### 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.9E991 ECCN: 

## BOEING PROPRIETARY, CONFIDENTIAL, AND/OR TRADE SECRET Copyright © 2009 The Boeing Company Unpublished Work - All Rights Reserved Boeing claims copyright in each page of this document only to the extent that the page contains copyrightable subject matter.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, BBJ, DC-8, DC-9, DC-10, KC-10, KDC-10, MD-10, MD-11, MD-80, MD-88, MD-90, P-8A, Poseidon and the Boeing livery are all trademarks owned by The Boeing Company; and no trademark license is granted in connection with this document unless provided in writing by Boeing.

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: July 23, 2009 737-28A1212 Revision 1: August 27, 2010 1 of 99 5.0BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: July 23, 2009 737-28A1212 Revision 1: August 27, 2010 2 of 99 **BOEING SERVICE BULLETIN 737-28A1212 ALERT**  **ALERT**

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

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: July 23, 2009 737-28A1212 Revision 1: August 27, 2010 3 of 99 **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

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: July 23, 2009 737-28A1212 Revision 1: August 27, 2010 4 of 99 **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:

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: July 23, 2009 737-28A1212 Revision 1: August 27, 2010 5 of 991. 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.

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: July 23, 2009 737-28A1212 Revision 1: August 27, 2010 6 of 99 **BOEING SERVICE BULLETIN 737-28A1212 ALERT**  **ALERT**Pages with no vertical lines have no important changes. **REVISION HISTORY** July 23, 2009 Original Issue: August 27, 2010 Revision 1:

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: July 23, 2009 737-28A1212 Revision 1: August 27, 2010 7 of 99 **BOEING SERVICE BULLETIN 737-28A1212 ALERT**  **ALERT**BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: July 23, 2009 737-28A1212 Revision 1: August 27, 2010 8 of 99 **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.

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: July 23, 2009 737-28A1212 Revision 1: August 27, 2010 9 of 99**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.

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: July 23, 2009 737-28A1212 Revision 1: August 27, 2010 10 of 99 **BOEING SERVICE BULLETIN 737-28A1212 ALERT**  **ALERT**BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: July 23, 2009 737-28A1212 Revision 1: August 27, 2010 11 of 99 **BOEING SERVICE BULLETIN 737-28A1212 ALERT**  **ALERT**BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: July 23, 2009 737-28A1212 Revision 1: August 27, 2010 12 of 99 **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.
**DESCRIPTION CONFIGURATION**  **GROUP** 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

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: July 23, 2009 737-28A1212 Revision 1: August 27, 2010 13 of 99**DESCRIPTION CONFIGURATION**  **GROUP** 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

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

- 4 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

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: July 23, 2009 737-28A1212 Revision 1: August 27, 2010 14 of 99 **BOEING SERVICE BULLETIN 737-28A1212 ALERT**  **ALERT DESCRIPTION**  **CONFIGURATION GROUP**  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

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: July 23, 2009 737-28A1212 Revision 1: August 27, 2010 15 of 99 **BOEING SERVICE BULLETIN 737-28A1212 ALERT**  **ALERT DESCRIPTION**  **CONFIGURATION GROUP**  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

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: July 23, 2009 737-28A1212 Revision 1: August 27, 2010 16 of 99 **BOEING SERVICE BULLETIN 737-28A1212 ALERT**  **ALERT DESCRIPTION**  **CONFIGURATION GROUP**  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 **Group Variable Number** 8 PA001 - PA014 1 PA015 - PA022 8 PA099 1 PA231 - PA232 1 PC001 - PC005 8 PG001 - PG017 1 PG018 - PG075 8 PG199 8 PG201 - PG202 1 PG203 - PG230 1 PG251 - PG255 8 PG271 - PG273 1 PG274 - PG279 8 PG301 - PG302 1 PG303 - PG314 8 PG331 1 PG332 1 PG351 - PG356 1 PG375 1 PG401 - PG403

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: July 23, 2009 737-28A1212 Revision 1: August 27, 2010 17 of 99 **BOEING SERVICE BULLETIN 737-28A1212 ALERT**  **ALERT Group**  **Variable Number**1 PG431 - PG440 2 PG441 - PG442 1 PG471 - PG475 1 PG501 - PG505 1 PG571 - PG578 2 PG579 - PG586 1 PG621 - PG630 1 PG651 - PG652 1 PG704 - PG705 2 PH001 2 PH011 - PH013 2 PH021 - PH024 1 PH701 - PH708 2 PH709 - PH715 2 PH731 - PH732 2 PH741 - PH743 1 PJ001 - PJ002 2 PJ003 - PJ006 3 PJ007 - PJ009 1 PJ031 - PJ032 1 PJ071 - PJ072 1 PJ101 - PJ104 2 PJ105 - PJ119 3 PJ201 - PJ219 4 PJ301 - PJ302 4 PJ551 - PJ561 4 PJ601 - PJ615 6 PJ811 5 PJ816 - PJ817 2 PK026 - PK029 2 PK041 - PK053 2 PK061 - PK067 3 PK068 - PK070

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: July 23, 2009 737-28A1212 Revision 1: August 27, 2010 18 of 99 **BOEING SERVICE BULLETIN 737-28A1212 ALERT**  **ALERT Group**  **Variable Number**2 PK081 - PK082 2 PK091 - PK099 2 PK101 - PK103 2 PK111 - PK120 2 PK141 - PK146 2 PK201 - PK204 2 PK211 - PK223 2 PK231 - PK241 2 PK251 - PK256 12 PK257 2 PK258 2 PK271 - PK274 2 PK281 - PK289 2 PK291 2 PK301 - PK318 2 PK341 2 PK351 - PK355 3 PK356 - PK359 12 PK360 2 PK361 2 PK391 2 PK431 - PK433 2 PK451 - PK452 2 PK461 - PK469 2 PK495 2 PK501 12 PK502 - PK504 2 PK511 - PK515 2 PK519 2 PK521 - PK528 2 PK541 - PK565 2 PK581 2 PK591 - PK599

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: July 23, 2009 737-28A1212 Revision 1: August 27, 2010 19 of 99 **BOEING SERVICE BULLETIN 737-28A1212 ALERT**  **ALERT Group**  **Variable Number**2 PK601 - PK606 3 PK607 - PK610 2 PK611 - PK617 2 PK621 - PK637 2 PK641 - PK642 3 PK661 2 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 12 PK871 - PK872 3 PK873 12 PK874 2 PK881 - PK884 2 PK901 - PK938 2 PK971 - PK974 2 PL001 - PL028 2 PL061 2 PL081 2 PL101 - PL113 2 PL151 2 PL171 - PL172 2 PL201 - PL203 2 PL221 2 PL401 - PL408 3 PL409 - PL410 2 PL411

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: July 23, 2009 737-28A1212 Revision 1: August 27, 2010 20 of 99 **BOEING SERVICE BULLETIN 737-28A1212 ALERT**  **ALERT Group**  **Variable Number**3 PL412 2 PL413 - PL417 12 PL421 2 PL441 2 PL451 - PL456 2 PL471 2 PL491 3 PL501 12 PL502 - PL503 3 PL504 - PL506 2 PL551 - PL562 2 PL581 3 PL601 - PL603 2 PL611 2 PL621 - PL626 3 PL631 - PL632 2 PL711 - PL712 2 PL716 - PL747 2 PL756 2 PL758 2 PL761 - PL770 2 PL781 - PL788 2 PL793 1 PL801 - PL803 2 PM001 - PM006 2 PM016 - PM017 2 PM021 - PM023 2 PM051 - PM066 3 PM101 - PM107 12 PM108 - PM119 12 PM141 - PM142 2 PM171 2 PM181

