Commercial 

Airplanes 737

Service Bulletin

ALERT

Number: 737-28A1212

Original Issue: July 23, 2009

Revision 1: August 27, 2010

ATA System: 2822

SUBJECT: FUEL - Engine Fuel Feed System - Fuel Pump Control Ground Fault Interrupter (GFI)

Relay Installation

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.

ECCN: 9E991

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Copyright © 2009 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Unpublished Work - All Rights Reserved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,

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5.0
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BLANK PAGE
Table of Contents

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

Summary ...................................................... 9

1. PLANNING INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

A. Effectivity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

1. Airplanes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

2. Spares Affected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

B. Concurrent Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

C. Reason . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

D. Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

E. Compliance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

F. Approval . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

G. Manpower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

H. Weight and Balance Changes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

I. Electrical Load Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

J. References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

1. Existing Data: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

2. Data supplied with this Service Bulletin: . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

3. Installation Drawings Used in the Preparation of this Service Bulletin: . . . . . . . . . . . 40

K. Publications Affected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

L. Interchangeability and Intermixability of Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

2. MATERIAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

A. Material - Price and Availability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

B. Industry Support Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

C. Parts Necessary For Each Airplane . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

1. Kits/Parts: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

2. Parts and Materials Supplied by the Operator: . . . . . . . . . . . . . . . . . . . . . . . . 46

3. Parts Modified and Reidentified: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

4. Parts Removed and Not Replaced: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

D. Parts Necessary to Change Spares . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

E. Special Tooling - Price and Availability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

F. Special Tooling Necessary to do this Service Bulletin . . . . . . . . . . . . . . . . . . . . . . . 47

3. ACCOMPLISHMENT INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

A. GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

B. WORK INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

FIGURE 1: M181, M182, M183 RELAY MODULE ASSEMBLY REPLACEMENT [Group 1, 8] . . . . . 54

FIGURE 2: REPLACEMENT OF THE FUEL PUMP POWER RELAYS [Group 2, Configuration 1] . . . 56

FIGURE 3: REPLACEMENT OF THE FUEL PUMP POWER RELAYS [Group 3, 9-13, Configuration 1] . 58

FIGURE 4: REPLACEMENT OF THE FUEL PUMP POWER RELAYS [Group 4, Configuration 1] . . . 60

FIGURE 5: REPLACEMENT OF THE FUEL PUMP POWER RELAYS [Group 5, Configuration 1] . . . 62

FIGURE 6: REPLACEMENT OF THE FUEL PUMP POWER RELAY [Group 6, Configuration 1] . . . 65

FIGURE 7: REPLACEMENT OF THE FUEL PUMP POWER RELAY [Group 7, Configuration 1] . . . 68

FIGURE 8: W0044 WIRE BUNDLE ROUTING [Group 2-3, 6-7, 9-13, Configuration 1] . . . . . . . . . 71

FIGURE 9: WIRE BUNDLE W0044 - WIRING CHANGES [Group 2, Configuration 1] . . . . . . . . . 72

FIGURE 10: WIRE BUNDLE W0044 - WIRING CHANGES [Group 3, 12, Configuration 1] . . . . . . . 74

FIGURE 11: WIRE BUNDLE W0044 - WIRING CHANGES [Group 6-7, 9, Configuration 1] . . . . . . . 76

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BOEING SERVICE BULLETIN 737-28A1212

ALERT ALERT
FIGURE 12: WIRE BUNDLE W0044 - WIRING CHANGES [Group 10, Configuration 1] . . . . . . . . . 77

FIGURE 13: WIRE BUNDLE W0044 - WIRING CHANGES [Group 11, 13, Configuration 1] . . . . . . . 78

FIGURE 14: FUEL BOOST PUMP CONNECTOR - WIRE LOCATION [Group 8, Configuration 1] . . . 80

FIGURE 15: FUEL BOOST PUMP GROUNDS - WIRE LOCATION [Group 8, Configuration 1] . . . . . 81

FIGURE 16: FUEL BOOST PUMP CONNECTOR - WIRING CHANGES [Group 8, Configuration 1] . . 82

FIGURE 17: FUEL BOOST PUMP CONNECTOR - WIRE LOCATION [Group 8, Configuration 2] . . . 84

FIGURE 18: FUEL BOOST PUMP GROUNDS - WIRE LOCATION [Group 8, Configuration 2] . . . . . 85

FIGURE 19: FUEL BOOST PUMP CONNECTOR - WIRING CHANGES [Group 8, Configuration 2] . . 86

FIGURE 20: FUEL BOOST PUMP CONTROL GROUND FAULT INTERRUPTER (GFI) CONTROL RELAY

REFERENCE [Group 1; Group 2-7, Configuration 1; Group 8; Group 9-13, Configuration 1] . 87

FIGURE 21: WIRE BUNDLE W0044 WIRING CHANGES [Group 1, 8] . . . . . . . . . . . . . . . . . . 88

FIGURE 22: RELAY MOUNTING PANEL - GROUND STUDS AND BONDING JUMPER INSTALLATION

[Group 2-7, 9-13] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90

Appendix A: ELECTRICAL BONDING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94

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BOEING SERVICE BULLETIN 737-28A1212

ALERT ALERT
Commercial 

Airplanes 737

Service Bulletin

ALERT

Revision Transmittal Sheet Number: 737-28A1212

Original Issue: July 23, 2009

Revision 1: August 27, 2010

ATA System: 2822

SUBJECT: FUEL - Engine Fuel Feed System - Fuel Pump Control Ground Fault Interrupter (GFI)

Relay Installation

This revision includes all pages of the service bulletin.

COMPLIANCE INFORMATION RELATED TO THIS REVISION

More work is necessary on airplanes changed in accordance with the original issue of this service bulletin:

- Group 2 through 7 Airplanes and Group 9 through 11 airplanes that incorporated original issue of this service

bulletin have to incorporate Accomplishment Instructions, Work instructions, Part 2 that provides work instructions

to install a Bonding Jumper between the relay mounting panel and P6 Load Control Center structure, and

measure the electrical bonding resistance between the GFI relays and the relay mounting panel.

-Group 1 and Group 8 airplanes that incorporated original issue of this service bulletin have to incorporate

Accomplishment Instructions, Work instructions, Part 3 that provides work instructions to measure the electrical

bonding resistance between the GFI relays and the Relay Module Assemblies M181, M182, and M183 in

accordance with Revision 1 of BAE Service Bulletin 65-49808-24-01, and to measure the electrical bonding

resistance between the Relay Module Assemblies M181, M182, and M183 and the P6 Load Control Center

structure.

Airplanes PM541-PM548 were added to Group 2 of this service bulletin effectivity.

REASON FOR REVISION

This revision is sent to add instructions for installation of a Bonding Jumper between P6-2 relay panel and P6

side panel for Group 2 through Group 7 and Group 9 through Group 13 airplanes. Instructions are added to

clean/prepare the contact surfaces of the relays and P6-2 panels to obtain the required electrical bonding. This

revision adds instructions to measure the electrical bonding resistance between the GFI relays and the P6-2

relay panel and between the P6-2 relay panel and P6 side panel. This revision is sent to add airplanes to the

service bulletin effectivity. Also, this revision adds instructions for Group 1 and Group 8 airplanes to measure

the electrical bonding resistance between M181, M182, and M183 Relay Module Assemblies and P6 Load

Control Center structure. Also, access instructions were added to the service bulletin.

These sections were changed:

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1. Airplanes PM541-PM548 are added to the service bulletin effectivity. Added new airplane configurations

to the group configuration table.

2. Group 12 and Group 13 had been added to the configuration table. Airplanes delivered with Auxiliary Tank

wire provisions have been moved to Group 12 and Group 13. Group/Configuration information has been

added to define those airplanes that have already accomplished initial release of the service bulletin.

3. Changed the concurrent requirements reference from original issue of BAE Component Service Bulletin

65-49808-24-01 to Revision 1 of the BAE Component Service Bulletin 65-49808-24-01.

4. Removed the reference to the Fault Isolation Manual and changed the IPC reference in Paragraph 1.K.,

Publications affected. The 737-100/-200/-300/-400/-500 airplane models do not have a Fault Isolation

Manual.

5. Task hour tables had been added for each airplane group configuration. The task hour estimates were

changed to include the removal and installation of the galley number one.

6. Three kits, availability, and price information was added to paragraph 2.A. Material Information.

7. The work instructions were changed to include:

a. The removal and installation of the galley number one to get access to the work location.

b. The installation of a bonding jumper.

c. To prepare/clean the contact surfaces of the relays and mounting panel to obtain the required electrical

bonding.

d. To measure the bonding resistance between the GFI relays and mounting panel.

e. To measure the bonding resistance between the mounting panel and P6 Load Control Center structure.

f. Added Part 2 and Part 3 for airplanes that incorporated original issue of the service bulletin.

8. Terminology has been changed in the Work Instructions to agree with the terminology defined in Paragraph

3.A. General Information - Notes.

9. Figure 1 was changed to change the reference to Revision 1 of the BAE Component Service Bulletin

65-49808-24-01. Step was added to measure the electrical bonding resistance between Relay Module

Assemblies M181, M182, and M183 and the P6 Load Control Center structure.

10. Figure 2, 3, 4, 5, 6, 7 have been changed to prepare/clean the contact surfaces of the relays and mounting

panel in order to obtain the required electrical bonding.

11. Figure 22 has been added. this figure provides instructions to add a bonding jumper between relay mounting

panel and P6 Load Control Center structure and measure the bonding resistance between the relay mounting

panel and P6 Load Control Center structure.

12. Appendix A that provides information for electrical bonding was added to Paragraph 3.A., Work Instructions.

Vertical lines are put on the left edge of each page, except in Paragraph 1.A., Effectivity, to show the location

of important changes.

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BOEING SERVICE BULLETIN 737-28A1212

ALERT ALERT
Pages with no vertical lines have no important changes.

REVISION HISTORY

Original Issue: July 23, 2009

Revision 1: August 27, 2010

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BOEING SERVICE BULLETIN 737-28A1212

ALERT ALERT

BLANK PAGE
Commercial 

Airplanes 737

Service Bulletin

ALERT

Summary Number: 737-28A1212

Original Issue: July 23, 2009

Revision 1: August 27, 2010

ATA System: 2822

SUBJECT: FUEL - Engine Fuel Feed System - Fuel Pump Control Ground Fault Interrupter (GFI)

Relay Installation

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

BAE Component Service Bulletin 65-49808-24-01, Revision 1, is necessary to be accomplished prior to or

concurrent with this service bulletin for Group 1 and Group 8 airplanes. BAE Component Service Bulletin

65-49808-24-01 gives the parts and instructions to replace relays in the M181, M182, and M183 Relay Module

Assemblies.

BACKGROUND

This service bulletin gives the instructions to replace the power control relays for the fuel boost pumps. The

relays are located in the P6 circuit breaker panel in the flight compartment. The new relays include a Ground

Fault Interrupt (GFI) feature. The GFI relay feature will protect the fuel pumps from damage caused by electrical

arcing because the electrical power will be removed from the pump if a ground fault is detected. Electrical arcing

could create a possible source of ignition of flammable fuel vapors in the fuel tanks. Ignition of flammable fuel

vapors could cause a fire or explosion which could put the airplane in an unsafe condition.

This service bulletin is the result of the safety assessments conducted by Boeing under SFAR 88, "Fuel Tank

System Fault Tolerance Evaluation Requirements".

This change affects section 9 of the Maintenance Planning Data (MPD) Document. The Airworthiness Limitations

(AWL) "28-AWL-23" (737-100/200/200C airplanes) and "28-AWL-22" (737-300/400/500 airplanes) are related

to this service bulletin.

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ACTION (PRR 35440-10RS)

Airplane Work

1. Get access to the flight compartment.

2. For Groups 2, 3, 4, 5, 6, 7, 9, 10, 11, 12, 13 airplanes, at the P6 Load Control Center install two ground

studs and a ground bonding jumper.

3. For Groups 2, 3, 4, 5, 6, 7, 9, 10, 11, 12, 13 airplanes measure the electrical bonding between the P6-2

relay panel and P6 Load Control Center structure.

4. For Group 2 Configuration 1, and Group 4 Configuration 1, replace (6) relays with Ground Fault Interrupt

(GFI) relays. For Group 3 Configuration 1, Group 5-7 Configuration 1, and Group 9-13 Configuration 1,

replace (8) relays with Ground Fault Interrupt (GFI) relays. Measure the electrical bonding between the GFI

relays and the P6-2 panel.

5. For Groups 1 and 8 airplanes install the Ground Fault Interrupt (GFI) relays in Relay Module Assemblies

M181, M182, and M183 in accordance with BAE Component Service Bulletin 65-49808-24-01 and change

wire W044. Measure the electrical bonding between M181, M182, M183 and the adjacent P6 Load Control

Center structure.

6. Do a Ground Fault Interrupter (GFI) - Operational Test of the GFI relay installation for the fuel boost pumps.

EFFECTIVITY

All 737-100/-200/-200C/-300/-400/-500 Airplanes.

COMPLIANCE

The Federal Aviation Administration (FAA) will possibly release an Airworthiness Directive related to this service

bulletin. The Airworthiness Directive will make the compliance tasks and times given in this service bulletin

mandatory.

Boeing recommends that operators make the changes shown in this service bulletin within 60 months after the

date of Revision 1 of this service bulletin.

INDUSTRY SUPPORT INFORMATION

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

MANPOWER

Refer to Paragraph 1.G., Manpower.

MATERIAL INFORMATION

Operator Supplied Parts/Materials.

Refer to Paragraph 2.A., Material - Price and Availability.

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BOEING SERVICE BULLETIN 737-28A1212

ALERT ALERT
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BOEING SERVICE BULLETIN 737-28A1212

ALERT ALERT
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BOEING SERVICE BULLETIN 737-28A1212

ALERT ALERT

BLANK PAGE
Commercial 

Airplanes 737

Service Bulletin

ALERT

Number: 737-28A1212

Original Issue: July 23, 2009

Revision 1: August 27, 2010

ATA System: 2822

SUBJECT: FUEL - Engine Fuel Feed System - Fuel Pump Control Ground Fault Interrupter (GFI)

Relay Installation

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 D6-19567 Part 3 for Airplane Variable Number, Line

Number, and Serial Number data.

