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Commercial Airplanes MD11 Service Bulletin Number: MD11-28-146 Original Issue: May 15, 2015 ATA System: 2822 SUBJECT: FUEL - Engine Fuel Supply - Replace Fuel Pump Housing Electrical Connectors Export of this technology is controlled under the United States Export Administration Regulations (EAR) (15 CFR 300-774). An export license may be required before it is used for development, production or use by foreign persons from specific countries. The controller of this data has the individual responsibility to abide by all export laws.
9E991ECCN:
BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET Copyright © 2015 Boeing.
Unpublished Work. All Rights Reserved.
Treatment of this document and its content is governed by contract with Boeing. Rights to use this document are licensed on a per aircraft basis and such rights may not be transferable. For more information, contact The Boeing Company.
Boeing, the Boeing signature, the Boeing symbol, 707, 717, 727, 737, 747, 757, 767, 777, 787, Dreamliner, BBJ, DC-8, DC-9, DC-10, KC-10, KC-46, KDC-10, MD-10, MD-11, MD-80, MD-88, MD-90, P-8, Poseidon and Boeing liveries are all trademarks owned by The Boeing Company; and no trademark license is granted in connection with this document unless provided in writing by Boeing.
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2.0
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
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Table of Contents
S u m m a r y5
1. PLANNING INFORMATION9
A . E f f e c t i v i t y9
1. Airplanes9
2 . S p a r e s A f f e c t e d ........................................ 1 0 B. Concurrent Requirements ...................................... 1 0 C. Reason ................................................ 1 0 D. Description .............................................. 1 1 E. Compliance .............................................. 1 1 F . A p p r o v a l ............................................... 1 1 G. Manpower .............................................. 1 2 H. Weight and Balance Changes .................................... 1 4 I. Electrical Load Data ......................................... 1 4 J . R e f e r e n c e s .............................................. 1 5
1. Existing Data: ......................................... 1 5
2. Data Supplied with this Service Bulletin: ........................... 1 5
3. Installation Drawings Used in the Preparation of this Service Bulletin: ........... 1 5 K. Publications Affected ........................................ 1 5 L. Interchangeability and Intermixability of Parts ........................... 1 6 M. Software Accomplishment Summary ................................ 1 6
2. MATERIAL INFORMATION ........................................ 1 7 A. Material - Price and Availability ................................... 1 7 B. Industry Support Information .................................... 1 7 C. Parts Necessary for Each Airplane ................................. 1 7 1 . K i t s / P a r t s ............................................ 1 7
2. Parts and Materials Supplied by the Operator ........................ 2 0
3. Parts Modified and Reidentified ................................ 2 1
4. Parts Removed and Not Replaced .............................. 2 1 D. Parts Necessary to Change Spares ................................. 2 1 E. Special Tooling - Price and Availability ............................... 2 1 F. Special Tooling Necessary to do this Service Bulletin ....................... 2 1