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: July 23, 2009 737-28A1212 Revision 1: August 27, 2010 21 of 99 **BOEING SERVICE BULLETIN 737-28A1212 ALERT**  **ALERT Group**  **Variable Number**2 PM251 - PM255 2 PM281 - PM283 2 PM381 - PM399 2 PM401 - PM417 2 PM541 - PM550 4 PM551 - PM564 3 PN001 - PN002 2 PN021 - PN043 2 PN081 - PN086 2 PN101 - PN117 2 PN131 - PN163 2 PN401 - PN420 2 PN431 - PN433 2 PN451 - PN456 2 PN471 - PN474 2 PN481 2 PN491 - PN493 2 PN501 4 PN502 2 PN511 4 PN512 10 PN521 2 PP001 - PP054 2 PP101 - PP169 2 PP181 - PP187 4 PP188 - PP199 2 PP201 - PP205 2 PP221 2 PP231 - PP243 2 PP281 - PP286 2 PP301 - PP305 2 PP351 - PP353 2 PP376 - PP384

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: July 23, 2009 737-28A1212 Revision 1: August 27, 2010 22 of 99 **BOEING SERVICE BULLETIN 737-28A1212 ALERT**  **ALERT Group**  **Variable Number**2 PP391 - PP393 2 PP401 - PP440 11 PP471 - PP475 13 PP501 - PP520 2 PP521 - PP522 2 PP631 - PP634 2 PP651 - PP652 2 PP671 - PP689 11 PP690 - PP694 2 PP695 - PP699 2 PP701 - PP706 11 PP707 - PP716 2 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 4 PP966 - PP967 2 PP981 - PP982 4 PP983 - PP990 2 PP991 4 PP993 2 PQ001 - PQ016 2 PQ026 - PQ041 2 PQ051 - PQ092 2 PQ101 - PQ199

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: July 23, 2009 737-28A1212 Revision 1: August 27, 2010 23 of 99 **BOEING SERVICE BULLETIN 737-28A1212 ALERT**  **ALERT Group**  **Variable Number**2 PQ201 - PQ202 4 PQ221 - PQ230 2 PQ231 - PQ232 4 PQ233 - PQ237 2 PQ241 - PQ242 4 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 5 PQ931 - PQ935 4 PQ951 4 PQ971 - PQ997 4 PR001 - PR017 4 PR021 - PR034 5 PR041 - PR045 5 PR061 - PR072

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: July 23, 2009 737-28A1212 Revision 1: August 27, 2010 24 of 99 **BOEING SERVICE BULLETIN 737-28A1212 ALERT**  **ALERT Group**  **Variable Number**4 PR077 - PR080 5 PR081 - PR082 4 PR091 - PR092 4 PR096 4 PR101 4 PR121 - PR122 4 PR131 - PR132 4 PR141 - PR143 4 PR161 - PR172 4 PR181 2 PS601 - PS631 2 PS636 - PS638 2 PS641 - PS644 4 PS651 - PS657 4 PS666 - PS669 4 PS691 - PS692 2 PS701 - PS706 2 PS751 - PS799 4 PS811 4 PS836 - PS837 2 PS841 - PS846 2 PS851 - PS852 2 PS856 13 PS861 - PS863 13 PS866 - PS868 2 PS871 - PS874 2 PS896 - PS897 2 PS901 - PS941 13 PS956 - PS957 4 PS961 - PS963 4 PS971 - PS978 4 PT001 - PT015 4 PT021 - PT031

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: July 23, 2009 737-28A1212 Revision 1: August 27, 2010 25 of 99 **BOEING SERVICE BULLETIN 737-28A1212 ALERT**  **ALERT Group**  **Variable Number**4 PT041 - PT064 4 PT101 - PT105 5 PT121 - PT138 4 PT146 - PT148 4 PT161 - PT170 5 PT181 - PT188 4 PT211 - PT220 5 PT295 4 PT301 - PT309 5 PT331 - PT360 4 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 5 PT871 - PT886 4 PT901 - PT930 4 PT971 - PT973 4 PT981 - PT985 4 PT996 4 PU001 - PU025 4 PU301 4 PU311 - PU313

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: July 23, 2009 737-28A1212 Revision 1: August 27, 2010 26 of 99 **BOEING SERVICE BULLETIN 737-28A1212 ALERT**  **ALERT Group**  **Variable Number**2 PV001 4 PV002 - PV055 4 PV201 - PV209 4 PV226 - PV229 5 PV231 - PV237 4 PV271 - PV272 5 PV281 - PV287 4 PV296 4 PV301 - PV302 5 PV351 4 PV356 - PV357 4 PW001 - PW0544 PW061 - PW068 4 PW072 4 PW086 - PW088 4 PW091 - PW0944 PW101 - PW102 4 PW106 4 PW111 - PW120 4 PW156 - PW1574 PW161 - PW171 4 PW201 - PW252 4 PW261 - PW268 4 PW271 - PW276 4 PW278 4 PW281 - PW293 4 PW296 5 PW301 - PW3274 PW401 - PW408 4 PW411 - PW418 4 PW421 - PW4244 PW431 - PW435 5 PW441 - PW450

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: July 23, 2009 737-28A1212 Revision 1: August 27, 2010 27 of 99 **BOEING SERVICE BULLETIN 737-28A1212 ALERT**  **ALERT Group**  **Variable Number**5 PW461 - PW467 5 PW501 - PW504 6 PW511 - PW522 6 PW524 5 PW525 - PW529 6 PW530 4 PW531 - PW550 4 PW556 - PW557 5 PW561 - PW564 5 PW571 - PW576 4 PW591 - PW596 4 PW611 - PW622 4 PW631 - PW6374 PW661 - PW662 4 PW681 - PW683 7 PW701 9 PW702 5 PW711 - PW7174 PW741 - PW742 4 PW761 4 PW771 4 PW831 4 PW851 - PW856 1 PX071 1 PX701 1 PY001 - PY006 2 PY007 - PY008 2 PY021 - PY022 2 PY031 2 PY036 - PY037 2 PY046 - PY048 2 PY051 - PY053 2 PY056 - PY057

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: July 23, 2009 737-28A1212 Revision 1: August 27, 2010 28 of 99 **BOEING SERVICE BULLETIN 737-28A1212 ALERT**  **ALERT Group**  **Variable Number**2 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 1 PY301 - PY304 1 PY321 - PY323 1 PY341 - PY344 2 PY345 - PY346 1 PY361 - PY362 2 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

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: July 23, 2009 737-28A1212 Revision 1: August 27, 2010 29 of 99 **BOEING SERVICE BULLETIN 737-28A1212 ALERT**  **ALERT Group**  **Variable Number**2 PY671 - PY672 2 PY721 2 PY741 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.

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: July 23, 2009 737-28A1212 Revision 1: August 27, 2010 30 of 99 **BOEING SERVICE BULLETIN 737-28A1212 ALERT**  **ALERT**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.

