# Boeing Alert Service Bulletin MD11-78A017: Revision 1 - Rights: © The Boeing Company. Filed by the FAA in regulations.gov docket FAA-2023-2403; AD 2024-24-03 incorporates this document by reference. Not covered by OpenAirDocs’ CC0 dedication. - Document: [Boeing Alert Service Bulletin MD11-78A017](https://openairdocs.org/service-documents/boeing/md11-78a017.md) - Title as filed: SB-MD11-78A017 Revision 1- - Pages: 208 - PDF: https://openairdocs.org/files/sha256/69/d5/69d5826ed5596ae9e1b6fe74554342bfd28dcd22e397756451c09fcb325cc922 - Page: https://openairdocs.org/service-documents/boeing/md11-78a017/file/69d5826ed559 ## Text Some pages are OCR from a scan. OCR can misread letters and numbers. Each page's text from the PDF; open the PDF at a page with #page=N. ### Page 1 Commercial Airplanes MD11 Service Bulletin ALERT Number: MD11-78A017 Original Issue: December 04, 2023 Revision 1: June 04, 2024 ATA System: 7800 7834 7151 SUBJECT: ENGINE EXHAUST - Thrust Reverser - Thrust Reverser Wire Harnesses Inspection and Test EXPORT CONTROLLED - This technology or software is subject to the U.S. Export Administration Regulations (EAR), (15 C.F.R. Parts 730-774). No authorization from the U.S. Department of Commerce is required for export, re-export, in-country transfer, or access EXCEPT to country group E:1 or E:2 countries/persons per Supp.1 to Part 740 of the EAR. 9E991ECCN: Copyright © 2024 The Boeing Company 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: December 04, 2023 MD11-78A017Revision 1: June 04, 2024 1 of 208 4.0 ### Page 2 Export Controlled ECCN: 9E991 See page 1 for details Original Issue: December 04, 2023 MD11-78A017Revision 1: June 04, 2024 2 of 208 BOEING SERVICE BULLETIN MD11-78A017 ALERTALERT BLANK PAGE ### Page 3 Table of Contents Revision Transmittal Sheet ............................................ 5 S u m m a r y ...................................................... 9 1. PLANNING INFORMATION ........................................ 1 3 A . E f f e c t i v i t y ............................................... 1 3 1. Airplanes ............................................ 1 3 2 . S p a r e s A f f e c t e d ........................................ 1 4 B. Concurrent Requirements ...................................... 1 4 C. Reason ................................................ 1 4 D. Description .............................................. 1 5 E. Compliance .............................................. 1 5 F . A p p r o v a l ............................................... 3 1 G. Manpower .............................................. 3 2 H. Weight and Balance Changes .................................... 3 3 I. Electrical Load Data ......................................... 3 3 J . R e f e r e n c e s .............................................. 3 4 1. Existing Data: ......................................... 3 4 2. Data Supplied with this Service Bulletin: ........................... 3 4 3. Installation Drawings Used in the Preparation of this Service Bulletin: ........... 3 4 4 . P r o c e s s D a t a : ......................................... 3 4 K. Publications Affected ........................................ 3 4 L. Interchangeability and Intermixability of Parts ........................... 3 5 M. Software Accomplishment Summary ................................ 3 5 2. MATERIAL INFORMATION ........................................ 3 7 A. Material - Price and Availability ................................... 3 7 B. Industry Support Information .................................... 