This service bulletin is for the airplanes shown below. Refer to PRR35440-10RS for data about

this change.

GROUP CONFIGURATION DESCRIPTION

737-100/200/200C Airplanes that require BAE Component Service

Bulletin 65-49808-24-01, Revision 1. W0044 Wire Bundle Wiring

Changes.

1 -

Airplanes that did not incorporate the original issue of SB

737-28A1212.

1

Airplanes that incorporated the original issue of SB 737-28A1212.

These airplanes did not measure the electrical bonding between the

GFI relays and the Relay Module Assemblies M181, M182, and M

183. Also these airplanes did not measure the electrical bonding

between Relay Module Assemblies M181, M182, and M183 and P6

Load Control Center structure.

2

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13 of 99
GROUP CONFIGURATION DESCRIPTION

737-100/200/200C/300/400/500 Airplanes - 6 Relays without Spacers,

located in the P6 panel.

2 -

Airplanes that did not incorporate the original issue of SB

737-28A1212.

1

Airplanes that incorporated the original issue of SB 737-28A1212.

These airplanes did not install the Ground Bonding Jumper between

P6-2 Relay Panel and P6 Load Control Center structure.

2

737-100/200/300/400/500 Airplanes - (8) S283A004-1 Relays

including (2) Relays installed for the Auxiliary Fuel Tanks. W0044

Wire Bundle Wiring Changes.

3 -

Airplanes that did not incorporate the original issue of SB

737-28A1212.

1

Airplanes that incorporated the original issue of SB 737-28A1212.

These airplanes did not install the Ground Bonding Jumper between

P6-2 Relay Panel and P6 Load Control Center structure.

2

4 - 737-100/200/300/400/500 Airplanes - (6) S283A004-6 Relays.

Airplanes that did not incorporate the original issue of SB

737-28A1212.

1

Airplanes that incorporated the original issue of SB 737-28A1212.

These airplanes did not install the Ground Bonding Jumper between

P6-2 Relay Panel and P6 Load Control Center structure.

2

737-300/400/500 Airplanes - (4) S283A004-6 Relays and (2)

S283A004-1 Relays.

5 -

Airplanes that did not incorporate the original issue of SB

737-28A1212.

1

Airplanes that incorporated the original issue of SB 737-28A1212.

These airplanes did not install the Ground Bonding Jumper between

P6-2 Relay Panel and P6 Load Control Center structure.

2

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BOEING SERVICE BULLETIN 737-28A1212

ALERT ALERT
GROUP CONFIGURATION DESCRIPTION

737-300/400/500 Airplanes - (4) S283A004-6 Relays and (4)

S283A004-1 Relays including (2) Relays installed for the Auxiliary

Fuel Tanks.

6 -

Airplanes that did not incorporate the original issue of SB

737-28A1212.

1

Airplanes that incorporated the original issue of SB 737-28A1212.

These airplanes did not install the Ground Bonding Jumper between

P6-2 Relay Panel and P6 Load Control Center structure.

2

737-300/400/500 Airplanes - (6) S283A004-6 Relays and (2)

S283A004-1 Relays including (2) Relays installed for the Auxiliary

Fuel Tanks. W0044 Wire Bundle Wiring Changes.

7 -

Airplanes that did not incorporate the original issue of SB

737-28A1212.

1

Airplanes that incorporated the original issue of SB 737-28A1212.

These airplanes did not install the Ground Bonding Jumper between

P6-2 Relay Panel and P6 Load Control Center structure.

2

737-100/200 Airplanes that require BAE Component Service Bulletin

65-49808-24-01, Revision dated February 19, 2008, and Fuel Boost

Pumps Connector and Grounds Inspections. W0044 Wire Bundle

Wiring Changes.

8 -

737-100/200 Airplanes on which Boeing Service Bulletin 737-28A1263

, and the original issue of SB 737-28A1212 have not been

incorporated.

1

737-100/200 Airplanes on which Boeing Service Bulletin 737-28A1263

has been incorporated previously, and the original issue of SB

737-28A1212 has not been incorporated.

2

737-100/200 Airplanes on which Boeing Service Bulletin 737-28A1263

has not been incorporated, and the original issue of SB 737-28A1212

has been incorporated. These airplanes did not measure the electrical

bonding between the GFI relays and the Relay Module Assemblies

M181, M182, and M 183. Also these airplanes did not measure the

electrical bonding between Relay Module Assemblies M181, M182,

and M183 and P6 Load Control Center structure.

3

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BOEING SERVICE BULLETIN 737-28A1212

ALERT ALERT
GROUP CONFIGURATION DESCRIPTION

737-300/400/500 Airplanes - (8) S283A004-1 Relays including (2)

Relays installed for the Auxiliary Fuel Tanks. W0044 Wire Bundle

Wiring Changes.

9 -

Airplanes that did not incorporate the original issue of SB

737-28A1212.

1

Airplanes that incorporated the original issue of SB 737-28A1212.

These airplanes did not install the Ground Bonding Jumper between

P6-2 Relay Panel and P6 Load Control Center structure.

2

737-100/200 Airplanes - (8) S283A004-1 Relays including (2) Relays

installed for the Auxiliary Fuel Tanks. W0044 Wire Bundle Wiring

Changes.

10 -

Airplanes that did not incorporate the original issue of SB

737-28A1212.

1

Airplanes that incorporated SB 737-28A1212 R0. These airplanes

did not install the Ground Bonding Jumper between P6-2 Relay Panel

and P6 Load Control Center structure.

2

737-300/400/500 Airplanes - (8) S283A004-1 Relays including (2)

Relays installed for the Auxiliary Fuel Tanks. W0044 Wire Bundle

Wiring Changes.

11 -

Airplanes that did not incorporate the original issue of SB

737-28A1212.

1

Airplanes that incorporated the original issue of SB 737-28A1212.

These airplanes did not install the Ground Bonding Jumper between

P6-2 Relay Panel and P6 Load Control Center structure.

2

737-100/200/300/400/500 Airplanes delivered with provisional wires

for Auxiliary Tank - (8) S283A004-1 Relays including (2) Relays

installed for Auxiliary Tank (if installed), and W0044 Wire Bundle

Wiring Changes.

12 -

Airplanes that did not incorporate the original issue of SB

737-28A1212.

1

Airplanes that incorporated the original issue of SB 737-28A1212.

These airplanes did not install the Ground Bonding Jumper between

P6-2 Relay Panel and P6 Load Control Center structure.

2

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GROUP CONFIGURATION DESCRIPTION

737-300/400/500 Airplanes delivered with provisional wires for

Auxiliary Tank - (8) S283A004-1 Relays including (2) Relays installed

for Auxiliary Tank (if installed). and W0044 Wire Bundle Wiring

Changes.

13 -

Airplanes that did not incorporate the original issue of SB

737-28A1212.

1

Airplanes that incorporated the original issue of SB 737-28A1212.

These airplanes did not install the Ground Bonding Jumper between

P6-2 Relay Panel and P6 Load Control Center structure.

2

Airplane Models:

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

Variable Number Group

PA001 - PA014 8

PA015 - PA022 1

PA099 8

PA231 - PA232 1

PC001 - PC005 1

PG001 - PG017 8

PG018 - PG075 1

PG199 8

PG201 - PG202 8

PG203 - PG230 1

PG251 - PG255 1

PG271 - PG273 8

PG274 - PG279 1

PG301 - PG302 8

PG303 - PG314 1

PG331 8

PG332 1

PG351 - PG356 1

PG375 1

PG401 - PG403 1

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Variable Number Group

PG431 - PG440 1

PG441 - PG442 2

PG471 - PG475 1

PG501 - PG505 1

PG571 - PG578 1

PG579 - PG586 2

PG621 - PG630 1

PG651 - PG652 1

PG704 - PG705 1

PH001 2

PH011 - PH013 2

PH021 - PH024 2

PH701 - PH708 1

PH709 - PH715 2

PH731 - PH732 2

PH741 - PH743 2

PJ001 - PJ002 1

PJ003 - PJ006 2

PJ007 - PJ009 3

PJ031 - PJ032 1

PJ071 - PJ072 1

PJ101 - PJ104 1

PJ105 - PJ119 2

PJ201 - PJ219 3

PJ301 - PJ302 4

PJ551 - PJ561 4

PJ601 - PJ615 4

PJ811 6

PJ816 - PJ817 5

PK026 - PK029 2

PK041 - PK053 2

PK061 - PK067 2

PK068 - PK070 3

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Variable Number Group

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 - PK256 2

PK257 12

PK258 2

PK271 - PK274 2

PK281 - PK289 2

PK291 2

PK301 - PK318 2

PK341 2

PK351 - PK355 2

PK356 - PK359 3

PK360 12

PK361 2

PK391 2

PK431 - PK433 2

PK451 - PK452 2

PK461 - PK469 2

PK495 2

PK501 2

PK502 - PK504 12

PK511 - PK515 2

PK519 2

PK521 - PK528 2

PK541 - PK565 2

PK581 2

PK591 - PK599 2

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Variable Number Group

PK601 - PK606 2

PK607 - PK610 3

PK611 - PK617 2

PK621 - PK637 2

PK641 - PK642 2

PK661 3

PK662 - PK666 2

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 - PK872 12

PK873 3

PK874 12

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 - PL408 2

PL409 - PL410 3

PL411 2

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Variable Number Group

PL412 3

PL413 - PL417 2

PL421 12

PL441 2

PL451 - PL456 2

PL471 2

PL491 2

PL501 3

PL502 - PL503 12

PL504 - PL506 3

PL551 - PL562 2

PL581 2

PL601 - PL603 3

PL611 2

PL621 - PL626 2

PL631 - PL632 3

PL711 - PL712 2

PL716 - 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 - PM107 3

PM108 - PM119 12

PM141 - PM142 12

PM171 2

PM181 2

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Variable Number Group

PM251 - PM255 2

PM281 - PM283 2

PM381 - PM399 2

PM401 - PM417 2

PM541 - PM550 2

PM551 - PM564 4

PN001 - PN002 3

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

PN491 - PN493 2

PN501 2

PN502 4

PN511 2

PN512 4

PN521 10

PP001 - PP054 2

PP101 - PP169 2

PP181 - PP187 2

PP188 - PP199 4

PP201 - PP205 2

PP221 2

PP231 - PP243 2

PP281 - PP286 2

PP301 - PP305 2

PP351 - PP353 2

PP376 - PP384 2

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Variable Number Group

PP391 - PP393 2

PP401 - PP440 2

PP471 - PP475 11

PP501 - PP520 13

PP521 - PP522 2

PP631 - PP634 2

PP651 - PP652 2

PP671 - PP689 2

PP690 - PP694 11

PP695 - PP699 2

PP701 - PP706 2

PP707 - PP716 11

PP717 - 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 - PP965 2

PP966 - PP967 4

PP981 - PP982 2

PP983 - PP990 4

PP991 2

PP993 4

PQ001 - PQ016 2

PQ026 - PQ041 2

PQ051 - PQ092 2

PQ101 - PQ199 2

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Variable Number Group

PQ201 - PQ202 2

PQ221 - PQ230 4

PQ231 - PQ232 2

PQ233 - PQ237 4

PQ241 - PQ242 2

PQ243 4

PQ251 - PQ267 4

PQ281 - PQ299 4

PQ301 - PQ307 4

PQ331 - PQ332 4

PQ341 - PQ348 4

PQ361 - PQ373 4

PQ391 - PQ395 4

PQ401 - PQ418 4

PQ421 4

PQ431 - PQ438 4

PQ447 - PQ448 4

PQ451 4

PQ454 4

PQ471 - PQ475 4

PQ479 - PQ481 4

PQ486 - PQ487 4

PQ491 - PQ493 4

PQ771 - PQ772 4

PQ791 - PQ793 4

PQ801 - PQ805 4

PQ931 - PQ935 5

PQ951 4

PQ971 - PQ997 4

PR001 - PR017 4

PR021 - PR034 4

PR041 - PR045 5

PR061 - PR072 5

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Variable Number Group

PR077 - PR080 4

PR081 - PR082 5

PR091 - PR092 4

PR096 4

PR101 4

PR121 - PR122 4

PR131 - PR132 4

PR141 - PR143 4

PR161 - PR172 4

PR181 4

PS601 - PS631 2

PS636 - PS638 2

PS641 - PS644 2

PS651 - PS657 4

PS666 - PS669 4

PS691 - PS692 4

PS701 - PS706 2

PS751 - PS799 2

PS811 4

PS836 - PS837 4

PS841 - PS846 2

PS851 - PS852 2

PS856 2

PS861 - PS863 13

PS866 - PS868 13

PS871 - PS874 2

PS896 - PS897 2

PS901 - PS941 2

PS956 - PS957 13

PS961 - PS963 4

PS971 - PS978 4

PT001 - PT015 4

PT021 - PT031 4

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Variable Number Group

PT041 - PT064 4

PT101 - PT105 4

PT121 - PT138 5

PT146 - PT148 4

PT161 - PT170 4

PT181 - PT188 5

PT211 - PT220 4

PT295 5

PT301 - PT309 4

PT331 - PT360 5

PT381 - PT399 4

PT401 - PT438 4

PT501 - PT517 4

PT561 - PT565 4

PT581 - PT586 4

PT611 - PT621 4

PT641 - PT644 4

PT651 - PT656 4

PT671 - PT672 4

PT681 - PT685 4

PT701 - PT703 4

PT716 - PT717 4

PT721 - PT725 4

PT801 - PT834 4

PT851 - PT854 4

PT871 - PT886 5

PT901 - PT930 4

PT971 - PT973 4

PT981 - PT985 4

PT996 4

PU001 - PU025 4

PU301 4

PU311 - PU313 4

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Variable Number Group

PV001 2

PV002 - PV055 4

PV201 - PV209 4

PV226 - PV229 4

PV231 - PV237 5

PV271 - PV272 4

PV281 - PV287 5

PV296 4

PV301 - PV302 4

PV351 5

PV356 - PV357 4

PW001 - PW054 4

PW061 - PW068 4

PW072 4

PW086 - PW088 4

PW091 - PW094 4

PW101 - PW102 4

PW106 4

PW111 - PW120 4

PW156 - PW157 4

PW161 - PW171 4

PW201 - PW252 4

PW261 - PW268 4

PW271 - PW276 4

PW278 4

PW281 - PW293 4

PW296 4

PW301 - PW327 5

PW401 - PW408 4

PW411 - PW418 4

PW421 - PW424 4

PW431 - PW435 4

PW441 - PW450 5

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Variable Number Group

PW461 - PW467 5

PW501 - PW504 5

PW511 - PW522 6

PW524 6

PW525 - PW529 5

PW530 6

PW531 - PW550 4

PW556 - PW557 4

PW561 - PW564 5

PW571 - PW576 5

PW591 - PW596 4

PW611 - PW622 4

PW631 - PW637 4

PW661 - PW662 4

PW681 - PW683 4

PW701 7

PW702 9

PW711 - PW717 5

PW741 - PW742 4

PW761 4

PW771 4

PW831 4

PW851 - PW856 4

PX071 1

PX701 1

PY001 - PY006 1

PY007 - PY008 2

PY021 - PY022 2

PY031 2

PY036 - PY037 2

PY046 - PY048 2

PY051 - PY053 2

PY056 - PY057 2

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Variable Number Group

PY101 - PY103 2

PY111 - PY113 2

PY131 - PY135 2

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 - PY344 1

PY345 - PY346 2

PY361 - PY362 1

PY381 2

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

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ALERT ALERT
Variable Number Group

PY671 - PY672 2

PY721 2

PY741 2

2. Spares Affected

None.

