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Commercial Airplanes MD11 Service Bulletin ALERT Number: MD11-28A150 Original Issue: October 06, 2016 ATA System: 2822 SUBJECT: FUEL - Distribution - Tail Tank Transfer Pump Wire Assemblies - Inspection, Repair and Replacement 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 © 2016 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Unpublished Work.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.
Original Issue: October 06, 2016 MD11-28A150 1 of 96
2.0
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: October 06, 2016 MD11-28A150 2 of 96 BOEING SERVICE BULLETIN MD11-28A150
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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 1 D. Description .............................................. 1 1 E. Compliance .............................................. 1 1 F . A p p r o v a l ............................................... 1 2 G. Manpower .............................................. 1 3 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 4
1. Existing Data: ......................................... 1 4
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 5 M. Software Accomplishment Summary ................................ 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 . K i t s / P a r t s ............................................ 1 7
2. Parts and Materials Supplied by the Operator ........................ 2 1
3. Parts Modified and Reidentified ................................ 2 1
4. Parts Removed and Not Replaced .............................. 2 2 D. Parts Necessary to Change Spares ................................. 2 2 E. Special Tooling - Price and Availability ............................... 2 2 F. Special Tooling Necessary to do this Service Bulletin ....................... 2 2
3. ACCOMPLISHMENT INSTRUCTIONS .................................. 2 3 A. GENERAL INFORMATION ..................................... 2 3 B. WORK INSTRUCTIONS ....................................... 2 6 FIGURE 1: TAIL TANK TRANSFER PUMP WIRE ASSEMBLIES - DETAILED INSPECTION ..... 2 9 FIGURE 2: TAIL TANK TRANSFER PUMP WIRE ASSEMBLY - REPAIR "SINGLE Y" WIRE HARNESS BREAKOUT ........................................... 3 2 FIGURE 3: TAIL TANK TRANSFER PUMP WIRE ASSEMBLY - REPAIR "SHOWERHEAD" WIRE HARNESS BREAKOUT ........................................... 3 9 FIGURE 4: TAIL TANK TRANSFER PUMP WIRE ASSEMBLY - REPAIR "DOUBLE Y" WIRE HARNESS BREAKOUT ........................................... 4 5 FIGURE 5: TAIL TANK TRANSFER PUMP WIRE ASSEMBLIES - REMOVAL ............. 5 1 FIGURE 6: TAIL TANK TRANSFER PUMP WIRE ASSEMBLIES - INSTALLATION [Group 1] ..... 5 8 FIGURE 7: TAIL TANK TRANSFER PUMP WIRE ASSEMBLIES - INSTALLATION [Group 2] ..... 6 7 APPENDIX A: WIRE HARNESS INSPECTION LOCATIONS ........................ 7 6 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: October 06, 2016 MD11-28A150 3 of 96 BOEING SERVICE BULLETIN MD11-28A150
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APPENDIX B: WIRE HARNESS PLASTIC FERRULE PART NUMBER AND LOCATION DIAGRAM . . . 77 APPENDIX C: CLAMP INSTALLATION .................................... 7 8 APPENDIX D: EXTRUDED CHANNEL AND STRAP INSTALLATIONS ................... 7 9 APPENDIX E: HARDWARE INSTALLATION ................................. 8 0 APPENDIX F: SINGLE OVERBRAID GROUNDING TO SINGLE COUPLER INSTALLATION ...... 8 1 APPENDIX G: GROUND STUD INSTALLATION ............................... 8 2 APPENDIX H: WIRE TERMINATION TABLES - REMOVAL ........................ 8 3 APPENDIX I: WIRE TERMINATION TABLES - INSTALLATION ...................... 8 6 APPENDIX J: IN-LINE FUSE INSTALLATION ................................ 8 9 APPENDIX K: LOGIC DIAGRAM ....................................... 9 4 APPENDIX L: PART DEMAND INTENT ................................... 9 6 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: October 06, 2016 MD11-28A150 4 of 96 BOEING SERVICE BULLETIN MD11-28A150
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Commercial Airplanes MD11 Service Bulletin ALERT SummaryNumber: MD11-28A150Original Issue: October 06, 2016 ATA System: 2822 SUBJECT: FUEL - Distribution - Tail Tank Transfer Pump Wire Assemblies - Inspection, Repair and Replacement
THIS DOCUMENT 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 DOCUMENT TO THE NEW OPERATOR. IF APPLICABLE SPARES HAVE BEEN SOLD, SEND THIS DOCUMENT TO THE NEW OWNER.