3 7 C. Parts Necessary for Each Airplane ................................. 3 7 1 . K i t s / P a r t s : ........................................... 3 7 2. Parts and Materials Supplied by the Operator: ........................ 3 7 3. Parts Modified and Reidentified: ............................... 3 8 4. Parts Removed and Not Replaced: .............................. 3 8 D. Parts Necessary to Change Spares ................................. 3 8 E. Special Tooling - Price and Availability ............................... 3 8 F. Special Tooling Necessary to do this Service Bulletin ....................... 3 9 3. ACCOMPLISHMENT INSTRUCTIONS .................................. 4 1 A. GENERAL INFORMATION ..................................... 4 1 B. WORK INSTRUCTIONS ....................................... 4 3 FIGURE 1: ENGINE 1 PYLON - PRECOOLER INSTALLED PYLON WIRE HARNESSES - INSPECTION .................................................. 8 1 FIGURE 2: ENGINE 2 PYLON - PRECOOLER INSTALLED PYLON WIRE HARNESSES - INSPECTION .................................................. 9 1 FIGURE 3: ENGINE 3 PYLON - PRECOOLER INSTALLED PYLON WIRE HARNESSES - INSPECTION .................................................. 9 8 FIGURE 4: ENGINE 1 PYLON - PRECOOLER REMOVED PYLON WIRE HARNESSES - INSPECTION ................................................. 1 0 8 FIGURE 5: ENGINE 2 PYLON - PRECOOLER REMOVED PYLON WIRE HARNESSES - INSPECTION ................................................. 1 1 8 Export Controlled ECCN: 9E991 See page 1 for details Original Issue: December 04, 2023 MD11-78A017Revision 1: June 04, 2024 3 of 208 BOEING SERVICE BULLETIN MD11-78A017 ALERTALERT ### Page 4 FIGURE 6: ENGINE 3 PYLON - PRECOOLER REMOVED PYLON WIRE HARNESSES - INSPECTION ................................................. 1 2 6 FIGURE 7: ENGINE 1 PYLON AND ENGINE 3 PYLON - JUNCTION BOX ASSEMBLY ELECTRICAL CONNECTORS - DISCONNECTION ............................ 1 3 6 FIGURE 8: ENGINE 1 PYLON AND ENGINE 3 PYLON - JUNCTION BOX ASSEMBLY - REMOVAL . 139 FIGURE 9: ENGINE 2 PYLON - JUNCTION BOX ASSEMBLY ELECTRICAL CONNECTORS - DISCONNECTION ...................................... 1 4 3 FIGURE 10: ENGINE 2 PYLON - JUNCTION BOX ASSEMBLY - REMOVAL .............. 1 4 5 FIGURE 11: BENCHWORK - JUNCTION BOX COVER - REMOVAL .................. 1 4 8 FIGURE 12: BENCHWORK - JUNCTION BOX ASSEMBLY - INSPECTION .............. 1 5 0 FIGURE 13: BENCHWORK - JUNCTION BOX COVER - INSPECTION ................ 1 5 2 FIGURE 14: BENCHWORK - JUNCTION BOX COVER - INSTALLATION ............... 1 5 4 FIGURE 15: BENCHWORK - JUNCTION BOX COVER - REPLACEMENT ............... 1 5 6 FIGURE 16: ENGINE 1 PYLON AND ENGINE 3 PYLON - JUNCTION BOX ASSEMBLY - INSTALLATION ................................................. 1 5 8 FIGURE 17: ENGINE 2 PYLON - JUNCTION BOX ASSEMBLY - INSTALLATION ........... 1 6 2 FIGURE 18: ENGINE - LEFT SIDE AND RIGHT SIDE THRUST REVERSER ELECTRICAL HARNESS - INSPECTION ......................................... 1 6 5 FIGURE 19: ENGINE - RIGHT SIDE THRUST REVERSER ELECTRICAL HARNESS - REPLACEMENT ................................................. 1 6 7 FIGURE 20: ENGINE - LEFT SIDE THRUST REVERSER ELECTRICAL HARNESS - REPLACEMENT . 169 FIGURE 21: ENGINE 1 AND ENGINE 3 - CORE MISCELLANEOUS WIRE HARNESS ASSEMBLY - INSPECTION ......................................... 1 7 1 FIGURE 22: ENGINE 2 - CORE MISCELLANEOUS WIRE HARNESS ASSEMBLY - INSPECTION . 175 FIGURE 23: ENGINE - CORE MISCELLANEOUS WIRE HARNESS ASSEMBLY - REPLACEMENT . 