B. Concurrent Requirements

BAE Component Service Bulletin 65-49808-24-01, Revision 1, is necessary to be accomplished prior

to or concurrent with this service bulletin for Group 1 and Group 8 airplanes. BAE Component Service

Bulletin 65-49808-24-01 gives the parts and instructions to replace relays in the M181, M182, and

M183 Relay Module Assemblies.

C. Reason

This service bulletin gives the instructions to replace the power control relays for the fuel boost pumps.

The relays are located in the P6 circuit breaker panel in the flight compartment. The new relays include

a ground fault interrupt (GFI) feature. The GFI relay feature will protect the fuel pumps from damage

caused by electrical arcing because the electrical power will be removed from the pump if a ground

fault is detected. Electrical arcing could create a possible source of ignition of flammable fuel vapors

in the fuel tanks. Ignition of flammable fuel vapors could cause a fire or explosion which could put the

airplane in an unsafe condition.

This service bulletin is the result of the safety assessments conducted by Boeing under SFAR 88, "Fuel

Tank System Fault Tolerance Evaluation Requirements".

This change affects section 9 of the Maintenance Planning Data (MPD) Document.The Airworthiness

Limitations (AWL) "28-AWL-23" (737-100/200/200C airplanes) and "28-AWL-22" (737-300/400/500

airplanes) are related to this service bulletin.

These sections were changed:

1. Airplanes PM541-PM548 are added to the service bulletin effectivity. Added new airplane

configurations to the group configuration table.

2. Group 12 and Group 13 had been added to the configuration table. Airplanes delivered with Auxiliary

Tank wire provisions have been moved to Group 12 and Group 13. Group/Configuration information

has been added to define those airplanes that have already accomplished initial release of the

service bulletin.

3. Changed the concurrent requirements reference from original issue of BAE Component Service

Bulletin 65-49808-24-01 to Revision 1 of the BAE Component Service Bulletin 65-49808-24-01.

4. Removed the reference to the Fault Isolation Manual and changed the IPC reference in Paragraph

1.K., Publications affected. The 737-100/-200/-300/-400/-500 airplane models do not have a Fault

Isolation Manual.

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5. Task hour tables had been added for each airplane group configuration. The task hour estimates

were changed to include the removal and installation of the galley number one.

6. Three kits, availability, and price information was added to paragraph 2.A. Material Information.

7. The work instructions were changed to include:

a. The removal and installation of the galley number one to get access to the work location.

b. The installation of a bonding jumper.

c. To prepare/clean the contact surfaces of the relays and mounting panel to obtain the required

electrical bonding.

d. To measure the bonding resistance between the GFI relays and mounting panel.

e. To measure the bonding resistance between the mounting panel and P6 Load Control Center

structure.

f. Added Part 2 and Part 3 for airplanes that incorporated original issue of the service bulletin.

8. Terminology has been changed in the Work Instructions to agree with the terminology defined in

Paragraph 3.A. General Information - Notes.

9. Figure 1 was changed to change the reference to Revision 1 of the BAE Component Service

Bulletin 65-49808-24-01. Step was added to measure the electrical bonding resistance between

Relay Module Assemblies M181, M182, and M183 and the P6 Load Control Center structure.

10. Figure 2, 3, 4, 5, 6, 7 have been changed to prepare/clean the contact surfaces of the relays and

mounting panel in order to obtain the required electrical bonding.

11. Figure 22 has been added. this figure provides instructions to add a bonding jumper between relay

mounting panel and P6 Load Control Center structure and measure the bonding resistance between

the relay mounting panel and P6 Load Control Center structure.

12. Appendix A that provides information for electrical bonding was added to Paragraph 3.A., Work

Instructions.

D. Description

Airplane Work

1. Get access to the flight compartment.

2. For Groups 2, 3, 4, 5, 6, 7, 9, 10, 11, 12, 13 airplanes, at the P6 Load Control Center install two

ground studs and a ground bonding jumper.

3. For Groups 2, 3, 4, 5, 6, 7, 9, 10, 11, 12, 13 airplanes measure the electrical bonding between the

P6-2 relay panel and P6 Load Control Center structure.

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4. For Group 2 Configuration 1, and Group 4 Configuration 1, replace (6) relays with Ground Fault

Interrupt (GFI) relays. For Group 3 Configuration 1, Group 5-7 Configuration 1, and Group 9-13

Configuration 1, replace (8) relays with Ground Fault Interrupt (GFI) relays. Measure the electrical

bonding between the GFI relays and the P6-2 panel.

5. For Groups 1 and 8 airplanes install the Ground Fault Interrupt (GFI) relays in Relay Module

Assemblies M181, M182, and M183 in accordance with BAE Component Service Bulletin

65-49808-24-01 and change wire W044. Measure the electrical bonding between M181, M182,

M183 and the adjacent P6 Load Control Center structure.

6. Do a Ground Fault Interrupter (GFI) - Operational Test of the GFI relay installation for the fuel

boost pumps.

Revision 1 - More work is necessary on airplanes changed in accordance with the original issue of this

service bulletin. Group 2 through 7 Airplanes and Group 9 through 11 airplanes that incorporated

original issue of this service bulletin have to incorporate Accomplishment Instructions, Work instructions,

Part 2 that provides work instructions to install a Bonding Jumper between the relay mounting panel

and P6 Load Control Center structure, and measure the electrical bonding resistance between the GFI

relays and the relay mounting panel. Group 1 and Group 8 airplanes that incorporated original issue

of this service bulletin have to incorporate Accomplishment Instructions, Work instructions, Part 3 that

provides work instructions to measure the electrical bonding resistance between the GFI relays and

the Relay Module Assemblies M181, M182, and M183 in accordance with Revision 1 of BAE Service

Bulletin 65-49808-24-01, and to measure the electrical bonding resistance between the Relay Module

Assemblies M181, M182, and M183 and the P6 Load Control Center structure.

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 1-2

Group 2:

Affected Maintenance Zones

Model Zone

737-200, 737-200C 1-2

Group 2:

Affected Maintenance Zones

Model Zone

737-300, 737-400 102

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Group 3-4, 10, 12:

Affected Maintenance Zones

Model Zone

737-200 1-2

Group 4-5:

Affected Maintenance Zones

Model Zone

737-300, 737-400, 737-500 102

Group 6-7, 9:

Affected Maintenance Zones

Model Zone

737-400 102

Group 8:

Affected Maintenance Zones

Model Zone

737-100, 737-200 1-2, 3-5, 4-5

Group 11, 13:

Affected Maintenance Zones

Model Zone

737-300 102

E. Compliance

The Federal Aviation Administration (FAA) will possibly release an Airworthiness Directive related to

this service bulletin. The Airworthiness Directive will make the compliance tasks and times given in this

service bulletin mandatory.

Boeing recommends that operators make the changes shown in this service bulletin within 60 months

after the date of Revision 1 of this service bulletin.

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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.

G. Manpower

The table below shows an estimate of the task-hours necessary to do this change 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.

Group 1:

Task Number of Persons Task-Hours Elapsed Hours

Open Access 1 0.50 0.50

Figure 1 1 1.25 1.25

Figure 21 1 1.90 1.90

Close Access 1 0.50 0.50

Test 2 2.50 1.25

TOTAL FOR EACH AIRPLANE 6.65 5.40

Group 2, Configuration 1:

Task Number of Persons Task-Hours Elapsed Hours

Open Access 1 0.50 0.50

Removal of the Galley number one 2 8.00 4.00

Figure 2 1 3.50 3.50

Figure 9 1 0.40 0.40

Figure 22 1 1.00 1.00

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Group 2, Configuration 1:

Task Number of Persons Task-Hours Elapsed Hours

Close Access 1 0.50 0.50

Installation of the Galley number 3 12.00 4.00

one

Test 2 2.50 1.25

TOTAL FOR EACH AIRPLANE 28.40 15.15

Group 3, 12, Configuration 1:

Task Number of Persons Task-Hours Elapsed Hours

Open Access 1 0.50 0.50

Removal of the Galley number one 2 8.00 4.00

Figure 3 1 4.50 4.50

Figure 10 1 1.60 1.60

Figure 22 1 1.00 1.00

Close Access 1 0.50 0.50

Installation of the Galley number 3 12.00 4.00

one

Test 2 2.50 1.25

TOTAL FOR EACH AIRPLANE 30.60 17.35

Group 4, Configuration 1:

Task Number of Persons Task-Hours Elapsed Hours

Open Access 1 0.50 0.50

Figure 4 1 3.50 3.50

Figure 22 1 1.00 1.00

Close Access 1 0.50 0.50

Test 2 2.50 1.25

TOTAL FOR EACH AIRPLANE 8.00 6.75

Group 5, Configuration 1:

Task Number of Persons Task-Hours Elapsed Hours

Open Access 1 0.50 0.50

Figure 5 1 3.50 3.50

Figure 22 1 1.00 1.00

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Group 5, Configuration 1:

Task Number of Persons Task-Hours Elapsed Hours

Close Access 1 0.50 0.50

Test 2 2.50 1.25

TOTAL FOR EACH AIRPLANE 8.00 6.75

Group 6, Configuration 1:

Task Number of Persons Task-Hours Elapsed Hours

Open Access 1 0.50 0.50

Removal of the Galley number one 2 8.00 4.00

Figure 6 1 4.50 4.50

Figure 11 1 0.40 0.40

Figure 22 1 1.00 1.00

Close Access 1 0.50 0.50

Installation of the Galley number 3 12.00 4.00

one

Test 2 2.50 1.25

TOTAL FOR EACH AIRPLANE 29.40 16.15

Group 7, Configuration 1:

Task Number of Persons Task-Hours Elapsed Hours

Open Access 1 0.50 0.50

Removal of the Galley number one 2 8.00 4.00

Figure 7 1 4.50 4.50

Figure 11 1 0.40 0.40

Figure 22 1 1.00 1.00

Close Access 1 0.50 0.50

Installation of the Galley number 3 12.00 4.00

one

Test 2 2.50 1.25

TOTAL FOR EACH AIRPLANE 29.40 16.15

Group 8, Configuration 1:

Task Number of Persons Task-Hours Elapsed Hours

Open Access 1 0.50 0.50

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Group 8, Configuration 1:

Task Number of Persons Task-Hours Elapsed Hours

Figure 1 1 1.25 1.25

Figure 16 1 1.20 1.20

Figure 21 1 1.90 1.90

Close Access 1 0.50 0.50

Test 2 2.50 1.25

TOTAL FOR EACH AIRPLANE 7.85 6.60

Group 8, Configuration 2:

Task Number of Persons Task-Hours Elapsed Hours

Open Access 1 0.50 0.50

Figure 1 1 1.25 1.25

Figure 19 1 0.40 0.40

Figure 21 1 1.90 1.90

Close Access 1 0.50 0.50

Test 2 2.50 1.25

TOTAL FOR EACH AIRPLANE 7.05 5.80

Group 9, Configuration 1:

Task Number of Persons Task-Hours Elapsed Hours

Open Access 1 0.50 0.50

Removal of the Galley number one 2 8.00 4.00

Figure 3 1 4.50 4.50

Figure 11 1 0.40 0.40

Figure 22 1 1.00 1.00

Close Access 1 0.50 0.50

Installation of the Galley number 3 12.00 4.00

one

Test 2 2.50 1.25

TOTAL FOR EACH AIRPLANE 29.40 16.15

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Group 10, Configuration 1:

Task Number of Persons Task-Hours Elapsed Hours

Open Access 1 0.50 0.50

Removal of the Galley number one 2 8.00 4.00

Figure 3 1 4.50 4.50

Figure 12 1 0.40 0.40

Figure 22 1 1.00 1.00

Close Access 1 0.50 0.50

Installation of the Galley number 3 12.00 4.00

one

Test 2 2.50 1.25

TOTAL FOR EACH AIRPLANE 29.40 16.15

Group 11, 13, Configuration 1:

Task Number of Persons Task-Hours Elapsed Hours

Open Access 1 0.50 0.50

Removal of the Galley number one 2 8.00 4.00

Figure 3 1 4.50 4.50

Figure 13 1 1.60 1.60

Figure 22 1 1.00 1.00

Close Access 1 0.50 0.50

Installation of the Galley number 3 12.00 4.00

one

Test 2 2.50 1.25

TOTAL FOR EACH AIRPLANE 30.60 17.35

Group 2-7, 9-13, Configuration 2:

Task Number of Persons Task-Hours Elapsed Hours

Open Access 1 0.50 0.50

Figure 22 1 1.00 1.00

Close Access 1 0.50 0.50

Test 2 2.50 1.25

TOTAL FOR EACH AIRPLANE 4.50 3.25

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Group 1, Configuration 2; Group 8, Configuration 3:

Task Number of Persons Task-Hours Elapsed Hours

Open Access 1 0.50 0.50

Figure 1 1 1.25 1.25

Close Access 1 0.50 0.50

Test 2 2.50 1.25

TOTAL FOR EACH AIRPLANE 4.75 3.50

NOTE: The change to the relay module assembly in accordance with BAE Component Service Bulletin

65-49808-24-01 is not included.