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: July 23, 2009 737-28A1212 Revision 1: August 27, 2010 31 of 99 **BOEING SERVICE BULLETIN 737-28A1212 ALERT**  **ALERT**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 Zone**  **Model** 1-2 737-100, 737-200, 737-200C **Group 2:**
**Affected Maintenance Zones Zone**  **Model** 1-2 737-200, 737-200C **Group 2:**
**Affected Maintenance Zones Zone**  **Model** 102 737-300, 737-400

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: July 23, 2009 737-28A1212 Revision 1: August 27, 2010 32 of 99 **BOEING SERVICE BULLETIN 737-28A1212 ALERT**  **ALERT Group 3-4, 10, 12:** 
**Affected Maintenance Zones Zone**  **Model** 1-2 737-200 **Group 4-5:**
**Affected Maintenance Zones Zone**  **Model** 102 737-300, 737-400, 737-500 **Group 6-7, 9:**
**Affected Maintenance Zones Zone**  **Model** 102 737-400 **Group 8:**
**Affected Maintenance Zones Zone**  **Model** 1-2, 3-5, 4-5 737-100, 737-200 **Group 11, 13:**
**Affected Maintenance Zones Zone**  **Model** 102 737-300 **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.

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: July 23, 2009 737-28A1212 Revision 1: August 27, 2010 33 of 99 **BOEING SERVICE BULLETIN 737-28A1212 ALERT**  **ALERT 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: Elapsed Hours**  **Task-Hours Number of Persons**  **Task** 0.50 0.50 1 Open Access 1.25 1.25 1 Figure 1 1.90 1.90 1 Figure 21 0.50 0.50 1 Close Access 1.25 2.50 2 Test 5.40 6.65 TOTAL FOR EACH AIRPLANE **Group 2, Configuration 1: Elapsed Hours**  **Task-Hours Number of Persons**  **Task** 0.50 0.50 1 Open Access 4.00 8.00 2 Removal of the Galley number one 3.50 3.50 1 Figure 2 0.40 0.40 1 Figure 9 1.00 1.00 1 Figure 22

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: July 23, 2009 737-28A1212 Revision 1: August 27, 2010 34 of 99 **BOEING SERVICE BULLETIN 737-28A1212 ALERT**  **ALERT Group 2, Configuration 1:**  **Elapsed Hours Task-Hours**  **Number of Persons Task**  0.50 0.50 1 Close Access 4.00 12.00 3 Installation of the Galley number one 1.25 2.50 2 Test 15.15 28.40 TOTAL FOR EACH AIRPLANE **Group 3, 12, Configuration 1: Elapsed Hours**  **Task-Hours Number of Persons**  **Task** 0.50 0.50 1 Open Access 4.00 8.00 2 Removal of the Galley number one 4.50 4.50 1 Figure 3 1.60 1.60 1 Figure 10 1.00 1.00 1 Figure 22 0.50 0.50 1 Close Access 4.00 12.00 3 Installation of the Galley number one 1.25 2.50 2 Test 17.35 30.60 TOTAL FOR EACH AIRPLANE **Group 4, Configuration 1: Elapsed Hours**  **Task-Hours Number of Persons**  **Task** 0.50 0.50 1 Open Access 3.50 3.50 1 Figure 4 1.00 1.00 1 Figure 22 0.50 0.50 1 Close Access 1.25 2.50 2 Test 6.75 8.00 TOTAL FOR EACH AIRPLANE **Group 5, Configuration 1: Elapsed Hours**  **Task-Hours Number of Persons**  **Task** 0.50 0.50 1 Open Access 3.50 3.50 1 Figure 5 1.00 1.00 1 Figure 22

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: July 23, 2009 737-28A1212 Revision 1: August 27, 2010 35 of 99 **BOEING SERVICE BULLETIN 737-28A1212 ALERT**  **ALERT Group 5, Configuration 1:**  **Elapsed Hours Task-Hours**  **Number of Persons Task**  0.50 0.50 1 Close Access 1.25 2.50 2 Test 6.75 8.00 TOTAL FOR EACH AIRPLANE **Group 6, Configuration 1: Elapsed Hours**  **Task-Hours Number of Persons**  **Task** 0.50 0.50 1 Open Access 4.00 8.00 2 Removal of the Galley number one 4.50 4.50 1 Figure 6 0.40 0.40 1 Figure 11 1.00 1.00 1 Figure 22 0.50 0.50 1 Close Access 4.00 12.00 3 Installation of the Galley number one 1.25 2.50 2 Test 16.15 29.40 TOTAL FOR EACH AIRPLANE **Group 7, Configuration 1: Elapsed Hours**  **Task-Hours Number of Persons**  **Task** 0.50 0.50 1 Open Access 4.00 8.00 2 Removal of the Galley number one 4.50 4.50 1 Figure 7 0.40 0.40 1 Figure 11 1.00 1.00 1 Figure 22 0.50 0.50 1 Close Access 4.00 12.00 3 Installation of the Galley number one 1.25 2.50 2 Test 16.15 29.40 TOTAL FOR EACH AIRPLANE **Group 8, Configuration 1: Elapsed Hours**  **Task-Hours Number of Persons**  **Task** 0.50 0.50 1 Open Access

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: July 23, 2009 737-28A1212 Revision 1: August 27, 2010 36 of 99 **BOEING SERVICE BULLETIN 737-28A1212 ALERT**  **ALERT Group 8, Configuration 1:**  **Elapsed Hours Task-Hours**  **Number of Persons Task**  1.25 1.25 1 Figure 1 1.20 1.20 1 Figure 16 1.90 1.90 1 Figure 21 0.50 0.50 1 Close Access 1.25 2.50 2 Test 6.60 7.85 TOTAL FOR EACH AIRPLANE **Group 8, Configuration 2: Elapsed Hours**  **Task-Hours Number of Persons**  **Task** 0.50 0.50 1 Open Access 1.25 1.25 1 Figure 1 0.40 0.40 1 Figure 19 1.90 1.90 1 Figure 21 0.50 0.50 1 Close Access 1.25 2.50 2 Test 5.80 7.05 TOTAL FOR EACH AIRPLANE **Group 9, Configuration 1: Elapsed Hours**  **Task-Hours Number of Persons**  **Task** 0.50 0.50 1 Open Access 4.00 8.00 2 Removal of the Galley number one 4.50 4.50 1 Figure 3 0.40 0.40 1 Figure 11 1.00 1.00 1 Figure 22 0.50 0.50 1 Close Access 4.00 12.00 3 Installation of the Galley number one 1.25 2.50 2 Test 16.15 29.40 TOTAL FOR EACH AIRPLANE