179 FIGURE 24: ENGINE - 30 DEGREE BULKHEAD WIRE HARNESS ASSEMBLY - INSPECTION . . . 183 FIGURE 25: ENGINE - 30 DEGREE BULKHEAD WIRE HARNESS ASSEMBLY - REPLACEMENT . 186 APPENDIX A: LOGIC DIAGRAM FOR PARAGRAPH 1.E., COMPLIANCE: TABLE 1: WORK PACKAGE 1 - ENGINE 1, ENGINE 2, AND ENGINE 3 PYLON THRUST REVERSER WIRE HARNESSES DETAILED INSPECTION ................................... 1 8 8 APPENDIX B: LOGIC DIAGRAM FOR PARAGRAPH 1.E., COMPLIANCE: TABLE 2: WORK PACKAGE 2 - THRUST REVERSER CONTROL SYSTEM WIRE HARNESSES DETAILED INSPECTIONS A N D W I R E I N T E G R I T Y T E S T S ............................... 1 9 0 APPENDIX C: DATA SHEET - GENERAL INFORMATION ......................... 2 0 6 APPENDIX D: DATA SHEET - DETAILED INSPECTION FINDING .................... 2 0 7 APPENDIX E: DATA SHEET - WIRE INTEGRITY TEST FINDING .................... 2 0 8 Export Controlled ECCN: 9E991 See page 1 for details Original Issue: December 04, 2023 MD11-78A017Revision 1: June 04, 2024 4 of 208 BOEING SERVICE BULLETIN MD11-78A017 ALERTALERT ### Page 5 Commercial Airplanes MD11 Service Bulletin ALERT Revision Transmittal SheetNumber: MD11-78A017Original Issue: December 04, 2023 Revision 1: June 04, 2024 ATA System: 7800 7834 7151 SUBJECT: ENGINE EXHAUST - Thrust Reverser - Thrust Reverser Wire Harnesses Inspection and Test This revision includes all pages of the service bulletin. COMPLIANCE INFORMATION RELATED TO THIS REVISION Federal Aviation Administration (FAA) Notice of Proposed Rule Making NPRM AD-2023-00888-T, is related to this service bulletin. No more work is necessary on airplanes changed in accordance with the original issue of this service bulletin. REASON FOR REVISION This revision is sent to incorporate operator comments and to clarify the inspection/test requirements of the Junction Box Assembly. These sections were changed: 1. Throughout the service bulletin: a. At numerous locations, changed "Junction Box" to "Junction Box Assembly". b. Removed the phrase "Burn Marks". c. Added additional step to connect connectors after passing Wire Harness Insulation Resistance Test. 2. Boeing warranty statement was updated to add "inspections, configuration changes, and/or repair procedures". 3. In Paragraph 1.A.2, Spares Affected: a. Changed referenced paragraph from Paragraph 3.B to Paragraph 2.C. 4. In Paragraph 1.E. Compliance: a. Added Federal Aviation Administration (FAA) Notice of Proposed Rule Making statement. b. In Table 2, labeled actions 4, 5, 6, 7, 8, and 9 for clarity. Export Controlled ECCN: 9E991 See page 1 for details Original Issue: December 04, 2023 MD11-78A017Revision 1: June 04, 2024 5 of 208 ### Page 6 c. In Table 2, added footnotes (d) and (e). d. In Table 2, changed required actions for CONDITION 9, CONDITION 10, CONDITION 11, CONDITION 12, CONDITION 13, and CONDITION 14. e. Added reporting requirement. 5. In Paragraph 1.J. References, added NPRM reference. 6. In Paragraph 1.K. Publications Affected, changed to None. 7. In Paragraph 2.C.2, Parts Necessary for Each Airplane: a. Changed cage code in footnote (c). b. Changed footnote (f). c. Added footnotes (g) and (h). 8. In Paragraph 3.A. General Information, added a caution note, changed note 16 and added notes 17, 18 and 19. 9. In Paragraph 3.B. Work Instructions, Work Package 1, added step 4 for reporting requirement. 