H. Weight and Balance Changes

Change in Moment

(Pound-Inches)

Change in Weight

Airplane (Pounds)

All Airplanes Negligible Negligible

I. Electrical Load Data

1. Direct Current (DC) Loads

Airplanes Amperes Bus

Groups 1, 2, and 8 - 0.71 DC Bus 1

- 0.71 DC Bus 2

Groups 3, 9, 10, and 11 - 0.95 DC Bus 1

- 0.95 DC Bus 2

Group 4 + 0.03 DC Bus 1

+ 0.03 DC Bus 2

Group 5 - 0.22 DC Bus 1

- 0.22 DC Bus 2

Group 6 - 0.46 DC Bus 1

- 0.46 DC Bus 2

Group 7 - 0.21 DC Bus 1

- 0.21 DC Bus 2

2. Type

Continuous

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J. References

1. Existing Data:

a. Engineering Change Memo PRR 35440-10RS

b. Standard Wiring Practices Manual (SWPM) 20-00-11, 20-10-11, 20-30-12, 20-60-00, 20-60-08,

20-71-11, 20-81-11

c. 737-100/200 Aircraft Maintenance Manual (AMM) 24-22-00, 25-31-11

d. 737-300/400/500 Aircraft Maintenance Manual (AMM) 24-22-00, 25-31-11

e. 737 Wiring Diagram 28-23-01, 28-23-02

f. Boeing Service Bulletin 737-28A1263, "FUEL - Engine Fuel Feed System - Fuel Boost Pump

Electrical Wire and Sleeve in Fuel Tank Conduit - Inspection / Replacement"

g. BAE Component Service Bulletin 65-49808-24-01

2. Data supplied with this Service Bulletin:

None.

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

Drawing Number Title

69-73627-( ) RELAY ASSY - LOAD CONTROL CENTER

65-49815 LOAD CONTROL CENTER (STRUCTURE) P-6 PANEL

65C25703 LOAD CONTROL CENTER INSTL - P6 PANEL

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.

None.

K. Publications Affected

1. Publications:

Publication Chapter-Section

737 Maintenance Manual 28-22

737 Wiring Diagram Manual 28-23

737-100/200 IPC 24-50 , 737-100/200 IPC

28-20, 737-300/400/500 IPC 28-22, 737-

300/400/500 IPC 28-23

737 Illustrated Parts Catalog

737 Schematic Diagram 28-20

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Publication Chapter-Section

737 Maintenance Planning Document Section 9

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.

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BLANK PAGE
2. MATERIAL INFORMATION

A. Material - Price and Availability

Boeing can supply the kits shown in Paragraph 2.C., Parts Necessary for Each Airplane, as shown

below. If there is a limit to the quantity of available kits, a supply sequence is given by Spares. More

kits become available as shown in the Reorder Lead Time (ROLT). ROLT is calculated from the date

Boeing gets the purchase order. Operators are encouraged to share schedule requirements with Boeing

for incorporation of the service bulletin.

Reference this service bulletin and submit your purchase order by one of these methods:

1. Order on-line via ATA Spec 2000 or The Boeing PART Page

2. Fax to (206) 662-7145

REFER TO THE BOEING PART PAGE ON MYBOEINGFLEET.COM OR CONTACT FIRST RESPONDER

AT FR@BOEING.COM FOR THE LATEST REORDER LEAD TIME (ROLT) AND PRICE INFORMATION

Unit Price as of

the date of this

Service Bulletin

(US Dollars)

ROLT as of the

date of this Service Bulletin (Calendar Days)

Kit Number Name

KIT - RETROFIT GFI RELAYS IN P6 - NON- 349 (e)

AUX CONFIGURATION

65C37854-12 (a)

KIT - RETROFIT GFI RELAYS IN P6 - AUX 349 (e)

OR AUX PROVISIONS CONFIGURATION

65C37854-13 (b) (d)

65C37854-14 (c) KIT - RETROFIT BONDING JUMPER 349 (e)

(a) This Top Kit is applicable to Group 2 Configuration 1.

(b) This Kit is applicable to: Group 3 Configuration 1, Group 6 Configuration 1, Group 7 Configuration 1, Group

9 Configuration 1, Group 10 Configuration 1, Group 11 Configuration 1, Group 12 Configuration 1, and

Group 13 Configuration 1.

(c) This Kit is applicable to: Group 2 Configuration 2, Group 3 Configuration 2, Group 4 Configuration 2, Group

5 Configuration 2, Group 6 Configuration 2, Group 7 Configuration 2, Group 9 Configuration 2, Group 10

Configuration 2, and Group 11 Configuration 2, Group 12 Configuration 2, and Group 13 Configuration 2.

(d) Airplanes in Group 12 and 13 have been delivered with wire provisions for Auxiliary Tank installation. If

Auxiliary Tanks have been installed on these airplanes operators need to order this kit. If Auxiliary Tanks

have not been installed on these airplanes there are more parts than necessary in this kit. Operators need

to order only the necessary parts to incorporate this service bulletin. The necessary parts can be ordered

as end item parts. Contact Boeing Spares for ordering the necessary end item parts from kit 65C37854-

13.

(e) At the time of the release of the service bulletin the price of the kits were not available. Boeing will provide

the price of the kits by an Information Notice (IN).

The kits/parts are subject to the terms and conditions of the Boeing standard purchase order

acknowledgment. Prices are in United States Dollars. Terms: Net 30 days.

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Reference this service bulletin and submit your purchase order by one of these methods:

1. Order on-line via ATA Spec 2000 or The Boeing PART Page

2. Fax to (206) 662-7145

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:

To get the kits/parts shown below, refer to Paragraph 2.A., Material - Price and Availability.

NOTE: One top kit and the items shown in Paragraph 2.C.2., Parts and Materials Supplied by

the Operator, are necessary for each airplane.

Kit 65C37854

Existing Part Notes

Number

New Part Number QTY Name

-12 -13 -14

Kit - Retrofit, GFI

RELAYS IN P6 -

NON-AUX CONFIGURATION

65C37854-12 - . .

Kit - Retrofit, GFI

RELAYS IN P6 -

AUX OR AUX

PROVISIONS

CONFIGURATION

65C37854-13 . - .

Kit - Retrofit, Bonding Jumper65C37854-14 1 1 -

TOP KIT - GFI RELAYS IN P6 -

NON-AUX CONFIGURATION

61-74479-1 1 . .

TOP KIT - GFI RELAYS IN P6 - AUX

OR AUX PROVISIONS CONFIGURATION

61-74479-2 . 1 .

Kit - Retrofit, Bonding Jumper65C37854-14 1 1 -

BONDING

JUMPER

BACJ40K5A5A6 . . 1

BACN10YR3CD . . 2 NUT

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Kit 65C37854

Existing Part Notes

Number

New Part Number QTY Name

-12 -13 -14

BACS12GU3K10 . . 2 SCREW

NAS1149D0316H . . 6 WASHER

(a) If grip length shown is not available at Boeing, fasteners supplied in kits may be one

grip length longer than indicated. Also, if any fasteners part numbers listed are not

available or have been superseded, substitute fasteners may be supplied in kits.

Boeing Document D-590 and Boeing Drawing 65-88700 are used to determine the

part numbers used as substitutes.

Kit 61-74479

New Part Number Name Notes -102 -101 -2 -1

61-74479-1 . . . - Top Kit, GFI Relays in P6 - Non- Aux Configuration (a)

Top Kit, GFI Relays in P6 - Aux or Aux Provisions (b)

Configuration

61-74479-2 . . - .

61-74479-101 . . . 1 Wire Kit, W0044 Wire Bundle

61-74479-102 . . 1 . Wire Kit, W0044 Wire Bundle

61-74479-2001 . . 1 1 Lacing Tape, White (a)

61-74479-2002 . . 1 1 Filler Wire (b)

Connector Identification Tape, Imprinted "D01606

M/W R00055 CTR R B/P"

61-74478-10301 1 1 . .

Connector Identification Tape, Imprinted "D01608

M/W R00054 CTR L B/P"

61-74478-10302 1 1 . .

Connector Identification Tape, Imprinted "D01818

M/W R00146 AFT AUX FWD BOOST PUMP"

61-74478-10401 1 . . .

Connector Identification Tape, Imprinted "D01820

M/W R00147 AFT AUX AFT BOOST PUMP"

61-74478-10402 1 . . .

Connector Identification Tape, Imprinted "D01602

M/W R00020 AFT B/P 2"

61-74479-10101 1 1 . .

Connector Identification Tape, Imprinted "D01604

M/W R00021 FWD B/P 2"

61-74479-10102 1 1 . .

Connector Identification Tape, Imprinted "D01610

M/W R00019 FWD B/P 1"

61-74479-10103 1 1 . .

Connector Identification Tape, Imprinted "D01612

M/W R00018 AFT B/P 1"

61-74479-10104 1 1 . .

BACC47CP2T 18 14 . . Contact

(a) Make from BMS 13-54, Type 3, Class 1, Length As Required.

(b) Make from BMS 13-48 Type 10, Class 1, AWG 18, Length As Required.

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2. Parts and Materials Supplied by the Operator:

Part Number / Specification QTY Name Notes

S283A004-1 (LEACH P/N 2, 4, 6, or 8 Ground Fault Interrupter (GFI) Relay (a) (b) (l)

9524G-10674)

S283A004-6 (LEACH P/N KCG- 4 or 6 Ground Fault Interrupter (GFI) Relay (a) (c)

X4L-001)

002-9667-001-000 4 or 6 Relay Installation Kit (a) (d)

MS27488-16-1 6 Seal Plug (e)

M23053/5-103-4 or M23053/5-104- (e) (f)

4

Thermofit Sleeve, Yellow, Inner As Required

Diameter 0.093 Inch or 0.125

Inch

031-9134-004 2 Contact (g) (h)

Connector Identification Sleeve, Im- (g) (f)

printed "D01142 M/W M00183 P6

REY MOD"

BACT19C-T 1

BMS 13-58, Type 1, Class 1, 10 Feet Wire (g) (i)

AWG 22

BMS 13-54, Type 3, Class 1, As Required Lacing Tape (g) (j)

Color White

BACT12C20 1 Splice (g)

Permacel, P-421 Tape As Required Adhesive Tape, Width 0.5 Inch (g) (k)

Sleeve, Inner Diameter 0.25 Inch, (g)

Imprinted "SM206"

TFE-4X Sleeve As Required

(a) Leach International North America (V58657) 6900 Orangethorpe Avenue, P.O. Box 5032 Buena Park,

CA 90622-5032 Phone: (714) 739-0770, FAX: (714) 670-1145

(b) For Group 2 Configuration 1 airplanes, quantity required is (6). For Group 3 Configuration 1, Group 9

Configuration 1, Group 10 Configuration 1, Group 11 Configuration 1 airplanes, quantity required is (8).

For Group 5 Configuration 1 and Group 7 Configuration 1 airplanes, quantity required is (2). For Group

6 Configuration 1 airplanes, quantity required is (4).

(c) For Group 4 Configuration 1 and Group 7 Configuration 1 airplanes, quantity required is (6). For Group

5 Configuration 1 and Group 6 Configuration 1 airplanes, quantity required is (4).

(d) Used for the installation of the S283A004-6 relays only. For Group 4 Configuration 1 and Group 7

Configuration 1 airplanes, quantity required is (6). For Group 5 Configuration 1 and Group 6 Configuration

1 airplanes, quantity required is (4).

(e) Used for Group 8 configuration 1 and Group 8 Configuration 2 airplanes only.

(f) It is acceptable to use an equivalent material as shown in SWPM 20-00-11 and SWPM 20-10-11.

(g) Used for Group 1, Group 8 Configuration 1, and Group 8 Configuration 2 airplanes only.

(h) ITT Cannon (71468) 666 E. Dyer Rd. Santa Ana, CA 92705-5684 Phone: (714) 628-4700, FAX: (714)

628-2249

(i) Cut and code the wires as follows: "W044-8005-22" and "W044-8006-22". Each wire length is 60 inches.

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Part Number / Specification QTY Name Notes

(j) BMS 13-54, Type 3, Class 1, Finish C, Size 75/12 or 110/14, Grade D, color white, length as required.

(k) It is acceptable to use an equivalent tape (with temperature grade D) as shown in SWPM 20-30-12.

(l) Airplanes in Group 12 and 13 have been delivered with wire provisions for Auxiliary Tank installation.

If Auxiliary Tanks have been installed on these airplanes operators need to order this kit. If Auxiliary

Tanks have not been installed on these airplanes there are more parts than necessary in this kit. Operators need to obtain only the necessary parts to incorporate this service bulletin.

3. Parts Modified and Reidentified:

The parts shown below are changed as shown in this service bulletin. The quantity (QTY) is the

number of parts changed on each airplane.