3. ACCOMPLISHMENT INSTRUCTIONS .................................. 2 3 A. GENERAL INFORMATION ..................................... 2 3 B. WORK INSTRUCTIONS ....................................... 2 6 FIGURE 1: BENCH WORK - MAKE ALIGNMENT PINS ......................... 3 0 FIGURE 2: LEFT WING REAR SPAR - DISCONNECT FUEL PUMP WIRES .............. 3 1 FIGURE 3: LEFT WING FWD SPAR - DISCONNECT FUEL PUMP WIRES .............. 3 4 FIGURE 4: RIGHT WING FWD SPAR - DISCONNECT FUEL PUMP WIRES .............. 3 8 FIGURE 5: RIGHT WING REAR SPAR - DISCONNECT FUEL PUMP WIRES ............. 4 2 FIGURE 6: CENTER WING REAR SPAR (UPPER AUX TANK) - DISCONNECT FUEL PUMP WIRES . 45 FIGURE 7: CENTER WING REAR SPAR (LOWER AUX TANK) - DISCONNECT FUEL PUMP WIRES . 48 FIGURE 8: HORIZONTAL FWD SPAR (TAIL TANK) - DISCONNECT FUEL PUMP WIRES ...... 5 3 FIGURE 9: CHANGE FUEL PUMP HOUSING ELECTRICAL CONNECTOR (ALL PUMPS) ...... 5 6 FIGURE 10: CHANGE FUEL PUMP HOUSING (ALL PUMPS) ...................... 6 0 FIGURE 11: LEFT WING REAR SPAR - ROUTE AND CLIP FUEL PUMP WIRES ........... 6 4 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
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FIGURE 12: LEFT WING FWD SPAR - ROUTE AND CLIP FUEL PUMP WIRES ............ 6 7 FIGURE 13: RIGHT WING FWD SPAR - ROUTE AND CLIP FUEL PUMP WIRES ........... 7 1 FIGURE 14: RIGHT WING REAR SPAR - ROUTE AND CLIP FUEL PUMP WIRES ........... 7 5 FIGURE 15: CENTER WING REAR SPAR (UPPER AUX TANK) - ROUTE AND CLIP FUEL PUMP WIRES .................................................. 7 8 FIGURE 16: CENTER WING REAR SPAR (LOWER AUX TANK) - ROUTE AND CLIP FUEL PUMP WIRES .................................................. 8 1 FIGURE 17: HORIZONTAL FWD SPAR (TAIL TANK) - ROUTE AND CLIP FUEL PUMP WIRES . . . 85 FIGURE 18: LEFT WING REAR SPAR - TERMINATE FUEL PUMP WIRES ............... 8 9 FIGURE 19: LEFT WING FWD SPAR - TERMINATE FUEL PUMP WIRES ............... 9 3 FIGURE 20: RIGHT WING FWD SPAR - TERMINATE FUEL PUMP WIRES ............... 9 6 FIGURE 21: RIGHT WING REAR SPAR - TERMINATE FUEL PUMP WIRES .............. 9 9 FIGURE 22: CENTER WING REAR SPAR (UPPER AUX TANK) - TERMINATE FUEL PUMP WIRES . 103 FIGURE 23: CENTER WING REAR SPAR (LOWER AUX TANK) - TERMINATE FUEL PUMP WIRES . 106 FIGURE 24: HORIZONTAL FWD SPAR (TAIL TANK) - TERMINATE FUEL PUMP WIRES ...... 1 0 9 APPENDIX A: 24 MONTH REPETITIVE INSPECTION ........................... 1 1 3 APPENDIX B: BOEING PART DEMAND INTENT - SURVEY ....................... 1 2 2 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
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Commercial Airplanes MD11 Service Bulletin SummaryNumber: MD11-28-146Original Issue: May 15, 2015 ATA System: 2822 SUBJECT: FUEL - Engine Fuel Supply - Replace Fuel Pump Housing Electrical Connectors
CONCURRENT REQUIREMENTS Refer to Paragraph 1.B., Concurrent Requirements.
BACKGROUND MD-11 and DC-10 operators have reported instances of fuel pump housing electrical connector failures related to ingress of airplane fluids. Currently installed fuel pump housing electrical connectors have 18 month repetitive inspection requirements related to Federal Aviation Administration (FAA) Airworthiness Directive (AD) 2011-11-05 and AD 2002-13-10. An improved fuel pump housing electrical connector has been developed in conjunction with Hydro-Aire to supersede the currently installed fuel pump housing electrical connectors. In addition to the new fuel pump housing electrical connector, the use of environmentally sealed terminal lugs will help to prevent the wicking of airplane fluids into the fuel pump wires and the fuel pump housing electrical connector. If not corrected, failure of the fuel pump housing electrical connector could result in a potential source of ignition in a fuel tank and consequent fire or explosion.
This service bulletin is the result of the safety assessments conducted by Boeing under a Special Federal Aviation Regulation (SFAR) 88, Fuel Tank System Fault Tolerance Evaluation Requirements.
Boeing Fleet Team Digest (FTD) MD-11 FTD 28-11001, MD-11 FTD 28-12001 and MD-11 FTD 28-13004 are related to this service bulletin.
This table is provided to operators for planning purposes only. Refer to the applicable sections for more information.