10. In Paragraph 3.B. Work Instructions, Work Package 2: a. Changed Step 6 instructions. b. Added step 9 for reporting requirement. c. In PART 5: (1) Changed Table 4. (2) Added a new Table 7 for Thrust Control Module Connector Disconnection for Engine 1, Engine 2 and Engine 3. All subsequent tables renumbered. d. In Part 9, changed all "in accordance ..." with " Refer to ... as an accepted procedure" e. In Part 10 and Part 13, added a note to examine potential source of voltage (exposed conductor) or electrical discharge (short circuit) during Junction Box inspection when identifying suspected arcing. f. In PART 12, changed part title and changed work instructions. g. Deleted instructions of PART 17. h. In PART 19, changed Table 14 and footnote (a). i. In PART 22 and PART 23, changed CMM reference. j. In PART 27, changed Table 19. Export Controlled ECCN: 9E991 See page 1 for details Original Issue: December 04, 2023 MD11-78A017Revision 1: June 04, 2024 6 of 208 BOEING SERVICE BULLETIN MD11-78A017 ALERTALERT ### Page 7 k. In PART 30, changed Table 20. l. Changed figures 14 and 15. 11. In Appendix B, Logic Diagram: a. Changed Title Description Table and Flag Note Table. b. Changed Action 4, Action 5 and Action 6 diagram flow. c. Removed Location Letters "A", "B", "C". "D", "E" and "F" and are no longer used in the logic diagram. 12. Changed Appendix C and added new Appendix D and Appendix E. Vertical lines are put on the left edge of each page, except in Paragraph 1.A., Effectivity and format changes, to show the location of all content changes. Pages with no vertical lines have no changes. REVISION HISTORY December 04, 2023Original Issue: June 04, 2024Revision 1: Export Controlled ECCN: 9E991 See page 1 for details Original Issue: December 04, 2023 MD11-78A017Revision 1: June 04, 2024 7 of 208 BOEING SERVICE BULLETIN MD11-78A017 ALERTALERT ### Page 8 Export Controlled ECCN: 9E991 See page 1 for details Original Issue: December 04, 2023 MD11-78A017Revision 1: June 04, 2024 8 of 208 BOEING SERVICE BULLETIN MD11-78A017 ALERTALERT BLANK PAGE ### Page 9 Commercial Airplanes MD11 Service Bulletin ALERT SummaryNumber: MD11-78A017Original Issue: December 04, 2023 Revision 1: June 04, 2024 ATA System: 7800 7834 7151 SUBJECT: ENGINE EXHAUST - Thrust Reverser - Thrust Reverser Wire Harnesses Inspection and Test 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 Accomplishment of this service bulletin will make sure that any damage to the Thrust Reverser (T/R) Control System wire harnesses, T/R wire harnesses, and engine core compartment electrical harness is found and repaired. Damage to the wire harnesses can cause an uncommanded T/R deployment. If this service bulletin is not done, an in-flight T/R deployment can cause a loss of control and affect Continued Safe Flight and Landing (CSFL). The Boeing Company has received a report of an MD-11 experiencing an uncommanded T/R deployment of the two transcowls on Engine 1 during takeoff at approximately 500 feet above ground level. In the Engine 1 pylon, damaged wiring was found, which could have caused or contributed to the deployment of the two transcowls. This service bulletin gives the instructions to inspect, test, and repair the T/R Control System wire harnesses, T/R wire harnesses, and engine core compartment electrical harness. The inspections in this service bulletin will make sure any damage to the T/R Control System wire harnesses, T/R wire harnesses, and engine core compartment electrical harness is found and repaired before an uncommanded deployment of the T/R occurs. Boeing Service Related Problem (SRP) MD11-SRP-78-0117 is related to this service bulletin. Boeing Fleet Team Digest (FTD) MD-11 FTD 78-23001 is related to this service bulletin. Export Controlled ECCN: 9E991 See page 1 for details Original