Existing Part QTY Name New Part Number Notes

Number

M181 Relay Module 65-49808-( ) (a)

Assembly

65-49808-( ) 1

M182 Relay Module 65-49808-( ) (a)

Assembly

65-49808-( ) 1

M183 Relay Module 65-49808-( ) (a)

Assembly

65-49808-( ) 1

(a) Make the change given in BAE Component service bulletin 65-49808-24-01. The BAE

component service bulletin gives the new part numbers for the M181, M182, and M183

modules.

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.

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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.

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. The instructions identified in Paragraph 3.B., Work Instructions, and the Figure(s)

give the recommended sequence of steps. The sequence of steps to do this service

bulletin can be changed.

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

definition of the acronyms.

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

4. The work instructions are divided into work packages. Task Hours and Elapsed Hours

for each package are given in Paragraph 1.G., Manpower. You can do each work

package independently.

5. Unless shown differently, these dimensions and tolerances are used:

– Linear dimensions are in inches

– Tolerance on linear dimensions, other than rivet and bolt edge margins, is plus

or minus 0.03 inch

– Tolerance on rivet and bolt edge margin is plus or minus 0.05 inch

– Angular tolerance is plus or minus 2 degrees

– Hole dimensions for standard solid rivets are in Structural Repair Manual (SRM)

51

– Torque limits to tighten nuts and bolts are in SRM 51

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

737 SRM 51. Alternate fasteners are listed in 737 SRM 51 and Boeing Drawing

65-88700. .

7. Refer to the SWPM 20-10-11 and SWPM 20-10-12 for the wire installation procedures,

and SWPM 20-10-19 for the wire separation requirements, as accepted procedures.

8. If the length of any fastener specified in this service bulletin does not meet installation

standards given in SRM Chapter 51, then a fastener of the same specification, or

an approved substitute, with a length which meets the installation standards given

in SRM Chapter 51 may be used. In addition, washers may be installed for fastener

grip length in accordance with SRM Chapter 51.

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9. 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.

10. 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.

11. If it is necessary to remove more parts for access, you can remove those parts. If

you can get access without removing identified parts, it is not necessary to remove

all of the identified parts. Jacking and shoring limitations must be observed.

12. Where the work instructions include installation of a kept part, a new or serviceable

part with the same part number can be installed as an alternative to the kept part.

The removed part can be discarded if a new or serviceable part is installed.

13. This service bulletin includes functional test procedures for the systems changed or

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

accordance with standard maintenance practices because of interruption to other

airplane systems.

14. Some Boeing parts are supplied in a temporary configuration. Those parts are

identified with a 'U', 'W', or 'Y' in place of the '-' (dash) in the part number. It is

permitted to install parts identified with a 'U', 'W', or 'Y' as an alternative to the '-'

(dash) part number. Boeing Drawing 005W0900 contains more data.

B. WORK INSTRUCTIONS

Group 1; Group 2-7, Configuration 1; Group 8; Group 9-13, Configuration 1:

PART 1

1. REMOVE THE EXISTING FUEL BOOST PUMP RELAYS AND INSTALL GFI FUEL BOOST PUMP

RELAYS

a. Remove the 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.

b. Get access to the flight compartment.

c. In the flight compartment, move the First Officer's seat forward to create room in front of P6

Load Control Panel. Refer to 737-100/200 AMM 25-11-0 or 737-300/400/500 AMM 25-11-11

as accepted procedures. If necessary remove the First Officer's seat if/as necessary. Refer

to 737-100/200 AMM 25-11-11 or 737-300/400/500 AMM 25-11-11 as accepted procedures.

d. In the flight compartment, remove and keep the adjacent lining panels outboard of the P6-2

circuit breaker panel. Refer to 737-100/200 AMM 25-16-11 or 737-300/400/500 AMM 25-11-21

as accepted procedures.

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e. Open and lower the P6-1 (65C25704-( ) ) and P6-2 (65C25704) panels.

f. Group 1, 8:

Change the M181, M182, and M183 relay module assemblies in accordance with FIGURE 1

and FIGURE 20.

g. Group 2-7, 9-13, Configuration 1:

Install Ground Studs and Bonding Jumper in accordance with FIGURE 22. measure the

electrical bonding resistance between P6-2 panel and the P6 side panel in accordance with

FIGURE 22.

h. Group 2, Configuration 1:

Replace the fuel pump power relays R18, R19, R20, R21, R54, and R55 in accordance with

FIGURE 2. Measure the electrical bonding between the fuel pump power relays R19, R18,

R21, R20, R54, R55 and P6-2 panel in accordance with FIGURE 2 .

i. Group 3, 9-13, Configuration 1:

Replace the fuel pump power relays R18, R19, R20, R21, R54, R55, R146, and R147 in

accordance with FIGURE 3. Measure the electrical bonding between the fuel pump power

relays R18, R19, R20, R21, R54, R55, R146, R147 and P6-2 panel in accordance with FIGURE

3 .

j. Group 4, Configuration 1:

Replace the fuel pump power relays R18, R19, R20, R21, R54, and R55 in accordance with

FIGURE 4 and FIGURE 20. Measure the electrical bonding between the fuel pump power

relays R18, R19, R20, R21, R54, R55 and P6-2 panel in accordance with FIGURE 4 .

k. Group 5, Configuration 1:

Replace the fuel pump power relays R18, R19, R20, R21, R54, and R55 in accordance with

FIGURE 5 and FIGURE 20. Measure the electrical bonding between the fuel pump power

relays R18, R19, R20, R21, R54, R55 and P6-2 panel in accordance with Figure 5.

l. Group 6, Configuration 1:

Replace the fuel pump power relays R18, R19, R20, R21, R54, R55, R146, and R147 in

accordance with FIGURE 6. Measure the electrical bonding between the fuel pump power

relays R18, R19, R20, R21, R54, R55, R146, R147 and P6-2 panel in accordance with FIGURE

6 .

m. Group 7, Configuration 1:

Replace the fuel pump power relays R18, R19, R20, R21, R54, R55, R146, and R147 in

accordance with FIGURE 7. Measure the electrical bonding between the fuel pump power

relays R18, R19, R20, R21, R54, R55, R146, R147 and P6-2 panel in accordance with FIGURE

7 .

n. Group 2-3, 6-7, 9-13, Configuration 1:

Remove the galley number one to get access to the W0044 wire bundle in the P6 panel. Refer

to 737-100/200 AMM 25-31-11 or 737-300/400/500 AMM 25-31-11 as an accepted procedure.

o. Group 2, Configuration 1:

Change the W0044 wire bundle in accordance with FIGURE 8, FIGURE 9, and FIGURE 20.

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ALERT ALERT
p. Group 3, 12, Configuration 1:

Change the W0044 wire bundle in accordance with Figures FIGURE 8, FIGURE 10, and

FIGURE 20.

q. Group 6-7, 9, Configuration 1:

Change the W0044 wire bundle in accordance with Figures FIGURE 8, FIGURE 11, and

FIGURE 20.

r. Group 10, Configuration 1:

Change the W0044 wire bundle in accordance with Figures FIGURE 8, FIGURE 12, and

FIGURE 20.

s. Group 11, Configuration 1:

Change the W0044 wire bundle in accordance with FIGURE 8, FIGURE 13, FIGURE 20.

t. Group 1, 8:

Change the W0044 wire bundle in accordance with FIGURE 21.

u. Group 2-3, 6-7, 9-13, Configuration 1:

Install the galley number one. Refer to 737-100/200 AMM 25-31-11 or 737-300/400/500 AMM

25-31-11 as an accepted procedure.

v. Group 8, Configuration 1:

If service bulletin 737-28A1263 has not been incorporated, change the wiring at the fuel boost

pump connectors in accordance with FIGURE 14, FIGURE 15, and FIGURE 16.

w. Group 8, Configuration 2:

If service bulletin 737-28A1263 has been incorporated, change the wiring at the fuel boost

pump connectors in accordance with FIGURE 17, FIGURE 18, and FIGURE 19.

x. In the flight compartment, install the adjacent lining panels outboard of the P6-2 circuit breaker

panel. Refer to 737-100/200 AMM 25-16-11 or 737-300/400/500 AMM 25-11-21 as accepted

procedures.

y. Close the P6-1 (65C25704-( ) ) and P6-2 (65C25704) panels.

z. Restore the position of the the First Officer's seat if it was moved forward to create room in

front of P6 Load Control Panel. Refer to 737-100/200 AMM 25-11-0 or 737-300/400/500 AMM

25-11-11 as accepted procedures. If the First Officer's seat was removed, install the First

Officer's seat. Refer to 737-100/200 AMM 25-11-11 or 737-300/400/500 AMM 25-11-11 as

accepted procedures.

aa. Restore the 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.

ab. Do the "GROUND FAULT INTERRUPTER (GFI) - OPERATIONAL TEST". Refer, as applicable,

to 737-100/200 AMM 28-22-41 or 737-300/400/500 AMM 28-22-41 as accepted procedures.

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BOEING SERVICE BULLETIN 737-28A1212

ALERT ALERT
Group 2-7, 9-13, Configuration 2:

PART 2, INSTALL GROUND STUDS AND BONDING JUMPER ON RELAY MOUNTING PANEL

AND TEST THE GFI RELAYS

1. Remove the 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. Get access to the flight compartment.

3. Install Ground Studs and Bonding Jumper in accordance with FIGURE 22.

4. Restore the electrical power to the airplane.

5. Do the "GROUND FAULT INTERRUPTER (GFI) - OPERATIONAL TEST". Refer, as applicable,

to 737-100/200 AMM 28-22-41 or 737-300/400/500 AMM 28-22-41 as accepted procedures.

6. Put the airplane back to a serviceable condition.

Group 1, Configuration 2; Group 8, Configuration 3:

PART 3, BOND GFI RELAYS TO MODULES AND TEST THE GFI RELAYS

1. Remove the 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. Get access to the flight compartment.

3. Remove the Relay Module Assemblies M181, M182, and M183 in accordance with FIGURE 1.

4. Measure the electrical bonding resistance between the GFI relays and the Relay Module Assemblies

M181, M182, and M183 in accordance with FIGURE 1 and BAE Component Service Bulletin

65-49808-24-01 Revision 1.

5. Measure the electrical bonding resistance between the Relay Module Assemblies M181, M182,

and M183 and the P6 Load Control Center in accordance with FIGURE 1.

6. Restore the electrical power to the airplane.

7. If in step instruction 4 GFI relays were removed from the Relay Module Assemblies M181, M182,

or M183 to restore the electrical bonding do the GROUND FAULT INTERRUPTER (GFI) -

OPERATIONAL TEST. Refer to 737-100/200 AMM 28-22-41 as an accepted procedure.

8. Put the airplane back to a serviceable condition.

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BOEING SERVICE BULLETIN 737-28A1212

ALERT ALERT
This Figure applies only to: Group 1, 8.

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

STEP TASK NAME IDENTIFICATION QTY MORE DATA

Relay Module As- 65-49808-( ) 3 M181, M182, M183. (a)

sembly

1 Remove/ Keep

Relay Module As- 65-49808-( ) 3 M181, M182, M183. (a)

sembly

2 Install

between M181, M182,

M183 and the adjacent

P6 Load Control Center

structure. (b)

3 Measure RESISTANCE 2.5 MILLIOHMS 6

(a) Make the changes in accordance with Revision 1 of the BAE Component Service Bulletin 65-49808-

24-01. Measure the electrical bonding resistance between the new relays installed and M181, M182,

FIGURE 1: M181, M182, M183 RELAY MODULE ASSEMBLY REPLACEMENT

(SHEET 1 OF 2)

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BOEING SERVICE BULLETIN 737-28A1212

ALERT ALERT
STEP TASK NAME IDENTIFICATION QTY MORE DATA

and M183 Relay Module Assemblies in accordance with Revision 1 of the BAE Component Service

Bulletin 65-49808-24-01.

(b) If the resistance measurement is greater than 2.5 Milliohms (0.0025 Ohms), remove the applicable

Module Assembly and repair the ground path from the Module to airplane structure. Refer to CMM

24-09-03 for the connections to the ground stud in the module. Refer to the airplane wire diagrams

WD 24-31-01 (for M181, pins 14 and 57) , or WD 21-58-01 (M182, pins 23 and 31), or WD 28-23-01

(M183, pin 7), as applicable, for the ground connections from the modules to airplane structure. Do

again step 3.

FIGURE 1: M181, M182, M183 RELAY MODULE ASSEMBLY REPLACEMENT

(SHEET 2 OF 2)

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BOEING SERVICE BULLETIN 737-28A1212

ALERT ALERT
This Figure applies only to: Group 2, Configuration 1.

FIGURE 2: REPLACEMENT OF THE FUEL PUMP POWER RELAYS

(SHEET 1 OF 2)

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BOEING SERVICE BULLETIN 737-28A1212

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

STEP TASK NAME IDENTIFICATION QTY MORE DATA

R18, R19, R20, R21,

R54, and R55.

1 Remove Fuel Pump Power Relay 10-60450-1 6

Remove the paint

around the relay

cutout, from the side

of the panel that will

be in contact with the

relay. (a)

2 Clean SURFACE - 6

On the bare metal

from which the paint

was removed. Refer to

SOPM 20-43-03 as an

accepted procedure.

ALODINE, TYPE -

2, CLASS A, or

TYPE 5, CLASS F

CHEMICAL CONVERSION

COATING

3 Apply

the contact surfaces of

the relay and the panel

to remove the contamination. (b)

4 Clean SURFACE - 12

R18, R19, R20, R21,

R54, and R55. Refer

to SWPM 20-81-22 as

an accepted procedure for installation of

similar LEACH relays.

S283A004-1 6

(LEACH P/N

9524G-10674)

5 Install Fuel Pump Power (GFI) Relay

between the flange of

the relay and the

mounting panel. (c)

0.0025 OHMS (2.5 6

MILLIOHMS)

6 Measure RESISTANCE

on any bare metal

around the relays. Refer to SOPM 20-41-02

as an accepted procedure.

BMS 10-11, TYPE -

1

7 Apply EPOXY PRIMER

(a) Abrasive clean by Hand or with a rotary brush in accordance with APPENDIX A, Paragraph 2.a.