CONCURRENT REQUIREMENTS None.
BACKGROUND This service bulletin provides instructions to do a Detailed Inspection of the Tail Tank Transfer Pump Wire Assemblies, AJS9013 and AJS9014, to find if metallic transitions are installed at the wire harness breakouts. If the metallic transitions are installed, no further action is required. If the metallic transitions are not installed, the operator has the option to replace the wire assemblies or repair the wire assemblies. If this service bulletin is not done, missing metallic transitions can cause damage and arcing of wires, which could result in engine fuel starvation.
During troubleshooting for a Tail Pump Off level 1 message which appeared during cruise, maintenance found wire damage to fourteen wires installed adjacent to the tail fuel tank front spar. These wires were broken and/or had insulation damage. Wire bundle damage was found at the Tail Tank L Trans Pump, ALT Eng Feed Pump, Tail Tank L Trans Pump Press SW and Tail Tank ALT Eng Feed Pump SW 1. The root cause of the damage was metallic transitions missing at the wire harness breakouts.
Boeing Fleet Team Digest (FTD) MD-11 FTD 28-15001 is 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 AffectedNoSpares Affected Paragraph 1.E., Compliance and Paragraph
1.F., Approval YesAD Related Paragraph 1.H., Weight and Balance ChangesYesWeight and Balance Change Paragraph 1.I., Electrical Load DataNoElectrical Load Changed Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: October 06, 2016 MD11-28A150 5 of 96
ReferenceAffectedPlanning Data Paragraph 1.K., Publications AffectedYesPublications Affected Paragraph 1.K., Publications AffectedNoAirplane Flight Operations Affected (Flight Crew Operations Manual and/or FAA Approved Airplane Flight Manual) Paragraph 2.C.1., Kits/PartsYesKits/Parts Required 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 Do a Detailed Inspection of the Tail Tank Transfer Pump Wire Assemblies to find if metallic transitions are installed at the wire harness breakouts. If all of the metallic transitions are installed, no further action is required.
If any of the metallic transitions are not installed, repair or replace the affected wire assemblies.
EFFECTIVITY MD-11 and MD-11F Airplanes. Refer to Paragraph 1.A.1., Airplanes, for the list of affected 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.
Refer to Paragraph 1.E., Compliance.
INDUSTRY SUPPORT INFORMATION At the time of release of this service bulletin, warranty remedies have not been determined. A subsequent revision or Information Notice will address the warranty remedies available, if any.
MANPOWER 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 L 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.
Original Issue: October 06, 2016 MD11-28A150 6 of 96 BOEING SERVICE BULLETIN MD11-28A150
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BOEING SERVICE BULLETIN MD11-28A150
ALERT ALERT
DO A DETAILED INSPECTION OF TAIL TANK TRANSFER PUMP WIRE ASSEMBLIES TO FIND IF METALLIC TRANSITIONS ARE INSTALLED AT THE WIRE HARNESS BREAKOUTS. IF ALL
ANY OF THE METAL TRANSITIONS NONSTALLED PERIORCE TED IF AFFECTED WIRE ASSEMBLIES. 2499474 Original Issue: October 06, 2016 Export Controlled ECCN: 9E991 - BOEING MD11-28A150 PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 7 of 96
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: October 06, 2016 MD11-28A150 8 of 96 BOEING SERVICE BULLETIN MD11-28A150
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BLANK PAGE
Commercial Airplanes MD11 Service Bulletin ALERT Number: MD11-28A150 Original Issue: October 06, 2016 ATA System: 2822 SUBJECT: FUEL - Distribution - Tail Tank Transfer Pump Wire Assemblies - Inspection, Repair and Replacement
THIS DOCUMENT 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 DOCUMENT TO THE NEW OPERATOR. IF APPLICABLE SPARES HAVE BEEN SOLD, SEND THIS DOCUMENT TO THE NEW OWNER.
1. PLANNING INFORMATION A. Effectivity
1. Airplanes This service bulletin is for the airplanes shown below.
DESCRIPTIONCONFIGURATIONGROUP MD-11 and MD-11F Airplanes after Fuselage Number 460 that use WSP1381-501 at Wire Assy - AJS9013 and WSP1382-501 at Wire Assy - AJS9014 as replacements.
-1 MD-11F Airplanes after Fuselage Number 460 that use WSP1381-502 at Wire Assy - AJS9013 and WSP1382-501 at Wire Assy - AJS9014 as replacements.