Issue: December 04, 2023 MD11-78A017Revision 1: June 04, 2024 9 of 208 ### Page 10 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.F., ApprovalNoAlternative Method of Compliance (AMOC) 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 AffectedNoAirplane Flight Operations Affected (Flight Crew Operations Manual and/or FAA Approved Air- plane Flight Manual) Paragraph 2.C.1., Kits/PartsNoKits/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 Work Package 1 1. Do a Detailed Inspection of the pylon T/R Control System wire harnesses for damage. Repair or replace any damaged wire found. Work Package 2 1. Do a Detailed Inspection and wire integrity tests of the T/R Control System wire harnesses, Left Side and Right Side T/R wire harnesses, Junction Box Assembly, 30 degree Bulkhead wire harnesses, and engine core electrical harness for damage. Repair or replace any damaged wire found. Repeat the Detailed Inspection and wire integrity tests of the T/R Control System wire harnesses, Left Side and Right Side T/R wire harnesses, Junction Box Assembly, 30 degree Bulkhead wire harnesses, and engine core electrical harness for damage. EFFECTIVITY MD-11 and MD-11F Airplanes equipped with General Electric Engines. Refer to Paragraph 1.A.1., Airplanes for the list of affected airplanes. COMPLIANCE Federal Aviation Administration (FAA) Notice of Proposed Rule Making NPRM AD-2023-00888-T, is related to this service bulletin. Refer to Paragraph 1.E., Compliance. Export Controlled ECCN: 9E991 See page 1 for details Original Issue: December 04, 2023 MD11-78A017Revision 1: June 04, 2024 10 of 208 BOEING SERVICE BULLETIN MD11-78A017 ALERTALERT ### Page 11 INDUSTRY SUPPORT INFORMATION Boeing warranty remedies are not available for the inspections, configuration changes, and/or repair procedures given in this service bulletin. MANPOWER Refer to Paragraph 1.G., Manpower. MATERIAL INFORMATION Boeing Supplied Kits/Parts. Refer to Paragraph 2.A., Material - Price and Availability. Export Controlled ECCN: 9E991 See page 1 for details Original Issue: December 04, 2023 MD11-78A017Revision 1: June 04, 2024 11 of 208 BOEING SERVICE BULLETIN MD11-78A017 ALERTALERT ### Page 12 (OCR) BOEING SERVICE BULLETIN MD11-78A017 ALERT ALERT WORK PACKAGE 2: DO A DETAILED INSPECTION AND WIRE INTEGRITY TESTS OF THE T/R CONTROL SYSTEM WIRE HARNESSES, LEFT SIDE AND RIGHT SIDE T/R WIRE HARNESSES, JUNCTION BOX ASSEMBLY, 30 DEGREE BULKHEAD WIRE HARNESSES, AND ENGINE CORE ELECTRICAL HARNESS FOR DAMAGE. REPAIR OR REPLACE ANY DAMAGED WIRE FOUND. REPEAT THE DETAILED INSPECTION AND WIRE INTEGRITY TESTS OF THE T/R CONTROL SYSTEM WIRE HARNESSES, LEFT SIDE AND RIGHT SIDE T/R WIRE HARNESSES, JUNCTION BOX ASSEMBLY, 30 DEGREE BULKHEAD 3047344 WIRE HARNESSES, AND ENGINE CORE ELECTRICAL HARNESS FOR DAMAGE. Original Issue: December 04, 2023 Revision 1: June 04, 2024 MD11-78A017 Export Controlled ECCN: 9E991 See page 1 for details 12 of 208 ### Page 13 Commercial Airplanes MD11 Service Bulletin ALERT Number: MD11-78A017 Original Issue: December 04, 2023 Revision 1: June 04, 2024 ATA System: 7800 7834 7151 SUBJECT: ENGINE EXHAUST - Thrust Reverser - Thrust Reverser Wire Harnesses Inspection and Test 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 bulletin is applicable to MD-11F Airplane(s), line number(s) 447-448, 451-454, 466-471, 474, 476, 478, 482-483, 486, 488, 491-493, 497, 499-505, 507-508, 513, 515, 517, 520-521, 523-524, 526-531, 534-535, 537, 540, 545, 547-551, 554-555, 564-565, 567, 570, 572, 576, 580, 587, 589, 592, 594-596, 598, 600-604, 