(b) Use Solvent to clean the contact surfaces in accordance with APPENDIX A, Paragraph 2.b.

(c) In accordance with APPENDIX A, Paragraph 5.b. Make sure that the resistance is 2.5 milliohms or

less. If the resistance measurement is greater than 0.0025 Ohms (2.5 milliohms), then remove the

relay, clean the faying surfaces, install the relay and measure the bonding resistance again.

FIGURE 2: REPLACEMENT OF THE FUEL PUMP POWER RELAYS

(SHEET 2 OF 2)

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BOEING SERVICE BULLETIN 737-28A1212

ALERT ALERT
This Figure applies only to: Group 3, 9-13, Configuration 1.

FIGURE 3: REPLACEMENT OF THE FUEL PUMP POWER RELAYS

(SHEET 1 OF 2)

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58 of 99

BOEING SERVICE BULLETIN 737-28A1212

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

STEP TASK NAME IDENTIFICATION QTY MORE DATA

R18, R19, R20, R21, R54,

R55, R146, and R147.

1 Remove Fuel Pump Power Relay 10-60450-6 8

Remove the paint around

the relay cutout, from the

side of the panel that will be

in contact with the relay. (a)

2 Clean SURFACE - 8

On the bare metal from

which the paint was removed. Refer to SOPM 20-

43-03 as an accepted procedure.

ALODINE, TYPE -

2, CLASS A, or

TYPE 5, CLASS F

CHEMICAL CONVERSION

COATING

3 Apply

the contact surfaces of the

relays and the panel to remove the contamination. (b)

4 Clean SURFACE - -

R18, R19, R20, R21, R54,

R55, R146, and R147. Refer to SWPM 20-81-22 as

an accepted procedure for

installation of similar

LEACH relays. (d)

S283A004-1 8

(LEACH P/N

9524G-10674)

5 Install Fuel Pump Power (GFI) Relay

between the flange of the

relay and the mounting

panel. (c)

0.0025 OHMS (2.5 8

MILLIOHMS)

6 Measure RESISTANCE

on any bare metal around

the relays. Refer to SOPM

20-41-02 as an accepted

procedure.

BMS 10-11, TYPE -

1

7 Apply EPOXY PRIMER

(a) Abrasive clean by Hand or with a rotary brush in accordance with APPENDIX A, Paragraph 2.a.

(b) Use Solvent to clean the contact surfaces in accordance with APPENDIX A, Paragraph 2.b.

(c) In accordance with APPENDIX A, Paragraph 5.b. Make sure that the resistance is 2.5 milliohms or

less. If the resistance measurement is greater than 0.0025 Ohms (2.5 milliohms), then remove the

relay, clean the faying surfaces, install the relay and measure the bonding resistance again.

(d) Airplanes in Group 12 and 13 have been delivered with wire provisions for Auxiliary Tanks installation.

If Auxiliary Tanks have been installed on these airplanes operators need to order this kit. If Auxiliary

Tanks have not been installed on these airplanes there are more parts than necessary in this kit. Operators need to obtain only the necessary parts to incorporate this service bulletin for Tank 1, Tank 2,

and Center Tank.

FIGURE 3: REPLACEMENT OF THE FUEL PUMP POWER RELAYS

(SHEET 2 OF 2)

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BOEING SERVICE BULLETIN 737-28A1212

ALERT ALERT
This Figure applies only to: Group 4, Configuration 1.

FIGURE 4: REPLACEMENT OF THE FUEL PUMP POWER RELAYS

(SHEET 1 OF 2)

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60 of 99

BOEING SERVICE BULLETIN 737-28A1212

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

STEP TASK NAME IDENTIFICATION QTY MORE DATA

R18, R19, R20, R21,

R54, and R55.

1 Remove Fuel Pump Power Relay KCD4N 6

Remove the paint from

both sides of the panel

that will be in contact with

the relay spacers and

spacer hardware. (a)

2 Clean SURFACE - 12

On the bare metal from

which the paint was removed. Refer to SOPM

20-43-03 as an accepted

procedure.

ALODINE, TYPE -

2, CLASS A, or

TYPE 5, CLASS F

CHEMICAL CONVERSION

COATING

3 Apply

the contact surfaces of

the relays, spacers, and

the panel, to remove the

contamination. (b)

4 Clean SURFACE - -

R18, R19, R20, R21,

R54, and R55. Refer to

SWPM 20-81-22 as an

accepted procedure for

installation of similar

LEACH relays.

S283A004-6 6

(LEACH P/N KCGX4L-001)

5 Install Fuel Pump Power (GFI)

Relay Spacer Kit 002-9667-001-000 6

between the flange of the

relay and the mounting

panel. (c)

0.0025 OHMS (2.5 6

MILLIOHMS)

6 Measure RESISTANCE

on any bare metal around

spacers. Refer to SOPM

20-41-02 as an accepted

procedure.

BMS 10-11, TYPE -

1

7 Apply EPOXY PRIMER

(a) Abrasive clean by Hand or with a rotary brush in accordance with APPENDIX A, Paragraph 2.a.

(b) Use Solvent to clean the contact surfaces in accordance with APPENDIX A, Paragraph 2.b..

(c) In accordance with APPENDIX A, Paragraph 5.b. Make sure that the resistance is 2.5 milliohms or less.

If the resistance measurement is greater than 0.0025 Ohms (2.5 milliohms), then remove the relay,

clean the faying surfaces, install the relay and measure the bonding resistance again.

FIGURE 4: REPLACEMENT OF THE FUEL PUMP POWER RELAYS

(SHEET 2 OF 2)

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BOEING SERVICE BULLETIN 737-28A1212

ALERT ALERT
This Figure applies only to: Group 5, Configuration 1.

FIGURE 5: REPLACEMENT OF THE FUEL PUMP POWER RELAYS

(SHEET 1 OF 3)

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BOEING SERVICE BULLETIN 737-28A1212

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

STEP TASK NAME IDENTIFICATION QTY MORE DATA

1 Remove Fuel Pump Power Relay KCD4N 4 R20, R21, R54, and R55.

2 Remove Fuel Pump Power Relay 10-60450-6 2 R18 and R19.

Remove the paint from

both sides of the panel that

will be in contact with the

relay spacers and spacer

hardware. (a)

3 Clean SURFACE - 8

Remove the paint around

the relay cutout, from the

side of the panel that will

be in contact with the relay. (a)

4 Clean SURFACE - 2

On the bare from which

the paint was removed.

Refer to SOPM 20-43-03

as an accepted procedure.

ALODINE, TYPE -

2, CLASS A, or

TYPE 5, CLASS F

CHEMICAL CONVERSION

COATING

5 Apply

the contact surfaces of the

relays, spacers, and the

panel, to remove the contamination. (b)

6 Clean SURFACE - -

R20, R21, R54, and R55.

Refer to SWPM 20-81-22

as an accepted procedure

for installation of similar

LEACH relays.

S283A004-6 4

(LEACH P/N KCGX4L-001)

7 Install Fuel Pump Power (GFI)

Relay Spacer Kit 002-9667-001-000 4

R18 and R19. Refer to

SWPM 20-81-22 as an accepted procedure for installation of similar LEACH relays.

S283A004-1 2

(LEACH P/N

9524G-10674)

8 Install Fuel Pump Power (GFI) Relay

between the flange of the

relay and the mounting

panel. (c)

0.0025 OHMS (2.5 6

MILLIOHMS)

9 Measure RESISTANCE

on any bare metal around

the relays and spacers.

Refer to SOPM 20-41-02

as an accepted procedure.

BMS 10-11, TYPE -

1

10 Apply EPOXY PRIMER

(a) Abrasive clean by Hand or with a rotary brush in accordance with APPENDIX A, Paragraph 2.a.

(b) Use Solvent to clean the contact surfaces in accordance with APPENDIX A, Paragraph 2.b.

FIGURE 5: REPLACEMENT OF THE FUEL PUMP POWER RELAYS

(SHEET 2 OF 3)

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BOEING SERVICE BULLETIN 737-28A1212

ALERT ALERT
STEP TASK NAME IDENTIFICATION QTY MORE DATA

(c) In accordance with APPENDIX A, Paragraph 5.b. Make sure that the resistance is 2.5 milliohms or less.

If the resistance measurement is greater than 0.0025 Ohms (2.5 milliohms), then remove the relay, clean

the faying surfaces, install the relay and measure the bonding resistance again.

FIGURE 5: REPLACEMENT OF THE FUEL PUMP POWER RELAYS

(SHEET 3 OF 3)

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BOEING SERVICE BULLETIN 737-28A1212

ALERT ALERT
This Figure applies only to: Group 6, Configuration 1.

FIGURE 6: REPLACEMENT OF THE FUEL PUMP POWER RELAY

(SHEET 1 OF 3)

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BOEING SERVICE BULLETIN 737-28A1212

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

STEP TASK NAME IDENTIFICATION QTY MORE DATA

1 Remove Fuel Pump Power Relay KCD4N 4 R20, R21, R54, and R55.

2 Remove Fuel Pump Power Relay 10-60450-6 4 R146, R147, R18, and R19.

Remove the paint from both

sides of the panel that will be

in contact with the relay

spacers and spacer hardware. (a)

3 Clean SURFACE - 8

Remove the paint around the

relay cutout, from the side of

the panel that will be in contact with the relay. (a)

4 Clean SURFACE - 4

On the bare metal from which

the paint was removed. Refer

to SOPM 20-43-03 as an accepted procedure.

ALODINE, TYPE -

2, CLASS A, or

TYPE 5, CLASS F

CHEMICAL CONVERSION

COATING

5 Apply

the contact surfaces of the

relays, spacers, and the panel, to remove the contamination. (b)

6 Clean SURFACE - -

R20, R21, R54, and R55. Refer to SWPM 20-81-22 as an

accepted procedure for installation of similar LEACH relays.

S283A004-6 4

(LEACH P/N KCGX4L-001)

7 Install Fuel Pump Power (GFI)

Relay Spacer Kit 002-9667-001-000 4

R146, R147, R18, and R19.

Refer to SWPM 20-81-22 as

an accepted procedure for installation of similar LEACH

relays.

S283A004-1 4

(LEACH P/N

9524G-10674)

8 Install Fuel Pump Power (GFI) Relay

between the flange of the relay and the mounting panel.

(c)

0.0025 OHMS (2.5 8

MILLIOHMS)

9 Measure RESISTANCE

on any bare metal around the

relays and spacers. Refer to

SOPM 20-41-02 as an accepted procedure.

BMS 10-11, TYPE -

1

10 Apply EPOXY PRIMER

(a) Abrasive clean by Hand or with a rotary brush in accordance with APPENDIX A, Paragraph 2.a.

(b) Use Solvent to clean the contact surfaces in accordance with APPENDIX A, Paragraph 2.b.

FIGURE 6: REPLACEMENT OF THE FUEL PUMP POWER RELAY

(SHEET 2 OF 3)

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BOEING SERVICE BULLETIN 737-28A1212

ALERT ALERT
STEP TASK NAME IDENTIFICATION QTY MORE DATA

(c) In accordance with APPENDIX A, Paragraph 5.b. Make sure that the resistance is 2.5 milliohms or less.

If the resistance measurement is greater than 0.0025 Ohms (2.5 milliohms), then remove the relay, clean

the faying surfaces, install the relay and measure the bonding resistance again.

FIGURE 6: REPLACEMENT OF THE FUEL PUMP POWER RELAY

(SHEET 3 OF 3)

BOEING PROPRIETARY -

Copyright © Unpublished Work - See page 1 for details.

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67 of 99

BOEING SERVICE BULLETIN 737-28A1212

ALERT ALERT
This Figure applies only to: Group 7, Configuration 1.

FIGURE 7: REPLACEMENT OF THE FUEL PUMP POWER RELAY

(SHEET 1 OF 3)

BOEING PROPRIETARY -

Copyright © Unpublished Work - See page 1 for details.

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68 of 99

BOEING SERVICE BULLETIN 737-28A1212

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

STEP TASK NAME IDENTIFICATION QTY MORE DATA

R18, R19, R20, R21,

R54, and R55.

Fuel Pump Power KCD4N 6

Relay

1 Remove

Fuel Pump Power 10-60450-6 2 R146 and R147.

Relay

2 Remove

Remove the paint from

both sides of the panel

that will be in contact with

the relay spacers and

spacer hardware. (a)

3 Clean SURFACE - 12

Remove the paint around

the relay cutout, from the

side of the panel that will

be in contact with the relay. (a)

4 Clean SURFACE - 2

On the bare from which

the paint was removed.

Refer to SOPM 20-43-03

as an accepted procedure.

ALODINE, TYPE -

2, CLASS A, or

TYPE 5, CLASS F

CHEMICAL CONVERSION COATING

5 Apply

the contact surfaces of

the relays, spacers, and

the panel, to remove the

contamination. (b)

6 Clean SURFACE - -

R18, R19, R20, R21,

R54, and R55. Refer to

SWPM 20-81-22 as an

accepted procedure for

installation of similar

LEACH relays.

S283A004-6 6

(LEACH P/N KCGX4L-001)

Fuel Pump Power

(GFI)

7 Install

Relay Spacer Kit 002-9667-001-000 6

R146 and R147. Refer to

SWPM 20-81-22 as an

accepted procedure for

installation of similar

LEACH relays.

S283A004-1 2

(LEACH P/N

9524G-10674)

Fuel Pump Power

(GFI) Relay

8 Install

between the flange of the

relay and the mounting

panel. (c)

0.0025 OHMS (2.5 8

MILLIOHMS)

9 Measure RESISTANCE

FIGURE 7: REPLACEMENT OF THE FUEL PUMP POWER RELAY

(SHEET 2 OF 3)

BOEING PROPRIETARY -

Copyright © Unpublished Work - See page 1 for details.

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69 of 99

BOEING SERVICE BULLETIN 737-28A1212

ALERT ALERT
STEP TASK NAME IDENTIFICATION QTY MORE DATA

on any bare metal around

the relays and spacers.