ReferenceAffectedPlanning Data Paragraph 1.A.2., Spares AffectedYesSpares Affected Paragraph 1.E., Compliance and Paragraph
1.F., Approval YesAD Related Paragraph 1.H., Weight and Balance ChangesNoWeight and Balance Change Paragraph 1.I., Electrical Load DataNoElectrical Load Changed Paragraph 1.K., Publications AffectedYesPublications Affected Paragraph 1.K., Publications AffectedYesAirplane Flight Operations Affected (Flight Crew Operations Manual and/or FAA Approved Airplane Flight Manual) Paragraph 2.C.1., Kits/PartsYesKits/Parts Required Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
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ReferenceAffectedPlanning Data Paragraph 2.C.2., Parts and Materials Supplied by the Operator YesOperator Supplied Parts/Material Paragraph 2.F., Special Tooling Necessary to do this Service Bulletin NoSpecial Tooling Required ACTION This service bulletin provides instructions to change/replace fuel pump housing electrical connectors or fuel pump housings as follows:
Option 1: Changes fuel pump housing electrical connectors, associated wires, fuel tank feed through components and installs sealed terminal lugs on fuel pump wiring.
Option 2: Changes fuel pump housings, associated wires, fuel tank feed through components and installs sealed terminal lugs on fuel pump wiring.
EFFECTIVITY All MD-11 and MD-11F Airplanes. Refer to Paragraph 1.A.1., Airplanes, for the list of affected airplanes.
Refer to Paragraph 1.A.2., Spares Affected for the list of affected components.
COMPLIANCE Boeing recommends that the change given in this service bulletin be done within 36 months after the original issue date of this service bulletin.
The FAA will possibly release an AD related to this service bulletin. The AD will make the compliance tasks and times given in this service bulletin mandatory.
INDUSTRY SUPPORT INFORMATION Boeing warranty remedies are not available for the configuration changes given in this service bulletin.
MANPOWER More DataElapsed HoursTotal Task HoursAirplanes
(a)30.5 - 42.556.5 - 77.0MD-11 and MD-11F Airplanes
(a) Manpower depends on option selected, refer to Paragraph 1.G., Manpower.
MATERIAL INFORMATION Boeing Supplied Kits/Parts.
Refer to Paragraph 2.A., Material - Price and Availability.
Operators are encouraged to complete the survey provided in APPENDIX B of this service bulletin to help Boeing predict the quantity and timing of the Boeing Supplied Kits/Parts.
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
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BOEING SERVICE BULLETIN MD11-28-146
PLACE FUEL PUMP HOUSIN
LECTRICAL CONNECTOR 2271029 Original Issue: May 15, 2015 Export Controlled ECCN: 9E991 - BOEING MD11-28-146 PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 7 of 122
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
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Commercial Airplanes MD11 Service Bulletin Number: MD11-28-146 Original Issue: May 15, 2015 ATA System: 2822 SUBJECT: FUEL - Engine Fuel Supply - Replace Fuel Pump Housing Electrical Connectors
1. PLANNING INFORMATION A. Effectivity
1. Airplanes This service bulletin is for the airplanes shown below.
DESCRIPTIONCONFIGURATIONGROUP MD-11 and MD-11F Airplanes.-1 Airplane Models:
MD-11, MD-11F GroupFuselage Number 1447 - 449 1451 - 459 1460 - 464 1466 - 469 1470 - 479 1480 - 489 1491 - 499 1500 - 509 1510 - 517 1519 1520 - 529 1530 - 539 1540 - 549 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
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GroupFuselage Number 1550 - 552 1554 - 559 1560 - 569 1570 - 579 1580 - 589 1590 - 599 1600 - 609 1610 - 619 1620 - 629 1630 - 639 1640 - 646
2. Spares Affected Examine your spares supply for the parts or components identified below. If any parts or components are found, refer to Paragraph 2.D., Parts Necessary to Change Spares, for the recommended action.
More DataNamePart Number
(a)FUEL PUMP HOUSING60-843, 60-843M, 60-843-1, 60-843-1M, 60- 843-2, 60-843-2M, 60-843-3, 60-845, 60-845M, 60-845-1, 60-845-1M, 60-845-2, 60-845-2M, 60-845-3
(a) Refer to Hydro-Aire SB 60-843/845-28-2 for fuel pump housing modification.