607-609, 613, 615-620, 624-631, 633-634, 637, 639-646 in 1 Group(s). Where the effectivity is presented with hyphens between line numbers, the airplane applicability means "through" and "inclusive", e.g. line numbers 1-9 means line numbers 1 through 9 inclusive. Refer to Service Bulletin Index D624N001 Part 3 for Airplane Variable Number, Line Number, and Serial Number data. The Fuselage Numbers and Group Information for the applicable airplanes is given below. DESCRIPTIONCONFIGURATIONGROUP MD-11, MD-11F Airplanes equipped with General Electric (GE) Engines. -1 Airplane Models: MD-11F GroupFuselage Number 1447 - 448 GroupFuselage Number 1451 - 454 GroupFuselage Number 1466 - 471 Export Controlled ECCN: 9E991 See page 1 for details Original Issue: December 04, 2023 MD11-78A017Revision 1: June 04, 2024 13 of 208 ### Page 14 GroupFuselage Number 1474 1476 1478 1482 - 483 1486 1488 1491 - 493 1497 1499 - 505 1507 - 508 1513 1515 1517 1520 - 521 GroupFuselage Number 1523 - 524 1526 - 531 1534 - 535 1537 1540 1545 1547 - 551 1554 - 555 1564 - 565 1567 1570 1572 1576 1580 GroupFuselage Number 1587 1589 1592 1594 - 596 1598 1600 - 604 1607 - 609 1613 1615 - 620 1624 - 631 1633 - 634 1637 1639 - 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.C., Parts Necessary for Each Airplanefor the recommended action. Part Number AUN7613-( ) B. Concurrent Requirements None. C. Reason Accomplishment of this service bulletin will make sure that any damage to the Thrust Reverser (T/R) Control System wire harnesses, T/R wire harnesses, and engine core compartment electrical harness is found and repaired. Damage to the wire harnesses can cause an uncommanded T/R deployment. If this service bulletin is not done an in-flight T/R deployment can cause a loss of control and affect Continued Safe Flight and Landing (CSFL). The Boeing Company has received a report of an MD-11 experiencing an uncommanded T/R deployment of the two transcowls on Engine 1 during takeoff at approximately 500 feet above ground level. In the Engine 1 pylon, damaged wiring was found, which could have caused or contributed to the deployment of the two transcowls. Export Controlled ECCN: 9E991 See page 1 for details Original Issue: December 04, 2023 MD11-78A017Revision 1: June 04, 2024 14 of 208 BOEING SERVICE BULLETIN MD11-78A017 ALERTALERT ### Page 15 This service bulletin gives the instructions to inspect, test, and repair the T/R Control System wire harnesses, T/R wire harnesses, and engine core compartment electrical harness. The inspections in this service bulletin will make sure any damage to the T/R Control System wire harnesses, T/R wire harnesses, and engine core compartment electrical harness is found and repaired before an uncommanded deployment of the T/R occurs. Boeing Service Related Problem (SRP) MD11-SRP-78-0117 is related to this service bulletin. Boeing Fleet Team Digest (FTD) MD-11 FTD 78-23001 is related to this service bulletin. D. Description Work Package 1 1. Do a Detailed Inspection of the pylon T/R Control System wire harnesses for damage. Repair or replace any damaged wire found. Work Package 2 1. Do a Detailed Inspection and wire integrity tests of the T/R Control System wire harnesses, Left Side and Right Side T/R wire harnesses, Junction Box Assembly, 30 degree Bulkhead wire harnesses, and engine core electrical harness for damage. Repair or replace any damaged wire found. Repeat the Detailed Inspection and wire integrity tests of the T/R Control System wire harnesses, Left Side and Right Side T/R wire harnesses, Junction