Refer to SOPM 20-41-02

as an accepted procedure.

BMS 10-11, TYPE -

1

10 Apply EPOXY PRIMER

(a) Abrasive clean by Hand or with a rotary brush in accordance with APPENDIX A, Paragraph 2.a.

(b) Use Solvent to clean the contact surfaces in accordance with APPENDIX A, Paragraph 2.b.

(c) In accordance with APPENDIX A, Paragraph 5.b. Make sure that the resistance is 2.5 milliohms or

less. If the resistance measurement is greater than 0.0025 Ohms (2.5 milliohms), then remove the

relay, clean the faying surfaces, install the relay and measure the bonding resistance again.

(d) Airplanes in Group 12 and 13 have been delivered with wire provisions for Auxiliary Tanks installation.

If Auxiliary Tanks have been installed on these airplanes operators need to order this kit. If Auxiliary

Tanks have not been installed on these airplanes there are more parts than necessary in this kit. Operators need to obtain only the necessary parts to incorporate the Auto Shutoff system for the Center

Tanks.

FIGURE 7: REPLACEMENT OF THE FUEL PUMP POWER RELAY

(SHEET 3 OF 3)

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ALERT ALERT
This Figure applies only to: Group 2-3, 6-7, 9-13, Configuration 1.

FIGURE 8: W0044 WIRE BUNDLE ROUTING

(SHEET 1 OF 1)

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ALERT ALERT
This Figure applies only to: Group 2, Configuration 1.

FIGURE 9: WIRE BUNDLE W0044 - WIRING CHANGES

(SHEET 1 OF 2)

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ALERT ALERT
The flag note numbers shown below agree with the numbers shown in the flag symbols in the figure.

FLAG NAME IDENTIFICATION QTY MORE DATA

NOTE

Use filler wire to build up diameter of wire

inside contact. Refer to SWPM 20-60-00

and SWPM 20-81-11 as accepted procedures.

1 Contact BACC47CP2T 12

Filler Wire 61-74479-2002 -

Use color white. Refer to SWPM 20-10-11

as an accepted procedure.

2 Lacing Tape 61-74479-2001 -

Imprinted "D1602 M/W R00020 AFT B/P

2". Install within 6 inches of connector.

Connector Identifi- 61-74479-10101 1

cation Tape

3

Imprinted "D1608 M/W R00054 CTR L

B/P". Install within 6 inches of connector.

Connector Identifi- 61-74478-10302 1

cation Tape

4

Imprinted "D1604 M/W R00021 FWD B/P

2". Install within 6 inches of connector.

Connector Identifi- 61-74479-10102 1

cation Tape

5

Imprinted "D1610 M/W R00019 FWD B/P

1". Install within 6 inches of connector.

Connector Identifi- 61-74479-10103 1

cation Tape

6

Imprinted "D1606 M/W R00055 CTR R

B/P". Install within 6 inches of connector.

Connector Identifi- 61-74478-10301 1

cation Tape

7

Imprinted "D1612 M/W R00018 AFT B/P

1". Install within 6 inches of connector.

Connector Identifi- 61-74479-10104 1

cation Tape

8

FIGURE 9: WIRE BUNDLE W0044 - WIRING CHANGES

(SHEET 2 OF 2)

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ALERT ALERT
This Figure applies only to: Group 3, 12, Configuration 1.

FIGURE 10: WIRE BUNDLE W0044 - WIRING CHANGES

(SHEET 1 OF 2)

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ALERT ALERT
The flag note numbers shown below agree with the numbers shown in the flag symbols in the figure.

FLAG NAME IDENTIFICATION QTY MORE DATA

NOTE

Use filler wire to build up diameter of

AWG 22 wire inside contact. Refer to

SWPM 20-60-00 and SWPM 20-81-11

as accepted procedures.(a)

1 Contact BACC47CP2T 1

Filler Wire 61-74479-2002 -

Use color white. Refer to SWPM 20-10-

11 as an accepted procedure.

2 Lacing Tape 61-74479-2001 -

Imprinted "D1602 M/W R00020 AFT B/P

2". Install within 6 inches of connector.

Connector Identifi- 61-74479-10101 1

cation Tape

3

Imprinted "D1608 M/W R00054 CTR L

B/P". Install within 6 inches of connector.

Connector Identifi- 61-74478-10302 1

cation Tape

4

Imprinted "D1604 M/W R00021 FWD B/P

2". Install within 6 inches of connector.

Connector Identifi- 61-74479-10102 1

cation Tape

5

Imprinted "D1610 M/W R00019 FWD B/P

1". Install within 6 inches of connector.

Connector Identifi- 61-74479-10103 1

cation Tape

6

Imprinted "D1606 M/W R00055 CTR R

B/P". Install within 6 inches of connector.

Connector Identifi- 61-74478-10301 1

cation Tape

7

Imprinted "D1612 M/W R00018 AFT B/P

1". Install within 6 inches of connector.

Connector Identifi- 61-74479-10104 1

cation Tape

8

Imprinted "D1818 M/W R00146 AFT AUX

FWD BOOST PUMP". Install within 6

inches of connector. (a)

Connector Identifi- 61-74478-10401 1

cation Tape

9

Imprinted "D1820 M/W R00147 AFT AUX

AFT BOOST PUMP". Install within 6

inches of connector. (a)

Connector Identifi- 61-74478-10402 1

cation Tape

10

(a) Airplanes in Group 12 have been delivered with wire provisions for Auxiliary Tanks installation.

If Auxiliary Tanks have been installed on these airplanes operators need to order this kit. If

Auxiliary Tanks have not been installed on these airplanes there are more parts than necessary

in this kit. Operators need to obtain only the necessary parts to incorporate this service bulletin

for Tank 1, Tank 2, and Center Tank.

FIGURE 10: WIRE BUNDLE W0044 - WIRING CHANGES

(SHEET 2 OF 2)

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ALERT ALERT
This Figure applies only to: Group 6-7, 9, Configuration 1.

The flag note numbers shown below agree with the numbers shown in the flag symbols in the figure.

FLAG NAME IDENTIFICATION QTY MORE DATA

NOTE

Use filler wire to build up diameter of

AWG 24 wire inside contact. Refer to

SWPM 20-60-00 and SWPM 20-81-11

as accepted procedures.

1 Contact BACC47CP2T 4

Filler Wire 61-74479-2002 -

Use color white. Refer to SWPM 20-10-

11 as an accepted procedure.

2 Lacing Tape 61-74479-2001 -

Imprinted "D1818 M/W R00146 AFT AUX

FWD BOOST PUMP". Install within 6

inches of connector.

Connector Identifi- 61-74478-10401 1

cation Tape

3

Imprinted "D1820 M/W R00147 AFT AUX

AFT BOOST PUMP". Install within 6

inches of connector.

Connector Identifi- 61-74478-10402 1

cation Tape

4

FIGURE 11: WIRE BUNDLE W0044 - WIRING CHANGES

(SHEET 1 OF 1)

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ALERT ALERT
This Figure applies only to: Group 10, Configuration 1.

The flag note numbers shown below agree with the numbers shown in the flag symbols in the figure.

FLAG NAME IDENTIFICATION QTY MORE DATA

NOTE

Use filler wire to build up diameter of AWG 22

wire inside contact. Refer to SWPM 20-60-00

and SWPM 20-81-11 as accepted procedures.

1 Contact BACC47CP2T 4

Filler Wire 61-74479-2002 -

Use color white. Refer to SWPM 20-10-11 as

an accepted procedure.

2 Lacing Tape 61-74479-2001 -

Imprinted "D1818 M/W R00146 AFT AUX FWD

BOOST PUMP". Install within 6 inches of connector.

Connector Identifi- 61-74478-10401 1

cation Tape

3

Imprinted "D1820 M/W R00147 AFT AUX AFT

BOOST PUMP". Install within 6 inches of connector.

Connector Identifi- 61-74478-10402 1

cation Tape

4

FIGURE 12: WIRE BUNDLE W0044 - WIRING CHANGES

(SHEET 1 OF 1)

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ALERT ALERT
This Figure applies only to: Group 11, 13, Configuration 1.

FIGURE 13: WIRE BUNDLE W0044 - WIRING CHANGES

(SHEET 1 OF 2)

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BOEING SERVICE BULLETIN 737-28A1212

ALERT ALERT
The flag note numbers shown below agree with the numbers shown in the flag symbols in the figure.

FLAG NAME IDENTIFICATION QTY MORE DATA

NOTE

Use filler wire to build up diameter of AWG

22 and AWG 24 wire inside contact. Refer to

SWPM 20-60-00 and SWPM 20-81-11 as

accepted procedures. (a)

1 Contact BACC47CP2T 16

Filler Wire 61-74479-2002 -

Use color white. Refer to SWPM 20-10-11 as

an accepted procedure.

2 Lacing Tape 61-74479-2001 -

Imprinted "D1602 M/W R00020 AFT B/P 2".

Install within 6 inches of connector.

Connector Identifi- 61-74479-10101 1

cation Tape

3

Imprinted "D1608 M/W R00054 CTR L B/P".

Install within 6 inches of connector.

Connector Identifi- 61-74478-10302 1

cation Tape

4

Imprinted "D1604 M/W R00021 FWD B/P 2".

Install within 6 inches of connector.

Connector Identifi- 61-74479-10102 1

cation Tape

5

Imprinted "D1610 M/W R00019 FWD B/P 1".

Install within 6 inches of connector.

Connector Identifi- 61-74479-10103 1

cation Tape

6

Imprinted "D1606 M/W R00055 CTR R B/P".

Install within 6 inches of connector.

Connector Identifi- 61-74478-10301 1

cation Tape

7

Imprinted "D1612 M/W R00018 AFT B/P 1".

Install within 6 inches of connector.

Connector Identifi- 61-74479-10104 1

cation Tape

8

Imprinted "D1818 M/W R00146 AFT AUX

FWD BOOST PUMP". Install within 6 inches

of connector. (a)

Connector Identifi- 61-74478-10401 1

cation Tape

9

Imprinted "D1820 M/W R00147 AFT AUX AFT

BOOST PUMP". Install within 6 inches of

connector. (a)

Connector Identifi- 61-74478-10402 1

cation Tape

10

(a) Airplanes in Group 13 have been delivered with wire provisions for Auxiliary Tanks installation. If

Auxiliary Tanks have been installed on these airplanes operators need to order this kit. If Auxiliary

Tanks have not been installed on these airplanes there are more parts than necessary in this kit.

Operators need to obtain only the necessary parts to incorporate this service bulletin for Tank 1,

Tank 2, and Center Tank.

FIGURE 13: WIRE BUNDLE W0044 - WIRING CHANGES

(SHEET 2 OF 2)

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BOEING SERVICE BULLETIN 737-28A1212

ALERT ALERT
This Figure applies only to: Group 8, Configuration 1.

FIGURE 14: FUEL BOOST PUMP CONNECTOR - WIRE LOCATION

(SHEET 1 OF 1)

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BOEING SERVICE BULLETIN 737-28A1212

ALERT ALERT
This Figure applies only to: Group 8, Configuration 1.

FIGURE 15: FUEL BOOST PUMP GROUNDS - WIRE LOCATION

(SHEET 1 OF 1)

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BOEING SERVICE BULLETIN 737-28A1212

ALERT ALERT
This Figure applies only to: Group 8, Configuration 1.

The flag note numbers shown below agree with the numbers shown in the flag symbols in the figure.

FLAG NAME IDENTIFICATION QTY MORE DATA

NOTE

Refer to SWPM 20-60-08 as an

accepted procedure.

1 Seal Plug MS27488-16-1 6

FIGURE 16: FUEL BOOST PUMP CONNECTOR - WIRING CHANGES

(SHEET 1 OF 2)

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BOEING SERVICE BULLETIN 737-28A1212

ALERT ALERT
FLAG NAME IDENTIFICATION QTY MORE DATA

NOTE

M23053/5-103-4 or 12 (a) (b)

M23053/5-104-4

Thermofit Sleeve, Yellow, Inner

Diameter 0.093 Inch or Thermofit

Sleeve, Yellow, Inner Diameter

0.125 Inch

2

BMS 13-54, Type 3, -

Class 1, Color White

Lacing Tape

It is acceptable to use an equivalent sleeve. Refer to SWPM 20-00-11 and SWPM 20-10-11 as accepted procedures.(a)

Cap and stow wire at this end with lacing tape and thermofit sleeve. Refer to SWPM 20-10-11 as an

accepted procedure.

(b)

FIGURE 16: FUEL BOOST PUMP CONNECTOR - WIRING CHANGES

(SHEET 2 OF 2)

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BOEING SERVICE BULLETIN 737-28A1212

ALERT ALERT
This Figure applies only to: Group 8, Configuration 2.

FIGURE 17: FUEL BOOST PUMP CONNECTOR - WIRE LOCATION

(SHEET 1 OF 1)

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BOEING SERVICE BULLETIN 737-28A1212

ALERT ALERT
This Figure applies only to: Group 8, Configuration 2.

FIGURE 18: FUEL BOOST PUMP GROUNDS - WIRE LOCATION

(SHEET 1 OF 1)

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BOEING SERVICE BULLETIN 737-28A1212

ALERT ALERT
This Figure applies only to: Group 8, Configuration 2.

The flag note numbers shown below agree with the numbers shown in the flag symbols in the figure.

FLAG NAME IDENTIFICATION QTY MORE DATA

NOTE

Refer to SWPM 20-60-08 as an

accepted procedure.

1 Seal Plug MS27488-16-1 2

M23053/5-103-4 or 4 (a) (b)

M23053/5-104-4

Thermofit Sleeve, Yellow, Inner

Diameter 0.093 Inch or Thermofit

Sleeve, Yellow, Inner Diameter

0.125 Inch

2

BMS 13-54, Type 3, -

Class 1, Color White

Lacing Tape

It is acceptable to use an equivalent sleeve. Refer to SWPM 20-00-11 and SWPM 20-10-11 as accepted procedures.(a)

Cap and stow wire at this end with lacing tape and thermofit sleeve. Refer to SWPM 20-10-11 as an

accepted procedure.

