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McDonnell DouglasCommercial Airplanes MD11 Service Bulletin ALERT Number: MD11-28A143 Original Issue: December 02, 2009 ATA System: 2822 SUBJECT: FUEL - Engine Fuel Supply - Fuel Pump Housing Electrical Connector Assembly and Fuel Boost/Transfer Pump - Inspection/Replacement 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.

9E991ECCN:

BOEING PROPRIETARY, CONFIDENTIAL, AND/OR TRADE SECRET Copyright © 2009 The Boeing Company Unpublished Work - All Rights Reserved Boeing claims copyright in each page of this document only to the extent that the page contains copyrightable subject matter.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.

Original Issue: December 02, 2009 MD11-28A143 1 of 44

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Table of Contents

Summary5

1. PLANNING INFORMATION7

A. Effectivity7

1. Airplanes7

2. Spares Affected8

B. Concurrent Requirements8

C. Reason8

D. Description8

E. Compliance9

F. Approval ............................................... 1 2 G. Manpower .............................................. 1 2 H. Weight and Balance Changes .................................... 1 3 I. Electrical Load Data ......................................... 1 3 J. References .............................................. 1 4

1. Existing Data .......................................... 1 4

2. Data supplied with this Service Bulletin ............................ 1 4

3. Installation Drawings Used in the Preparation of this Service Bulletin: ........... 1 4 K. Publications Affected ........................................ 1 4 L. Interchangeability and Intermixability of Parts ........................... 1 5

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. Kits/Parts ............................................ 1 7

2. Parts and Materials Supplied by the Operator ........................ 2 1

3. Parts Modified and Reidentified ................................ 2 2

4. Parts Removed and Not Replaced .............................. 2 2 D. Parts Necessary to Change Spares ................................. 2 2 E. Special Tooling - Price and Availability ............................... 2 3 F. Special Tooling Necessary to do this Service Bulletin ....................... 2 3

3. ACCOMPLISHMENT INSTRUCTIONS .................................. 2 5 A. GENERAL INFORMATION ..................................... 2 5 B. WORK INSTRUCTIONS ....................................... 2 7 APPENDIX A: FUEL BOOST/TRANSFER PUMP WIRING CHART FOR PART NUMBER 60-84355-1 . . 35 APPENDIX B: FUEL PUMP HOUSING ELECTRICAL CONNECTOR ASSEMBLY REPLACEMENT WITH P/N 60-84351 ............................................ 3 8 APPENDIX C: FUEL BOOST/TRANSFER PUMP WIRING CHART FOR PART NUMBER 60-84351 . . . 40 APPENDIX D: FUEL PUMP HOUSING ELECTRICAL CONNECTOR ASSEMBLY FOR PART NUMBER 60-84355-1 INSPECTION LOGIC DIAGRAM ......................... 4 3 APPENDIX E: FUEL PUMP HOUSING ELECTRICAL CONNECTOR ASSEMBLY FOR PART NUMBER 60-84351 INSPECTION LOGIC DIAGRAM .......................... 4 4

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McDonnell DouglasCommercial Airplanes MD11 Service Bulletin ALERT SummaryNumber: MD11-28A143Original Issue: December 02, 2009 ATA System: 2822 SUBJECT: FUEL - Engine Fuel Supply - Fuel Pump Housing Electrical Connector Assembly and Fuel Boost/Transfer Pump - Inspection/Replacement

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 Refer to Paragraph 1.B., Concurrent Requirements.

BACKGROUND MD-11 and DC-10 operators have reported instances of fuel pump housing electrical connector assembly, part number 60-84355-1, failures. Inspecting the fuel boost/transfer pump housing electrical connector assembly, fuel boost/transfer pump, and replacing any non-serviceable part with a serviceable part as required based on inspection results, will minimize the possibility of a potential ignition source in the fuel tanks and potential fuel tank explosion. If not corrected, insulation resistance degradation and/or arcing in the potted backside of the fuel boost/transfer pump housing electrical connector assembly could compromise the performance of the fuel boost/transfer pump housing electrical connector assembly and result in a failure that can introduce an ignition source into the fuel tank and potential fuel tank explosion.