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: July 23, 2009 737-28A1212 Revision 1: August 27, 2010 37 of 99 **BOEING SERVICE BULLETIN 737-28A1212 ALERT**  **ALERT Group 10, Configuration 1:**  **Elapsed Hours Task-Hours**  **Number of Persons Task**  0.50 0.50 1 Open Access 4.00 8.00 2 Removal of the Galley number one 4.50 4.50 1 Figure 3 0.40 0.40 1 Figure 12 1.00 1.00 1 Figure 22 0.50 0.50 1 Close Access 4.00 12.00 3 Installation of the Galley number one 1.25 2.50 2 Test 16.15 29.40 TOTAL FOR EACH AIRPLANE **Group 11, 13, Configuration 1: Elapsed Hours**  **Task-Hours Number of Persons**  **Task** 0.50 0.50 1 Open Access 4.00 8.00 2 Removal of the Galley number one 4.50 4.50 1 Figure 3 1.60 1.60 1 Figure 13 1.00 1.00 1 Figure 22 0.50 0.50 1 Close Access 4.00 12.00 3 Installation of the Galley number one 1.25 2.50 2 Test 17.35 30.60 TOTAL FOR EACH AIRPLANE **Group 2-7, 9-13, Configuration 2: Elapsed Hours**  **Task-Hours Number of Persons**  **Task** 0.50 0.50 1 Open Access 1.00 1.00 1 Figure 22 0.50 0.50 1 Close Access 1.25 2.50 2 Test 3.25 4.50 TOTAL FOR EACH AIRPLANE

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: July 23, 2009 737-28A1212 Revision 1: August 27, 2010 38 of 99 **BOEING SERVICE BULLETIN 737-28A1212 ALERT**  **ALERT Group 1, Configuration 2; Group 8, Configuration 3:**  **Elapsed Hours Task-Hours**  **Number of Persons Task**  0.50 0.50 1 Open Access 1.25 1.25 1 Figure 1 0.50 0.50 1 Close Access 1.25 2.50 2 Test 3.50 4.75 TOTAL FOR EACH AIRPLANE
**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**  **(Pounds) Airplane**  Negligible Negligible All Airplanes
**I. Electrical Load Data** 1. Direct Current (DC) Loads
**Bus Amperes**  **Airplanes** DC Bus 1 - 0.71 Groups 1, 2, and 8 DC Bus 2 - 0.71 DC Bus 1 - 0.95 Groups 3, 9, 10, and 11 DC Bus 2 - 0.95 DC Bus 1 + 0.03 Group 4 DC Bus 2 + 0.03 DC Bus 1 - 0.22 Group 5 DC Bus 2 - 0.22 DC Bus 1 - 0.46 Group 6 DC Bus 2 - 0.46 DC Bus 1 - 0.21 Group 7 DC Bus 2 - 0.21 2. Type Continuous

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: July 23, 2009 737-28A1212 Revision 1: August 27, 2010 39 of 99 **BOEING SERVICE BULLETIN 737-28A1212 ALERT**  **ALERT 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:
**Title Drawing Number**  RELAY ASSY - LOAD CONTROL CENTER 69-73627-( ) LOAD CONTROL CENTER (STRUCTURE) P-6 PANEL 65-49815 LOAD CONTROL CENTER INSTL - P6 PANEL 65C25703 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: **Chapter-Section Publication**  28-22 737 Maintenance Manual 28-23 737 Wiring Diagram Manual 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

28-20 737 Schematic Diagram

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: July 23, 2009 737-28A1212 Revision 1: August 27, 2010 40 of 99 **BOEING SERVICE BULLETIN 737-28A1212 ALERT**  **ALERT Chapter-Section**  **Publication** Section 9 737 Maintenance Planning Document 2. Damage Tolerance Based Structural Inspections: Boeing has evaluated the repairs and/or changes in this service bulletin for effects on Fatigue Critical Structure (FCS) and for changes to Damage Tolerance Inspections (DTI) required in the Maintenance Program. This service bulletin does not affect FCS, therefore DTIs are not necessary.
**L. Interchangeability and Intermixability of Parts** Accomplishment of this service bulletin does not affect interchangeability or intermixability of parts.

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: July 23, 2009 737-28A1212 Revision 1: August 27, 2010 41 of 99 **BOEING SERVICE BULLETIN 737-28A1212 ALERT**  **ALERT**BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: July 23, 2009 737-28A1212 Revision 1: August 27, 2010 42 of 99 **BOEING SERVICE BULLETIN 737-28A1212 ALERT**  **ALERT**

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 Ser vice Bulletin (Cal**  **endar Days) Name**  **Kit Number**

(e) 349 KIT - RETROFIT GFI RELAYS IN P6 - NON- AUX CONFIGURATION 65C37854-12 (a) (e) 349 KIT - RETROFIT GFI RELAYS IN P6 - AUX OR AUX PROVISIONS CONFIGURATION 65C37854-13 (b) (d) (e) 349 KIT - RETROFIT BONDING JUMPER 65C37854-14 (c) (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.

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: July 23, 2009 737-28A1212 Revision 1: August 27, 2010 43 of 99 **BOEING SERVICE BULLETIN 737-28A1212 ALERT**  **ALERT**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 Notes**  **Existing Part Number**  **Name QTY**  **New Part Number -14**  **-13 -12**  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 Jumper - 1 1 65C37854-14
TOP KIT - GFI RELAYS IN P6 -NON-AUX CONFIGURATION . . 1 61-74479-1

TOP KIT - GFI RELAYS IN P6 - AUXOR AUX PROVISIONS CONFIGURATION . 1

. 61-74479-2

Kit - Retrofit, Bonding Jumper - 1 1 65C37854-14
BONDING JUMPER 1

. . BACJ40K5A5A6
NUT 2

. . BACN10YR3CD

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: July 23, 2009 737-28A1212 Revision 1: August 27, 2010 44 of 99 **BOEING SERVICE BULLETIN 737-28A1212 ALERT**  **ALERT Kit 65C37854**  **Notes Existing Part**  **Number Name**  **QTY New Part Number**  **-14 -13**  **-12** SCREW 2

. . BACS12GU3K10 WASHER 6

. . NAS1149D0316H (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 Notes**  **Name New Part Number**  **-1 -2**  **-101 -102**  (a) Top Kit, GFI Relays in P6 - Non- Aux Configuration

- . . . 61-74479-1 (b) Top Kit, GFI Relays in P6 - Aux or Aux Provisions Configuration . - . . 61-74479-2
Wire Kit, W0044 Wire Bundle 1

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

. 1

. . 61-74479-102 (a) Lacing Tape, White 1 1

. . 61-74479-2001 (b) Filler Wire 1 1

. . 61-74479-2002 Connector Identification Tape, Imprinted "D01606 M/W R00055 CTR R B/P" . . 1 1 61-74478-10301 Connector Identification Tape, Imprinted "D01608 M/W R00054 CTR L B/P" . . 1 1 61-74478-10302 Connector Identification Tape, Imprinted "D01818 M/W R00146 AFT AUX FWD BOOST PUMP" . . . 1 61-74478-10401 Connector Identification Tape, Imprinted "D01820 M/W R00147 AFT AUX AFT BOOST PUMP" . . . 1 61-74478-10402 Connector Identification Tape, Imprinted "D01602 M/W R00020 AFT B/P 2" . . 1 1 61-74479-10101 Connector Identification Tape, Imprinted "D01604 M/W R00021 FWD B/P 2" . . 1 1 61-74479-10102 Connector Identification Tape, Imprinted "D01610 M/W R00019 FWD B/P 1" . . 1 1 61-74479-10103 Connector Identification Tape, Imprinted "D01612 M/W R00018 AFT B/P 1" . . 1 1 61-74479-10104
Contact

. . 14 18 BACC47CP2T (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.