B. Concurrent Requirements The service bulletin listed below must be done before or at the same time as this service bulletin:
DescriptionService BulletinCompany Modification of Fuel Pump HousingHydro-Aire SB 60- 843/845-28-2 Hydro-Aire, Incorporated C. Reason MD-11 and DC-10 operators have reported instances of fuel pump housing electrical connector failures related to ingress of airplane fluids. Currently installed fuel pump housing electrical connectors have 18 month repetitive inspection requirements related to Federal Aviation Administration (FAA) Airworthiness Directive (AD) 2011-11-05 and AD 2002-13-10. An improved fuel pump housing electrical connector has been developed in conjunction with Hydro-Aire to supersede the currently installed fuel Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
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pump housing electrical connectors. In addition to the new fuel pump housing electrical connector, the use of environmentally sealed terminal lugs will help to prevent the wicking of airplane fluids into the fuel pump wires and the fuel pump housing electrical connector. If not corrected, failure of the fuel pump housing electrical connector could result in a potential source of ignition in a fuel tank and consequent fire or explosion.
This service bulletin is the result of the safety assessments conducted by Boeing under a Special Federal Aviation Regulation (SFAR) 88, Fuel Tank System Fault Tolerance Evaluation Requirements.
Boeing Fleet Team Digest (FTD) MD-11 FTD 28-11001, MD-11 FTD 28-12001 and MD-11 FTD 28-13004 are related to this service bulletin.
D. Description This service bulletin provides instructions to change/replace fuel pump housing electrical connectors or fuel pump housings as follows:
Option 1: Changes fuel pump housing electrical connectors, associated wires, fuel tank feed through components and installs sealed terminal lugs on fuel pump wiring.
Option 2: Changes fuel pump housings, associated wires, fuel tank feed through components and installs sealed terminal lugs on fuel pump wiring.
The work in this service bulletin is done in the maintenance zone(s) given below.
Affected Maintenance Zones ZoneModel 141, 142, 311, 515, 517, 531, 532, 533, 541, 615, 617, 632, 633, 641 MD-11, MD-11F E. Compliance Boeing recommends that the change given in this service bulletin be done within 36 months after the original issue date of this service bulletin.
The FAA will possibly release an AD related to this service bulletin. The AD will make the compliance tasks and times given in this service bulletin mandatory.
F. Approval This service bulletin was examined by the 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.
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
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In addition, the Manager of the FAA Los Angeles Aircraft Certification Office approves the action (i.e.
inspection or modification) defined in this service bulletin as an alternative method of compliance to the requirements of paragraph (h)(1) and (h)(2) of AD 2011-11-05 and paragraph (a) and (b) of AD 2002-13-10. Accomplishment of this service bulletin extends the repetitive inspection requirements of AD 2002-13-10 paragraph (a) and AD 2011-11-05 paragraph (j) from 18 months to 24 months. All provisions of AD 2011-11-05 and AD 2002-13-10 that are not specifically referenced in the above statement remain fully applicable and must be complied with, except as noted below.
In addition, the Manager of the FAA Los Angeles Aircraft Certification Office approves the action (i.e.
inspection or modification) defined in this service bulletin and service bulletin MD11-28A133, when both actions are accomplished, as terminating action for the repetitive inspection requirements of the following Boeing Service Bulletins and FAA ADs:
1. MD11-28A112, Rev 00 and paragraphs (a) and (b) of AD 2002-13-10.
2. MD11-28A143, Rev 00, 01 and paragraph (j) of AD 2011-11-05.
In addition, the Manager of the FAA Los Angeles Aircraft Certification Office approves the action (i.e.
inspection or modification) defined in this service bulletin and service bulletin MD11-28A133, when both actions are accomplished, as terminating action for paragraph (a) of FAA AD 2000-22-21 and paragraph (i) of FAA AD 2011-11-05 and removal from the Airplane Flight Manual (AFM) Procedures Section and Flight Crew Operations Manual the associated Interim Operating Procedure (IOP) regarding abnormal operations for fuel pump electrical connector failures associated with Boeing Flight Operations Bulletin MD-11-00-03A and MD-11 Flight Crew Operations Manual Advisory Bulletin 2-05C. Paragraph
(b) of FAA AD 2000-22-21 affecting the AFM Limitations Section must still be complied with and is not terminated by this service bulletin.
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 inspect the work
• Time to cure the materials
• Time to make the parts
• Time to find the tools.
Option 1: Change Fuel Pump Housing Electrical Connectors Elapsed HoursTask HoursNumber of PersonsTask
2.02.01Open Access
0.50.51FIGURE 1 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
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