ACTION This service bulletin provides instructions to inspect/replace each fuel pump housing electrical connector assembly and fuel boost/transfer pump.

EFFECTIVITY MD-11 and MD-11F Airplanes. Refer to Paragraph 1.A.1., Airplanes for the list of affected airplanes.

COMPLIANCE Refer to Paragraph 1.E., Compliance.

INDUSTRY SUPPORT INFORMATION Boeing warranty remedies are not available for the configuration changes and repair procedures given in this service bulletin.

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MANPOWER Refer to Paragraph 1.G., Manpower.

MATERIAL INFORMATION Boeing Supplied Kits/Parts.

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

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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 NOTE: The fuel pump housing electrical connector replacement with part number 60-84351 was done on fuselage number 466 prior to the original issue of this service bulletin in accordance with Drawing SP11280022 and FAA Alternative Method of Compliance (AMOC) approval letter with referenced Boeing letter CP-L4L-09-00243.

This service bulletin is applicable to airplanes that have installed fuel pump housing electrical connector assembly part number 60-84355-1 in accordance with Service Bulletin MD11-28A138.

DESCRIPTIONCONFIGURATIONGROUP Applicable to airplanes without ER3060 gallon forward auxiliary.-1 Applicable to airplanes with ER3060 gallon forward auxiliary fuel tanks.

-2 Airplane Models:

MD-11, MD-11F GroupFuselage Number 1447 - 589 2590

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GroupFuselage Number 1591 - 596 2597 1598 - 607 2608 1609 - 612 2613 1614 2615 1616 - 646

2. Spares Affected Examine your spares supply for the parts or components identified in below. For the recommended use Paragraph 2.D., Parts Necessary to Change Spares. If any parts or components are found.

NamePart Number Pump Housing60-843-3 Pump Housing60-845-3 Connector60-84355-1 B. Concurrent Requirements None.

C. Reason MD-11 and DC-10 operators have reported instances of fuel pump housing electrical connector assembly, part number 60-84355-1, failures. Inspecting the fuel boost/transfer pump housing electrical connector assembly, fuel boost/transfer pump, and replacing any non-serviceable part with a serviceable part as required based on inspection results, will minimize the possibility of a potential ignition source in the fuel tanks and potential fuel tank explosion. If not corrected, insulation resistance degradation and/or arcing in the potted backside of the fuel boost/transfer pump housing electrical connector assembly could compromise the performance of the fuel boost/transfer pump housing electrical connector assembly and result in a failure that can introduce an ignition source into the fuel tank and potential fuel tank explosion.

D. Description This service bulletin provides instructions to inspect/replace fuel pump housing electrical connector assembly and fuel boost/transfer pump.

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

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Group 1:

Affected Maintenance Zones ZoneModel 141, 142, 311, 515, 517, 531, 532, 533, 541, 615, 617, 632, 633, 641 MD-11, MD-11F Group 2:

Affected Maintenance Zones ZoneModel 141, 142, 143, 311, 515, 517, 531, 532, 533, 541, 615, 617, 632, 633, 641 MD-11, MD-11F 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.

Federal Aviation Administration (FAA) Airworthiness Directive No. FAA AD 2007-15-05 is related to this service bulletin.

Refer to Appendix D and E for a logic diagram of the work instructions.

TABLE 1: FUEL PUMP HOUSING ELECTRICAL CONNECTOR ASSEMBLY P/N 60-84355-1 AND FUEL

BOOST/TRANSFER PUMP - REPLACEMENT/INSPECTION Repeat Interval (Not to Exceed) Compliance TimeActionCondition

(a)Within 10 months after the original issue date on this service bulletin.

Replace fuel pump electrical connector assemblies with P/N 60-84351 and restore in accordance with Accomplishment Instructions 3.B. Part 2 and Part

All Airplanes.

OR Within 10 months after the original issue date on this service bulletin.

Do continuity, resistance and insulation resistance inspection in accordance with Accomplishment Instructions 3.B. Part 3.

AND Replace fuel pump electrical connector assemblies with P/N 60-84351 and restore in accordance with Accomplishment Instructions 3.B. Part 2 and Part

(a)Within 12 months after inspection.

