a), (b), (c), (d) and (e) of FAA AD 97-26-07. All provisions of FAA AD 97-26-07 that are not specifically referenced in the above statement remain fully applicable and must be met. **G. Manpower** The table below shows an estimate of the task-hours necessary to do this inspection for each airplane. This estimate is for direct labor only, done by an experienced crew. Adjust the estimate with operator task-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 examine the work — Time to cure the materials — Time to make the parts — Time to find the tools. **Elapsed Hours Task-Hours**  **Number of Per- sons**  **Task**

2 4 2 Inspect 2 4 TOTAL FOR EACH AIRPLANE **H. Weight and Balance Changes** None. **I. Electrical Load Data** Not changed. **J. References** 1. Existing Data: a. Boeing Service Bulletin 747-28A2092, 747-28A2165 b. Federal Aviation Administration (FAA) Airworthiness Directive 96-26-06, 97-26-07 c. Standard Wiring Practices Manual (SWPM) 20-10-11, 20-10-12 d. 747-400 Aircraft Maintenance Manual (AMM) 28-22-03, 28-22-06

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: December 19, 1996 747-28A2204 Revision 3: March 11, 2010 22 of 28 **BOEING SERVICE BULLETIN 747-28A2204 ALERT**  **ALERT**2. Data supplied with this Service Bulletin: None. 3. Installation Drawings Used in the Preparation of this Service Bulletin: 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.
**Title Drawing Number**  Fuel Boost Pump Installation 65B92401 Plumbing Instl. - Fuel Feed, Auxiliary Tanks 1A and 4A 65B92482
**K. Publications Affected** 1. Publications: None. 2. Damage Tolerance Based Structural Inspections: Boeing has evaluated the repairs and/or changes in 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. **L. Interchangeability and Intermixability of Parts** Accomplishment of this service bulletin does not affect interchangeability or intermixability of parts.

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: December 19, 1996 747-28A2204 Revision 3: March 11, 2010 23 of 28 **BOEING SERVICE BULLETIN 747-28A2204 ALERT**  **ALERT**BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: December 19, 1996 747-28A2204 Revision 3: March 11, 2010 24 of 28 **BOEING SERVICE BULLETIN 747-28A2204 ALERT**  **ALERT**

BLANK PAGE**2. MATERIAL INFORMATION A. Material - Price and Availability**  None. **B. Industry Support Information** Boeing warranty remedies are not available for the inspection given in this service bulletin. **C. Parts Necessary For Each Airplane** 1. Kits/Parts: None. 2. Parts and Materials Supplied by the Operator: None. 3. Parts Modified and Reidentified: None. 4. Parts Removed and Not Replaced: None. **D. Parts Necessary to Change Spares** None **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.

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: December 19, 1996 747-28A2204 Revision 3: March 11, 2010 25 of 28 **BOEING SERVICE BULLETIN 747-28A2204 ALERT**  **ALERT**BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: December 19, 1996 747-28A2204 Revision 3: March 11, 2010 26 of 28 **BOEING SERVICE BULLETIN 747-28A2204 ALERT**  **ALERT**

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. Refer to the Boeing Standard Wiring Practices Manuals SWPM 20-10-11 and SWPM 20-10-12 for the wire installation procedures. **B. WORK INSTRUCTIONS** 1. Do the inspection of the wire bundle inside the conduit. a. On all except 747-400 airplanes, refer to 747-400 AMM 28-22-03, Main Tank Boost Pump Wiring - Inspection/Check. On airplanes RD121 and RJ151 only, this inspection must be done on the auxiliary jettison pump wire bundles, if the pumps are installed. Refer to the 747 AMM for the access and test data for these pumps. The inspection procedure is the same as mentioned above for the main tank boost pumps. b. On 747-400 airplanes, refer to 747-400 AMM 28-22-06, Main Tank Boost Pump Wiring - Inspection/Check. 2. Put the airplane back into serviceable condition.

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: December 19, 1996 747-28A2204 Revision 3: March 11, 2010 27 of 28 **BOEING SERVICE BULLETIN 747-28A2204 ALERT**  **ALERT FIGURE 1: BOOST PUMP REFERENCE LOCATOR**  **(SHEET 1 OF 1)**

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: December 19, 1996 747-28A2204 Revision 3 March 11, 2010 28 of 28 **BOEING SERVICE BULLETIN 747-28A2204 ALERT**  **ALERT**