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: July 23, 2009 737-28A1212 Revision 1: August 27, 2010 45 of 99 **BOEING SERVICE BULLETIN 737-28A1212 ALERT**  **ALERT**2. Parts and Materials Supplied by the Operator:
**Notes Name**  **QTY Part Number / Specification**  (a) (b) (l) Ground Fault Interrupter (GFI) Relay 2, 4, 6, or 8 S283A004-1 (LEACH P/N 9524G-10674) (a) (c) Ground Fault Interrupter (GFI) Relay 4 or 6 S283A004-6 (LEACH P/N KCG- X4L-001) (a) (d) Relay Installation Kit 4 or 6 002-9667-001-000 (e) Seal Plug 6 MS27488-16-1 (e) (f) M23053/5-103-4 or M23053/5-104- 4 As Required Thermofit Sleeve, Yellow, Inner Diameter 0.093 Inch or 0.125 Inch (g) (h) Contact 2 031-9134-004 (g) (f) Connector Identification Sleeve, Im- printed "D01142 M/W M00183 P6 REY MOD" 1 BACT19C-T

(g) (i) Wire 10 Feet BMS 13-58, Type 1, Class 1, AWG 22 (g) (j) Lacing Tape As Required BMS 13-54, Type 3, Class 1, Color White (g) Splice 1 BACT12C20 (g) (k) Adhesive Tape, Width 0.5 Inch As Required Permacel, P-421 Tape (g) Sleeve, Inner Diameter 0.25 Inch, Imprinted "SM206" As Required TFE-4X Sleeve (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.

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: July 23, 2009 737-28A1212 Revision 1: August 27, 2010 46 of 99 **BOEING SERVICE BULLETIN 737-28A1212 ALERT**  **ALERT Notes**  **Name QTY**  **Part Number / Specification** (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 AuxiliaryTanks 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.
**Notes New Part Number**  **Name QTY**  **Existing Part Number**  (a) 65-49808-( ) M181 Relay Module Assembly 1 65-49808-( ) (a) 65-49808-( ) M182 Relay Module Assembly 1 65-49808-( ) (a) 65-49808-( ) M183 Relay Module Assembly 1 65-49808-( ) (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.

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: July 23, 2009 737-28A1212 Revision 1: August 27, 2010 47 of 99 **BOEING SERVICE BULLETIN 737-28A1212 ALERT**  **ALERT**BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: July 23, 2009 737-28A1212 Revision 1: August 27, 2010 48 of 99 **BOEING SERVICE BULLETIN 737-28A1212 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.

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: July 23, 2009 737-28A1212 Revision 1: August 27, 2010 49 of 99 **BOEING SERVICE BULLETIN 737-28A1212 ALERT**  **ALERT**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.

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: July 23, 2009 737-28A1212 Revision 1: August 27, 2010 50 of 99 **BOEING SERVICE BULLETIN 737-28A1212 ALERT**  **ALERT**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.

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: July 23, 2009 737-28A1212 Revision 1: August 27, 2010 51 of 99 **BOEING SERVICE BULLETIN 737-28A1212 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.

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: July 23, 2009 737-28A1212 Revision 1: August 27, 2010 52 of 99 **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.

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: July 23, 2009 737-28A1212 Revision 1: August 27, 2010 53 of 99 **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.
**MORE DATA QTY**  **IDENTIFICATION NAME**  **TASK STEP**  M181, M182, M183. (a) 3 65-49808-( ) Relay Module As- sembly Remove/ Keep 1 M181, M182, M183. (a) 3 65-49808-( ) Relay Module As- sembly Install 2
between M181, M182, M183 and the adjacent P6 Load Control Center structure. (b) 6 2.5 MILLIOHMS RESISTANCE Measure 3

(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)** 

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: July 23, 2009 737-28A1212 Revision 1 August 27, 2010 54 of 99 **BOEING SERVICE BULLETIN 737-28A1212 ALERT**  **ALERT MORE DATA**  **QTY IDENTIFICATION**  **NAME TASK**  **STEP** 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)** 

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: July 23, 2009 737-28A1212 Revision 1 August 27, 2010 55 of 99 **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)** 

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: July 23, 2009 737-28A1212 Revision 1 August 27, 2010 56 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.
**MORE DATA QTY**  **IDENTIFICATION NAME**  **TASK STEP**  R18, R19, R20, R21, R54, and R55. 6 10-60450-1 Fuel Pump Power Relay Remove 1 Remove the paint around the relay cutout, from the side of the panel that will be in contact with the relay. (a) 6
- SURFACE Clean 2

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 Apply 3

the contact surfaces of the relay and the panelto remove the contamination. (b) 12
- SURFACE Clean 4

R18, R19, R20, R21, R54, and R55. Refer to SWPM 20-81-22 asan accepted procedure for installation of similar LEACH relays. 6 S283A004-1 (LEACH P/N 9524G-10674) Fuel Pump Power (GFI) Relay Install 5

between the flange of the relay and the mounting panel. (c) 6 0.0025 OHMS (2.5 MILLIOHMS) RESISTANCE Measure 6

on any bare metalaround the relays. Refer to SOPM 20-41-02as an accepted procedure. - BMS 10-11, TYPE 1 EPOXY PRIMER Apply 7

(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)** 

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: July 23, 2009 737-28A1212 Revision 1 August 27, 2010 57 of 99 **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)** 

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: July 23, 2009 737-28A1212 Revision 1 August 27, 2010 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.
**MORE DATA QTY**  **IDENTIFICATION NAME**  **TASK STEP**  R18, R19, R20, R21, R54, R55, R146, and R147. 8 10-60450-6 Fuel Pump Power Relay Remove 1 Remove the paint around the relay cutout, from the side of the panel that will be in contact with the relay. (a) 8
- SURFACE Clean 2

On the bare metal fromwhich 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 Apply 3

the contact surfaces of therelays and the panel to remove the contamination. (b) - - SURFACE Clean 4

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) 8 S283A004-1 (LEACH P/N 9524G-10674) Fuel Pump Power (GFI) Relay Install 5

between the flange of the relay and the mounting panel. (c) 8 0.0025 OHMS (2.5 MILLIOHMS) RESISTANCE Measure 6

on any bare metal around the relays. Refer to SOPM 20-41-02 as an accepted procedure. - BMS 10-11, TYPE 1 EPOXY PRIMER Apply 7

(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 AuxiliaryTanks 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)** 

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: July 23, 2009 737-28A1212 Revision 1 August 27, 2010 59 of 99 **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)** 

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: July 23, 2009 737-28A1212 Revision 1 August 27, 2010 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.
**MORE DATA QTY**  **IDENTIFICATION NAME**  **TASK STEP**  R18, R19, R20, R21, R54, and R55. 6 KCD4N Fuel Pump Power Relay Remove 1 Remove the paint from both sides of the panel that will be in contact with the relay spacers and spacer hardware. (a) 12
- SURFACE Clean 2

On the bare metal fromwhich 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 Apply 3

the contact surfaces of the relays, spacers, and the panel, to remove the contamination. (b) - - SURFACE Clean 4

R18, R19, R20, R21, R54, and R55. Refer to SWPM 20-81-22 as an accepted procedure for installation of similar LEACH relays. 6 S283A004-6(LEACH P/N KCGX4L-001) Fuel Pump Power (GFI) Install 5