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TABLE 1: FUEL PUMP HOUSING ELECTRICAL CONNECTOR ASSEMBLY P/N 60-84355-1 AND FUEL

BOOST/TRANSFER PUMP - REPLACEMENT/INSPECTION Repeat Interval (Not to Exceed) Compliance TimeActionCondition Before further flight.Do restoration in accordance with Accomplishment Instructions 3.B. Part 5.

(Serviceable Fuel pump and housing electrical connector assembly) Fuel pump housing electrical connector assembly wiring resistance reading is less than or equal to 2.5 ohms and terminal E is open.

AND Fuel boost/transfer pump resistance reading is less than or equal to 2.5 ohms and pin E is open.

AND Fuel pump housing electrical connector assembly wiring insulation resistance reading is greater than or equal to 10 gigaohm.

Before further flight.Replace fuel boost/transfer pump and restore in accordance with Accomplishment Instructions 3.B. Part 3 and Part 5.

(Defective Fuel boost/transfer pump) Fuel boost/transfer pump resistance reading is greater than 2.5 ohms or pin E is not open and fuel pump housing electrical connector assembly wiring resistance reading is less than or equal to 2.5 ohms and terminal E is open and fuel pump housing electrical connector assembly wiring insulation resistance reading is greater than or equal to 10 gigaohm.

(a)Before further flight.Replace fuel pump electrical connector assemblies with P/N 60-84351 and restore in accordance with Accomplishment Instructions 3.B. Part 2 and Part

(Defective Fuel pump housing electrical connector assembly) Fuel pump housing electrical connector assembly wiring resistance reading is greater than 2.5 ohms or terminal E is not open and fuel boost/transfer pump resistance reading is less than or equal to 2.5 ohms and pin E is open.

OR Fuel pump housing electrical connector assembly wiring insulation resistance reading is less than 10 gigaohm.

(a) REFER TO TABLE 2 AFTER REPLACEMENT OF FUEL PUMP HOUSING ELECTRICAL CONNECTOR ASSEMBLY P/N 60-84355-1 WITH P/N 60-84351.

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TABLE 2: FUEL PUMP HOUSING ELECTRICAL CONNECTOR ASSEMBLY P/N 60-84351 AND FUEL

BOOST/TRANSFER PUMP - INSPECTION Repeat Interval (Not to Exceed) Compliance TimeActionCondition 18 MonthsWithin 18 months after P/N 60-84351 installation.

Do continuity, resistance and insulation resistance inspection in accordance with Accomplishment Instructions 3.B. Part 4.

All Airplanes Before further flight.Do restoration in accordance with Accomplishment Instructions 3.B. Part 5.

(Serviceable Fuel pump and housing electrical connector assembly) Fuel pump housing electrical connector assembly wiring resistance reading is less than or equal to 2.5 ohms and terminal E is open.

AND Fuel boost/transfer pump resistance reading is less than or equal to 2.5 ohms and pin E is open.

AND Fuel pump housing electrical connector assembly wiring insulation resistance reading is greater than or equal to 10 megaohm.

Before further flight.Replace fuel boost/transfer pump and restore in accordance with Accomplishment Instructions 3.B. Part 4 and Part 5.

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TABLE 2: FUEL PUMP HOUSING ELECTRICAL CONNECTOR ASSEMBLY P/N 60-84351 AND FUEL

BOOST/TRANSFER PUMP - INSPECTION Repeat Interval (Not to Exceed) Compliance TimeActionCondition Before further flight.Replace fuel pump electrical connector assemblies with P/N 60-84351 and restore in accordance with Accomplishment Instructions 3.B. Part 4 and Part

OR Fuel pump housing electrical connector assembly wiring insulation resistance reading is less than 10 megaohm.

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.

In addition, the Manager of the FAA Los Angles 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 (l) of FAA AD 2007-15-05. All provisions of FAA AD 2007-15-05 that are not specifically referenced in the above statement remain fully applicable and must be complied with.

G. Manpower The table below shows an estimate of the task hours necessary to do this inspection for each airplane.

This estimate is for direct labor only, done by an experienced crew. Adjust the estimate with operator task hour data if necessary. The estimate does not include lost time. These are some examples of lost time:

Time to adjust to the workplace Time to schedule the work Time to inspect the work

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