-2 Airplane Models:
MD-11, MD-11F GroupFuselage Number 1461 - 464 1466 - 467 2468 1469 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: October 06, 2016 MD11-28A150 9 of 96
GroupFuselage Number 1470 2471 1472 - 473 2474 1475 - 479 1480 - 489 1491 - 499 2500 1501 - 507 2508 1509 1510 - 517 1519 1520 - 529 1530 - 539 1540 - 549 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 None.
B. Concurrent Requirements None.
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: October 06, 2016 MD11-28A150 10 of 96 BOEING SERVICE BULLETIN MD11-28A150
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C. Reason This service bulletin provides instructions to do a Detailed Inspection of the Tail Tank Transfer Pump Wire Assemblies, AJS9013 and AJS9014, to find if metallic transitions are installed at the wire harness breakouts. If the metallic transitions are installed, no further action is required. If the metallic transitions are not installed, the operator has the option to replace the wire assemblies or repair the wire assemblies.
If this service bulletin is not done, missing metallic transitions can cause damage and arcing of wires, which could result in engine fuel starvation.
During troubleshooting for a Tail Pump Off level 1 message which appeared during cruise, maintenance found wire damage to fourteen wires installed adjacent to the tail fuel tank front spar. These wires were broken and/or had insulation damage. Wire bundle damage was found at the Tail Tank L Trans Pump, ALT Eng Feed Pump, Tail Tank L Trans Pump Press SW and Tail Tank ALT Eng Feed Pump SW 1.
The root cause of the damage was metallic transitions missing at the wire harness breakouts.
Boeing Fleet Team Digest (FTD) MD-11 FTD 28-15001 is related to this service bulletin.
D. Description Do a Detailed Inspection of the Tail Tank Transfer Pump Wire Assemblies to find if metallic transitions are installed at the wire harness breakouts. If all of the metallic transitions are installed, no further action is required. If any of the metallic transitions are not installed, repair or replace the affected wire assemblies.
The work in this service bulletin is done in the maintenance zone(s) given below.
Group 1:
Affected Maintenance Zones ZoneModel 352MD-11, MD-11F Group 2:
Affected Maintenance Zones ZoneModel 352MD-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.
When more than one OPTION is given for a CONDITION, do only one of the OPTION numbers. When more than one ACTION is given for a CONDITION number or an OPTION number, do all of the ACTION numbers for that CONDITION number or OPTION number.
Do the required actions in accordance with Paragraph 3. Accomplishment Instructions.
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: October 06, 2016 MD11-28A150 11 of 96 BOEING SERVICE BULLETIN MD11-28A150
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A logic diagram showing compliance tasks and compliance times is included as an aid in APPENDIX K.
Table 1: DETAILED INSPECTION OF THE TAIL TANK TRANSFER PUMP WIRE ASSEMBLIES AJS9013 AND AJS9014 TO DETERMINE IF METALLIC TRANSITIONS ARE INSTALLED AT WIRE ASSEMBLY
BREAKOUTS Repeat Interval (Not to Exceed) Compliance TimeActionCondition -Within 27 months after the original issue date of this service bulletin.
Do PART 1: DETAILED INSPECTION
OF THE TAIL TANK TRANSFER PUMP
WIRE ASSEMBLIES FOR INSTALLED METALLIC TRANSITIONS.
All Airplanes --No further work is necessary for this condition.
CONDITION 1: ALL
METALLIC TRANSITIONS
INSTALLED -Before further flight.OPTION 1 (ACTION 1): Do PART 2:
REPAIR TAIL TANK TRANSFER PUMP WIRE ASSEMBLIES for each affected wire harness breakout.
CONDITION 2: ANY
METALLIC TRANSITION
NOT INSTALLED -Within 24 months after PART 2: REPAIR TAIL
TANK TRANSFER
PUMP WIRE ASSEM- BLIES for each affected wire harness breakout was accomplished.
OPTION 1 (ACTION 2): Do PART 3:
REPLACEMENT OF TAIL TANK
TRANSFER PUMP WIRE ASSEMBLIES for each affected wire assembly.
-Before further flight.OPTION 2: Do PART 3: REPLACE-
MENT OF TAIL TANK TRANSFER PUMP WIRE ASSEMBLIES for each affected wire assembly.
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.
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: October 06, 2016 MD11-28A150 12 of 96 BOEING SERVICE BULLETIN MD11-28A150