6 002-9667-001-000 Relay Spacer Kit
between the flange of the relay and the mounting panel. (c) 6 0.0025 OHMS (2.5 MILLIOHMS) RESISTANCE Measure 6

on any bare metal around spacers. Refer to SOPM 20-41-02 as an accepted procedure. - BMS 10-11, TYPE 1 EPOXY PRIMER Apply 7

(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)** 

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: July 23, 2009 737-28A1212 Revision 1 August 27, 2010 61 of 99 **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)** 

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: July 23, 2009 737-28A1212 Revision 1 August 27, 2010 62 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.
**MORE DATA QTY**  **IDENTIFICATION NAME**  **TASK STEP**  R20, R21, R54, and R55. 4 KCD4N Fuel Pump Power Relay Remove 1 R18 and R19. 2 10-60450-6 Fuel Pump Power Relay Remove 2 Remove the paint from both sides of the panel that will be in contact with the relay spacers and spacer hardware. (a) 8
- SURFACE Clean 3

Remove the paint around the relay cutout, from the side of the panel that willbe in contact with the relay. (a) 2
- SURFACE Clean 4

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 Apply 5

the contact surfaces of the relays, spacers, and thepanel, to remove the contamination. (b) - - SURFACE Clean 6

R20, R21, R54, and R55. Refer to SWPM 20-81-22 as an accepted procedure for installation of similar LEACH relays. 4 S283A004-6(LEACH P/N KCGX4L-001) Fuel Pump Power (GFI) Install 7

4 002-9667-001-000 Relay Spacer Kit R18 and R19. Refer toSWPM 20-81-22 as an accepted procedure for installation of similar LEACH relays. 2 S283A004-1 (LEACH P/N 9524G-10674) Fuel Pump Power (GFI) Relay Install 8

between the flange of the relay and the mounting panel. (c) 6 0.0025 OHMS (2.5 MILLIOHMS) RESISTANCE Measure 9

on any bare metal around the relays and spacers. Refer to SOPM 20-41-02 as an accepted procedure. - BMS 10-11, TYPE 1 EPOXY PRIMER Apply 10

(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)** 

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: July 23, 2009 737-28A1212 Revision 1 August 27, 2010 63 of 99 **BOEING SERVICE BULLETIN 737-28A1212 ALERT**  **ALERT MORE DATA**  **QTY IDENTIFICATION**  **NAME TASK**  **STEP** (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)** 

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: July 23, 2009 737-28A1212 Revision 1 August 27, 2010 64 of 99 **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)** 

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: July 23, 2009 737-28A1212 Revision 1 August 27, 2010 65 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.
**MORE DATA QTY**  **IDENTIFICATION NAME**  **TASK STEP**  R20, R21, R54, and R55. 4 KCD4N Fuel Pump Power Relay Remove 1 R146, R147, R18, and R19. 4 10-60450-6 Fuel Pump Power Relay Remove 2 Remove the paint from both sides of the panel that will be in contact with the relayspacers and spacer hardware. (a) 8
- SURFACE Clean 3

Remove the paint around the relay cutout, from the side ofthe panel that will be in contact with the relay. (a) 4
- SURFACE Clean 4

On the bare metal from which the paint was removed. Referto SOPM 20-43-03 as an accepted procedure. - ALODINE, TYPE 2, CLASS A, or TYPE 5, CLASS F CHEMICAL CONVERSION COATING Apply 5

the contact surfaces of therelays, spacers, and the panel, to remove the contamination. (b) - - SURFACE Clean 6

R20, R21, R54, and R55. Refer to SWPM 20-81-22 as anaccepted procedure for installation of similar LEACH relays. 4 S283A004-6(LEACH P/N KCGX4L-001) Fuel Pump Power (GFI) Install 7

4 002-9667-001-000 Relay Spacer Kit R146, R147, R18, and R19. Refer to SWPM 20-81-22 asan accepted procedure for installation of similar LEACH relays. 4 S283A004-1 (LEACH P/N 9524G-10674) Fuel Pump Power (GFI) Relay Install 8

between the flange of the relay and the mounting panel. (c) 8 0.0025 OHMS (2.5 MILLIOHMS) RESISTANCE Measure 9

on any bare metal around the relays and spacers. Refer toSOPM 20-41-02 as an accepted procedure. - BMS 10-11, TYPE 1 EPOXY PRIMER Apply 10

(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)** 

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: July 23, 2009 737-28A1212 Revision 1 August 27, 2010 66 of 99 **BOEING SERVICE BULLETIN 737-28A1212 ALERT**  **ALERT MORE DATA**  **QTY IDENTIFICATION**  **NAME TASK**  **STEP** (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. Original Issue: July 23, 2009 737-28A1212 Revision 1 August 27, 2010 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. Original Issue: July 23, 2009 737-28A1212 Revision 1 August 27, 2010 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.
**MORE DATA QTY**  **IDENTIFICATION NAME**  **TASK STEP**  R18, R19, R20, R21, R54, and R55. 6 KCD4N Fuel Pump Power Relay Remove 1
R146 and R147. 2 10-60450-6 Fuel Pump Power Relay Remove 2 Remove the paint from both sides of the panel that will be in contact with the relay spacers and spacer hardware. (a) 12
- SURFACE Clean 3

Remove the paint around the relay cutout, from the side of the panel that willbe in contact with the relay. (a) 2
- SURFACE Clean 4

On the bare from which the paint was removed. Refer to SOPM 20-43-03as an accepted procedure. - ALODINE, TYPE 2, CLASS A, or TYPE 5, CLASS FCHEMICAL CONVERSION COATING Apply 5

the contact surfaces of the relays, spacers, and the panel, to remove the contamination. (b) - - SURFACE Clean 6

R18, R19, R20, R21, R54, and R55. Refer to SWPM 20-81-22 as an accepted procedure for installation of similar LEACH relays. 6 S283A004-6(LEACH P/N KCGX4L-001) Fuel Pump Power (GFI) Install 7

6 002-9667-001-000 Relay Spacer Kit

R146 and R147. Refer to SWPM 20-81-22 as an accepted procedure for installation of similar LEACH relays. 2 S283A004-1 (LEACH P/N 9524G-10674) Fuel Pump Power (GFI) Relay Install 8

between the flange of the relay and the mounting panel. (c) 8 0.0025 OHMS (2.5 MILLIOHMS) RESISTANCE Measure 9

**FIGURE 7: REPLACEMENT OF THE FUEL PUMP POWER RELAY (SHEET 2 OF 3)** 

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: July 23, 2009 737-28A1212 Revision 1 August 27, 2010 69 of 99 **BOEING SERVICE BULLETIN 737-28A1212 ALERT**  **ALERT MORE DATA**  **QTY IDENTIFICATION**  **NAME TASK**  **STEP** on any bare metal around the relays and spacers. Refer to SOPM 20-41-02as an accepted procedure. - BMS 10-11, TYPE 1 EPOXY PRIMER Apply 10

(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 AuxiliaryTanks 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)** 

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: July 23, 2009 737-28A1212 Revision 1 August 27, 2010 70 of 99 **BOEING SERVICE BULLETIN 737-28A1212 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)** 

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: July 23, 2009 737-28A1212 Revision 1 August 27, 2010 71 of 99 **BOEING SERVICE BULLETIN 737-28A1212 ALERT**  **ALERT This Figure applies only to: Group 2, Configuration 1.** 