(b)

FIGURE 19: FUEL BOOST PUMP CONNECTOR - WIRING CHANGES

(SHEET 1 OF 1)

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BOEING SERVICE BULLETIN 737-28A1212

ALERT ALERT
This Figure applies only to: Group 1; Group 2-7, Configuration 1; Group 8; Group 9-13, Configuration 1.

FIGURE 20: FUEL BOOST PUMP CONTROL GROUND FAULT INTERRUPTER (GFI) CONTROL RELAY

REFERENCE

(SHEET 1 OF 1)

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BOEING SERVICE BULLETIN 737-28A1212

ALERT ALERT
This Figure applies only to: Group 1, 8.

The flag note numbers shown below agree with the numbers shown in the flag symbols in the figure.

FLAG NAME IDENTIFICATION QTY MORE DATA

NOTE

Refer to SWPM 20-71-11 as an accepted

procedure.

1 Contact 031-9134-004 2

Identify as shown. Cut to the necessary

length.

BMS13-58, Type 1, 2

Class 1, AWG 22, 60

inches in length

2 Wire

Use color white. Size 75/12 or 110/14.

Refer to SWPM 20-10-11 as an accepted

procedure.

BMS13-54, Type 3, -

Class 1, Finish C

Lacing Tape

Replace connector identification as necessary. Install within 6 inches of connector.

(a)

Connector Identifi- BACT19C-T 1

cation Tape

3

4 Splice BACT12C20 1 (b)

Permacel P-421, width - Length as required. (b) (c)

0.5 inch

Adhesive Tape

Length as required. Imprint "SM206" on

the sleeve with permanent ink. (b) (c)

TFE-4X Sleeve, inner 1

diameter 0.25 inch

Sleeve

Make from BACT19C-T or equivalent. Imprint "D01142 M/W M00183 P6 REY MOD" with permanent

ink. Refer to SWPM 20-10-11 as an accepted procedure.

(a)

Use splice, adhesive tape, and sleeve to assemble a sealed splice for high temperature unshielded wire (one wire to two wires). Refer to SWPM 20-30-12 as an accepted procedure.(b)

FIGURE 21: WIRE BUNDLE W0044 WIRING CHANGES

(SHEET 1 OF 2)

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BOEING SERVICE BULLETIN 737-28A1212

ALERT ALERT
FLAG NAME IDENTIFICATION QTY MORE DATA

NOTE

It is allowable to use an equivalent material with temperature Grade D. Refer to SWPM 20-30-12

as an accepted procedure.

(c)

FIGURE 21: WIRE BUNDLE W0044 WIRING CHANGES

(SHEET 2 OF 2)

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BOEING SERVICE BULLETIN 737-28A1212

ALERT ALERT
This Figure applies only to: Group 2-7, 9-13.

FIGURE 22: RELAY MOUNTING PANEL - GROUND STUDS AND BONDING JUMPER INSTALLATION

(SHEET 1 OF 4)

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ALERT ALERT
FIGURE 22: RELAY MOUNTING PANEL - GROUND STUDS AND BONDING JUMPER INSTALLATION

(SHEET 2 OF 4)

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BOEING SERVICE BULLETIN 737-28A1212

ALERT ALERT
STEP TASK NAME IDENTIFICATION QTY MORE DATA

in accordance with 737-100/200

SRM 51-30-02 or 737-300 SRM

51-40-05, or 737-400 SRM 51-

40-05, or 737-500 SRM 51-40-

05 as applicable. (a)

Remove/Dis- RIVET BACR15BB5D( ) 1

card

1

With 0.218-0.229 inch diameter

in accordance with 737-100/200

SRM 51-30-05 or 737-300 SRM

51-40-05, or 737-400 SRM 51-

40-05, or 737-500 SRM 51-40-

05 as applicable.

2 Drill HOLE - 2

in accordance with 737-100/200

SRM 51-30-05 or 737-300 SRM

51-40-05, or 737-400 SRM 51-

40-05, or 737-500 SRM 51-40-

05 as applicable.

3 Deburr HOLE - 2

remove the paint on both side,

the panel area around the hole,

and the support angle around

the hole. (b)

4 Clean SURFACE - 4

On any bare metal around the

holes. Refer to SOPM 20-43-03

as an accepted procedure.

ALODINE, TYPE 2, -

CLASS A, or TYPE

5, CLASS F

CHEMICAL CONVERSION COATING

5 Apply

FIGURE 22: RELAY MOUNTING PANEL - GROUND STUDS AND BONDING JUMPER INSTALLATION

(SHEET 3 OF 4)

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ALERT ALERT
STEP TASK NAME IDENTIFICATION QTY MORE DATA

6 Clean SURFACE - 4 to remove the contamination. (c)

in accordance with APPENDIX

A, Paragraph 1.

7 Install (New) BOLT BACS12GU3K10 2

Install (New) WASHER NAS1149D0316H 6

Install (New) NUT BACN10YR3CD 2

BONDING BACJ40K5A5A6 1

JUMPER

Install (New)

35 to 40 Inch-Pound in accordance with APPENDIX A, Paragraph 1.Torque NUT - 2

between bonding jumper terminal lug and structure. Make sure

that the resistance is 0.001

Ohms (1.0 milliohms) or less.

(d)

0.001 OHMS (1.0 2

MILLIOHMS)

8 Measure RESISTANCE

between the relay mounting

panel and P6 Load Control

Center structure. Make sure that

the resistance is 0.0025 Ohms

(2.5 milliohms) or less. (d)

0.0025 OHMS (2.5 1

MILLIOHMS)

9 Measure RESISTANCE

on any bare metal around the

ground studs. Refer to SOPM

20-41-02 as an accepted procedure.

BMS 10-11, TYPE -

1

10 Apply EPOXY PRIMER

(a) Operators that incorporated Service Bulletin 737-24-1145 have to use the "Optional" installation of the

ground studs in accordance with Detail C. Step 1 needs to be done only if the optional installation is

used.

(b) Abrasive clean by Hand or with a rotary brush in accordance with APPENDIX A, Paragraph 2.a.

(c) Use Solvent to clean the surface area around the holes in accordance with APPENDIX A, Paragraph

2.b.

(d) If the resistance measurement is greater than the maximum resistance shown, then disassemble parts,

clean faying surfaces, install parts and measure bonding resistance again. Refer to SWPM 20-20-00

as an accepted procedure.

FIGURE 22: RELAY MOUNTING PANEL - GROUND STUDS AND BONDING JUMPER INSTALLATION

(SHEET 4 OF 4)

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BOEING SERVICE BULLETIN 737-28A1212

ALERT ALERT
NOTE: APPENDIX A contains electrical bonding data out of BAC5117-4 and BAC5117-6. Operators may use

the electrical bonding data in APPENDIX A or BAC5117-4 or BAC5117-6 as applicable.

1. DIRECT STANDARD GROUND STUD INSTALLATION - SEE FIGURE 1

a. Surface Preparation

(1) Clean the structure surface in accordance with section 2.A. (CM1) and/or 2.B. (CM3).

(2) Clean a sufficient amount of the surface to ensure the entire area under the corrosion protective

washer 1 is clean.

(3) Clean the terminal or terminals. As given in section 3.B. (CM3).

(4) Clean the corrosion protective washer 1. As given in section 3.B. (CM3).

b. Direct Ground Stud Installation

(1) Install the direct ground stud and terminal or terminals.

(2) Torque the self-locking nut to 35-40 inch-pounds.

2. SURFACE PREPARATION AND CLEANING FOR ELECTRICAL BOND

a. Abrasive Clean by Hand (CM1) (Excerpts from; SWPM 20-20-00, 2.A. Cleaning Procedure 1 or SOPM

20-11-03, 3.B. Cleaning Method CM1, (1) Hand Application of Abrasives)

CAUTION: DO NOT USE THE ABRASIVE MATERIAL ON MATERIAL DIFFERENT FROM THE

TYPE ON WHICH IT WAS FIRST USED.

(1) Clean the specified surface by hand, using one of the following abrasive materials:

Appendix A: ELECTRICAL BONDING

(SHEET 1 OF 6)

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BOEING SERVICE BULLETIN 737-28A1212

ALERT ALERT
(a) Scotch - Brite Pad

(b) Garnet Sandpaper

(c) Wet/Dry Sandpaper

(2) Use a circular motion with the abrasive material.

(3) Continue until the coating is removed and the aluminum surface is bright. Remove a minimum

amount of aluminum.

(4) If the surface finish includes Corrosion Inhibiting Compound (CIC) applied on top of paint or primer,

remove the CIC a minimum of 0.10 inch beyond the area where the paint and primer is removed.

Use solvent cleaning method section 3.B (CM3) to remove the CIC.

(5) Do not allow the cleaned bonding surface to be contaminated.

(6) Remove all temporary protective coatings or masking from a cleaned bonding surface just prior

to assembly of a bond.

(7) Reclean the mating bonding surfaces in accordance with section 3.B. (CM3).

b. Solvent Clean (CM3) (Excerpts from; SWPM 20-20-00, 2.E. Cleaning Procedure 5 or SOPM 20-11-03,

3.D. Cleaning Method CM3)

CAUTION: BE SURE TO USE A SOLVENT THAT AGREES WITH THE SURFACE TO BE CLEANED.

(1) Solvent clean the surface.

(a) Use a solvent from this list:

1) Acetone

2) Ethyl alcohol, denatured

3) Isopropyl alcohol

4) Methyl Ethyl Ketone - sec-butyl alcohol, 1 - to - 1 mix

5) Methyl Propyl Ketone

6) Solvents with FB code in BAC5750

(b) Solvents used for final cleaning shall be transferred from the original containers only to new

or dedicated clean containers using new or dedicated clean equipment.

(c) Dispense solvent onto a clean wiper, BMS15-5 Class A. Do not dip wiper into solvent container.

Appendix A: ELECTRICAL BONDING

(SHEET 2 OF 6)

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(d) Rub the surface to be cleaned with solvent soaked wiper. Immediately wipe dry with a clean,

dry wiper. Do not allow solvent to evaporate to dryness. It may be necessary to remove residue

with a second dry wiper when using slow-evaporating solvents.

(e) Frequently exchange soiled wiper for a clean one.

(f) If unwanted matter stays, it could be because of fast solvent evaporation. Try to clean a smaller

area at one time.

(g) Repeat steps c. through e. until the wiper shows no soil.

3. TEST EQUIPMENT USED IN AREAS SUBJECT TO COMBUSTION, FIRE AND EXPLOSIONS

a. The test equipment to be used in Fire Hazard areas or Flammable leakage zones, must be approved

by Factory Mutual Approval Standard 3610 or qualified to Underwriter's Laboratory (UL) Standard 913,

for Class I, Group A, Atmosphere.

b. The following meters are approved for use in areas subject to combustion, fire, and explosions as

defined in UL Standard 913 for a Class I, Group A, Atmosphere:

(1) AVTRON Manufacturing Incorporated - Model T477W Bonding Meter

(2) BCD Electronics Ltd. - Model M1 Bonding Meter, serial number A0000112 and on

4. REQUIREMENTS

a. All designated bonds and all designated grounds must be tested to verify that the resistance requirements

specified in the service bulletin are met. Sampling is not allowed.

b. Measure the resistance of designated bonds and designated grounds between the points specified in

the service bulletin.

c. Only certified personnel are allowed to make resistance measurements of designated bonds and

grounds.

5. TEST METHODS

a. GENERAL

WARNING: USE OF THE WRONG TEST EQUIPMENT MAY CAUSE FIRE OR EXPLOSION

(1) Choose test equipment for measuring resistance as follows:

NOTE: Make sure that the meter to be used has a measuring range equal to or exceeding the

maximum allowable resistance for the measurement to be made.

Appendix A: ELECTRICAL BONDING

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(a) When measuring resistance in areas subject to combustion, fire and explosion, use only the

test equipment specified in section 6. Visually check test equipment prior to taking it to areas

subject to combustion, fire and explosion and verify that no physical damage has occurred

which might have impaired the vapor tightness of the instrument housing.

(2) All meters used for bonding resistance measurement must have a certified measuring range equal

to or exceeding the maximum allowable resistance for the measurement to be made.

(3) For meters which have range selectors, readings must be taken using the lowest range that contains

the measurement to be made.

(4) Impressions on electrical wire terminals caused by resistance measuring equipment that do not

expose the base metal are acceptable.

(5) Use the following conversion factors to convert from a meter reading displayed in milliohms /

microhms to an equivalent value in ohms.

Ohms=Milliohms/1,000

Ohms=Microhms/1,000,000

(6) Do not use test equipment on circuits which have power applied.

b. RESISTANCE MEASUREMENT FROM THE GFI RELAY TO THE RELAY MOUNTING PANEL

Appendix A: ELECTRICAL BONDING

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Appendix A: ELECTRICAL BONDING

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(1) Select the applicable test equipment in accordance with section 3.

(2) Place one ohmmeter probe any where on the Relay and the other probe on the Mounting Panel,

0.25 Inch from the flange of the Relay or from the spacer, as applicable.

(3) If the Panel and/or the Relay is covered by a surface finish, remove a sufficient amount of the

surface finish to allow the probes to contact the structure bonding surface.

NOTE: Carefully pierce the surface finish with the probes to make contact with the structure

bonding surface.

(4) Verify the resistance value shown on the ohmmeter is less than or equal to the resistance

requirement specified in the service bulletin.

(5) After testing is complete, re-apply chemical conversion coating to areas disturbed by the test

probes. Refer to SOPM 20-43-03 as an accepted procedure. For areas disturbed by the test probes

where the original finish included BMS 10-20 Type II, repair the chemical conversion coating, then

repair the BMS 10-20 Type II. Refer to SOPM 20-43-03 and SOPM 20-60-02 as accepted

procedures.

Appendix A: ELECTRICAL BONDING

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