**FIGURE 9: WIRE BUNDLE W0044 - WIRING CHANGES (SHEET 1 OF 2)** 

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: July 23, 2009 737-28A1212 Revision 1 August 27, 2010 72 of 99 **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.
**MORE DATA QTY**  **IDENTIFICATION NAME**  **FLAG NOTE**  Use filler wire to build up diameter of wire inside contact. Refer to SWPM 20-60-00and SWPM 20-81-11 as accepted procedures. 12 BACC47CP2T Contact 1

- 61-74479-2002 Filler Wire

Use color white. Refer to SWPM 20-10-11 as an accepted procedure. - 61-74479-2001 Lacing Tape 2 Imprinted "D1602 M/W R00020 AFT B/P 2". Install within 6 inches of connector. 1 61-74479-10101 Connector Identifi- cation Tape 3 Imprinted "D1608 M/W R00054 CTR L B/P". Install within 6 inches of connector. 1 61-74478-10302 Connector Identifi- cation Tape 4 Imprinted "D1604 M/W R00021 FWD B/P 2". Install within 6 inches of connector. 1 61-74479-10102 Connector Identifi- cation Tape 5 Imprinted "D1610 M/W R00019 FWD B/P 1". Install within 6 inches of connector. 1 61-74479-10103 Connector Identifi- cation Tape 6 Imprinted "D1606 M/W R00055 CTR R B/P". Install within 6 inches of connector. 1 61-74478-10301 Connector Identifi- cation Tape 7 Imprinted "D1612 M/W R00018 AFT B/P 1". Install within 6 inches of connector. 1 61-74479-10104 Connector Identifi- cation Tape 8

**FIGURE 9: WIRE BUNDLE W0044 - WIRING CHANGES (SHEET 2 OF 2)** 

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: July 23, 2009 737-28A1212 Revision 1 August 27, 2010 73 of 99 **BOEING SERVICE BULLETIN 737-28A1212 ALERT**  **ALERT This Figure applies only to: Group 3, 12, Configuration 1.** 

**FIGURE 10: WIRE BUNDLE W0044 - WIRING CHANGES (SHEET 1 OF 2)** 

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: July 23, 2009 737-28A1212 Revision 1 August 27, 2010 74 of 99 **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.
**MORE DATA QTY**  **IDENTIFICATION NAME**  **FLAG 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 BACC47CP2T Contact 1

- 61-74479-2002 Filler Wire

Use color white. Refer to SWPM 20-10- 11 as an accepted procedure. - 61-74479-2001 Lacing Tape 2 Imprinted "D1602 M/W R00020 AFT B/P 2". Install within 6 inches of connector. 1 61-74479-10101 Connector Identifi- cation Tape 3 Imprinted "D1608 M/W R00054 CTR L B/P". Install within 6 inches of connector. 1 61-74478-10302 Connector Identifi- cation Tape 4 Imprinted "D1604 M/W R00021 FWD B/P 2". Install within 6 inches of connector. 1 61-74479-10102 Connector Identifi- cation Tape 5 Imprinted "D1610 M/W R00019 FWD B/P 1". Install within 6 inches of connector. 1 61-74479-10103 Connector Identifi- cation Tape 6 Imprinted "D1606 M/W R00055 CTR R B/P". Install within 6 inches of connector. 1 61-74478-10301 Connector Identifi- cation Tape 7 Imprinted "D1612 M/W R00018 AFT B/P 1". Install within 6 inches of connector. 1 61-74479-10104 Connector Identifi- cation Tape 8 Imprinted "D1818 M/W R00146 AFT AUX FWD BOOST PUMP". Install within 6 inches of connector. (a) 1 61-74478-10401 Connector Identifi- cation Tape 9

Imprinted "D1820 M/W R00147 AFT AUX AFT BOOST PUMP". Install within 6 inches of connector. (a) 1 61-74478-10402 Connector Identifi- 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)** 

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: July 23, 2009 737-28A1212 Revision 1 August 27, 2010 75 of 99 **BOEING SERVICE BULLETIN 737-28A1212 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.
**MORE DATA QTY**  **IDENTIFICATION NAME**  **FLAG 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. 4 BACC47CP2T Contact 1

- 61-74479-2002 Filler Wire

Use color white. Refer to SWPM 20-10- 11 as an accepted procedure. - 61-74479-2001 Lacing Tape 2 Imprinted "D1818 M/W R00146 AFT AUX FWD BOOST PUMP". Install within 6 inches of connector. 1 61-74478-10401 Connector Identifi- cation Tape 3

Imprinted "D1820 M/W R00147 AFT AUX AFT BOOST PUMP". Install within 6 inches of connector. 1 61-74478-10402 Connector Identifi- cation Tape 4

**FIGURE 11: WIRE BUNDLE W0044 - WIRING CHANGES (SHEET 1 OF 1)** 

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: July 23, 2009 737-28A1212 Revision 1 August 27, 2010 76 of 99 **BOEING SERVICE BULLETIN 737-28A1212 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.
**MORE DATA QTY**  **IDENTIFICATION NAME**  **FLAG 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. 4 BACC47CP2T Contact 1

- 61-74479-2002 Filler Wire Use color white. Refer to SWPM 20-10-11 as an accepted procedure. - 61-74479-2001 Lacing Tape 2 Imprinted "D1818 M/W R00146 AFT AUX FWDBOOST PUMP". Install within 6 inches of connector. 1 61-74478-10401 Connector Identifi- cation Tape 3

Imprinted "D1820 M/W R00147 AFT AUX AFTBOOST PUMP". Install within 6 inches of connector. 1 61-74478-10402 Connector Identifi- cation Tape 4

**FIGURE 12: WIRE BUNDLE W0044 - WIRING CHANGES (SHEET 1 OF 1)** 

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: July 23, 2009 737-28A1212 Revision 1 August 27, 2010 77 of 99 **BOEING SERVICE BULLETIN 737-28A1212 ALERT**  **ALERT This Figure applies only to: Group 11, 13, Configuration 1.** 

**FIGURE 13: WIRE BUNDLE W0044 - WIRING CHANGES (SHEET 1 OF 2)** 

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: July 23, 2009 737-28A1212 Revision 1 August 27, 2010 78 of 99 **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.
**MORE DATA QTY**  **IDENTIFICATION NAME**  **FLAG 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) 16 BACC47CP2T Contact 1

- 61-74479-2002 Filler Wire

Use color white. Refer to SWPM 20-10-11 as an accepted procedure. - 61-74479-2001 Lacing Tape 2 Imprinted "D1602 M/W R00020 AFT B/P 2". Install within 6 inches of connector. 1 61-74479-10101 Connector Identifi- cation Tape 3 Imprinted "D1608 M/W R00054 CTR L B/P". Install within 6 inches of connector. 1 61-74478-10302 Connector Identifi- cation Tape 4 Imprinted "D1604 M/W R00021 FWD B/P 2". Install within 6 inches of connector. 1 61-74479-10102 Connector Identifi- cation Tape 5 Imprinted "D1610 M/W R00019 FWD B/P 1". Install within 6 inches of connector. 1 61-74479-10103 Connector Identifi- cation Tape 6 Imprinted "D1606 M/W R00055 CTR R B/P". Install within 6 inches of connector. 1 61-74478-10301 Connector Identifi- cation Tape 7 Imprinted "D1612 M/W R00018 AFT B/P 1". Install within 6 inches of connector. 1 61-74479-10104 Connector Identifi- cation Tape 8 Imprinted "D1818 M/W R00146 AFT AUX FWD BOOST PUMP". Install within 6 inches of connector. (a) 1 61-74478-10401 Connector Identifi- cation Tape 9

Imprinted "D1820 M/W R00147 AFT AUX AFT BOOST PUMP". Install within 6 inches of connector. (a) 1 61-74478-10402 Connector Identifi- 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)** 

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: July 23, 2009 737-28A1212 Revision 1 August 27, 2010 79 of 99 **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)** 

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: July 23, 2009 737-28A1212 Revision 1 August 27, 2010 80 of 99 **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)** 

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: July 23, 2009 737-28A1212 Revision 1 August 27, 2010 81 of 99 **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.
**MORE DATA QTY**  **IDENTIFICATION NAME**  **FLAG NOTE**  Refer to SWPM 20-60-08 as an accepted procedure. 6 MS27488-16-1 Seal Plug 1

**FIGURE 16: FUEL BOOST PUMP CONNECTOR - WIRING CHANGES (SHEET 1 OF 2)** 

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: July 23, 2009 737-28A1212 Revision 1 August 27, 2010 82 of 99 **BOEING SERVICE BULLETIN 737-28A1212 ALERT**  **ALERT MORE DATA**  **QTY IDENTIFICATION**  **NAME FLAG**  **NOTE** (a) (b) 12 M23053/5-103-4 or 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 TapeIt 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)** 

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: July 23, 2009 737-28A1212 Revision 1 August 27, 2010 83 of 99 **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)** 

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: July 23, 2009 737-28A1212 Revision 1 August 27, 2010 84 of 99 **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)** 

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: July 23, 2009 737-28A1212 Revision 1 August 27, 2010 85 of 99 **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.
**MORE DATA QTY**  **IDENTIFICATION NAME**  **FLAG NOTE**  Refer to SWPM 20-60-08 as an accepted procedure. 2 MS27488-16-1 Seal Plug 1 (a) (b) 4 M23053/5-103-4 or 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 TapeIt 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)** 

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: July 23, 2009 737-28A1212 Revision 1 August 27, 2010 86 of 99 **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)**

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: July 23, 2009 737-28A1212 Revision 1 August 27, 2010 87 of 99 **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.
**MORE DATA QTY**  **IDENTIFICATION NAME**  **FLAG NOTE**  Refer to SWPM 20-71-11 as an accepted procedure. 2 031-9134-004 Contact 1 Identify as shown. Cut to the necessary length. 2 BMS13-58, Type 1, Class 1, AWG 22, 60 inches in length Wire 2

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) 1 BACT19C-T Connector Identifi- cation Tape 3

(b) 1 BACT12C20 Splice 4 Length as required. (b) (c)

- Permacel P-421, width 0.5 inch Adhesive Tape Length as required. Imprint "SM206" on the sleeve with permanent ink. (b) (c) 1 TFE-4X Sleeve, inner 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)** 

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: July 23, 2009 737-28A1212 Revision 1 August 27, 2010 88 of 99 **BOEING SERVICE BULLETIN 737-28A1212 ALERT**  **ALERT MORE DATA**  **QTY IDENTIFICATION**  **NAME FLAG**  **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)** 

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: July 23, 2009 737-28A1212 Revision 1 August 27, 2010 89 of 99 **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)** 

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: July 23, 2009 737-28A1212 Revision 1 August 27, 2010 90 of 99 **BOEING SERVICE BULLETIN 737-28A1212 ALERT**  **ALERT FIGURE 22: RELAY MOUNTING PANEL - GROUND STUDS AND BONDING JUMPER INSTALLATION**  **(SHEET 2 OF 4)**

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: July 23, 2009 737-28A1212 Revision 1 August 27, 2010 91 of 99 **BOEING SERVICE BULLETIN 737-28A1212 ALERT**  **ALERT MORE DATA**  **QTY IDENTIFICATION**  **NAME TASK**  **STEP** 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) 1 BACR15BB5D( ) RIVET Remove/Dis- 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
- HOLE Drill 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. 2
- HOLE Deburr 3

remove the paint on both side, the panel area around the hole, and the support angle around the hole. (b) 4
- SURFACE Clean 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 FCHEMICAL CONVERSION COATING Apply 5

**FIGURE 22: RELAY MOUNTING PANEL - GROUND STUDS AND BONDING JUMPER INSTALLATION (SHEET 3 OF 4)** 

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: July 23, 2009 737-28A1212 Revision 1 August 27, 2010 92 of 99 **BOEING SERVICE BULLETIN 737-28A1212 ALERT**  **ALERT MORE DATA**  **QTY IDENTIFICATION**  **NAME TASK**  **STEP** to remove the contamination. (c) 4
- SURFACE Clean 6 in accordance with APPENDIX A, Paragraph 1. 2 BACS12GU3K10 BOLT Install (New) 7 6 NAS1149D0316H WASHER Install (New) 2 BACN10YR3CD NUT Install (New) 1 BACJ40K5A5A6 BONDING JUMPER Install (New)
35 to 40 Inch-Pound in accordance with APPENDIX A, Paragraph 1. 2
- NUT Torque

between bonding jumper terminal lug and structure. Make sure that the resistance is 0.001 Ohms (1.0 milliohms) or less. (d) 2 0.001 OHMS (1.0 MILLIOHMS) RESISTANCE Measure 8

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) 1 0.0025 OHMS (2.5 MILLIOHMS) RESISTANCE Measure 9

on any bare metal around the ground studs. Refer to SOPM20-41-02 as an accepted procedure. - BMS 10-11, TYPE 1 EPOXY PRIMER Apply 10

(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)** 

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: July 23, 2009 737-28A1212 Revision 1 August 27, 2010 93 of 99 **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)** 

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: July 23, 2009 737-28A1212 Revision 1 August 27, 2010 94 of 99 **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)** 

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: July 23, 2009 737-28A1212 Revision 1 August 27, 2010 95 of 99 **BOEING SERVICE BULLETIN 737-28A1212 ALERT**  **ALERT**(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 (SHEET 3 OF 6)** 

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: July 23, 2009 737-28A1212 Revision 1 August 27, 2010 96 of 99 **BOEING SERVICE BULLETIN 737-28A1212 ALERT**  **ALERT**(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 (SHEET 4 OF 6)** 

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: July 23, 2009 737-28A1212 Revision 1 August 27, 2010 97 of 99 **BOEING SERVICE BULLETIN 737-28A1212 ALERT**  **ALERT Appendix A: ELECTRICAL BONDING**  **(SHEET 5 OF 6)**

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: July 23, 2009 737-28A1212 Revision 1 August 27, 2010 98 of 99 **BOEING SERVICE BULLETIN 737-28A1212 ALERT**  **ALERT**(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 (SHEET 6 OF 6)** 

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: July 23, 2009 737-28A1212 Revision 1 August 27, 2010 99 of 99 **BOEING SERVICE BULLETIN 737-28A1212 ALERT**  **ALERT**