Box Assembly, 30 degree Bulkhead wire harnesses, and engine core electrical harness for damage. The work in this service bulletin is done in the maintenance zone(s) given below. Affected Maintenance Zones ZoneModel 112, 123, 127, 131, 132, 231, 232, 251, 252, 261, 262, 363, 364, 415, 433, 434, 437, 438, 443, 453, 454, 457, 465, 483, 484, 487, 488, 515, 516, 517, 615, 616, 617 MD-11F E. Compliance Federal Aviation Administration (FAA) Notice of Proposed Rule Making NPRM AD-2023-00888-T, is related to this service bulletin. Accomplish the required action(s), based on the applicable condition(s) in Tables 1 and 2, in accordance with Paragraph 3. Accomplishment Instructions. 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 or an OPTION, do all of the ACTION numbers for that CONDITION or OPTION. A logic diagram showing compliance tasks and compliance times is included as an aid in APPENDIX A and APPENDIX B. Export Controlled ECCN: 9E991 See page 1 for details Original Issue: December 04, 2023 MD11-78A017Revision 1: June 04, 2024 15 of 208 BOEING SERVICE BULLETIN MD11-78A017 ALERTALERT ### Page 16 Table 1: Work Package 1 - Engine 1, Engine 2, and Engine 3 Pylon Thrust Reverser Control System Wire Harnesses Detailed Inspection Repeat Interval (Not to Exceed) Boeing Recommended Compliance Time ActionCondition -Within 12 months after the original issue date of this service bulletin. Do PART 2: ENGINE 1, ENGINE 2, AND ENGINE 3 PYLON WIRE HARNESS DETAILED INSPEC- TION for wire chafing damage, signs of arcing, and riding conditions. (a) All Airplanes. -Before further flight. CONDITION 1 (ACTION 1): Do PART 4: WORK PACKAGE 1 RETURN TO SERVICE TESTS AND CLOSE ACCESS. CONDITION 1: NO WIRE CHAFING DAMAGE FOUND, NO SIGNS OF ARCING, AND NO RIDING CONDITIONS FOUND during PART 2: ENGINE 1, ENGINE 2, AND ENGINE 3 PYLON WIRE HARNESS DE- TAILED INSPECTION. -At the times speci- fied in Table 2. CONDITION 1 (ACTION 2): Do the actions specified in Work Package 2. -Before further flight. CONDITION 2 (ACTION 1): Do PART 3: WIRE HARNESS RE- PAIR. CONDITION 2: ANY WIRE CHAFING DAMAGE FOUND, ANY SIGNS OF ARC- ING, OR ANY RIDING CONDI- TIONS FOUND during PART 2: ENGINE 1, ENGINE 2, AND EN- GINE 3 PYLON WIRE HARNESS DETAILED INSPECTION. -Before further flight. CONDITION 2 (ACTION 2): Do PART 4: WORK PACKAGE 1 RETURN TO SERVICE TESTS AND CLOSE ACCESS. -At the times speci- fied in Table 2. CONDITION 2 (ACTION 3): Do the actions specified in Work Package 2. (a) Accomplishing the initial ACTION 1 through 3 inclusive specified in Work Package 2 terminates the Work Package 1 PART 2: ENGINE 1, ENGINE 2, AND ENGINE 3 PYLON WIRE HARNESS DETAILED IN- SPECTION requirement. Export Controlled ECCN: 9E991 See page 1 for details Original Issue: December 04, 2023 MD11-78A017Revision 1: June 04, 2024 16 of 208 BOEING SERVICE BULLETIN MD11-78A017 ALERTALERT ### Page 17 Table 2: Work Package 2 - Thrust Reverser Control System Wire Harnesses Detailed Inspections and Wire Integrity Tests Repeat Interval (Not to Exceed) Boeing Recommended Compliance Time ActionCondition -Within 27 months after the original issue date of this service bulletin. ACTION 1: Do PART 6: ENGINE 1 THRUST REVERSER CONTROL SYSTEM WIRE HARNESSES DETAILED INSPECTION AND WIRE INTEGRI- TY TESTS for wire chafing damage, riding conditions, signs of arcing, and wire integrity tests failure. (a)(b) All Airplanes. ACTION 2: Do PART 7: ENGINE 2 THRUST REVERSER CONTROL SYSTEM WIRE HARNESSES DETAILED INSPECTION AND WIRE INTEGRI- TY TESTS for wire chafing damage, riding conditions, signs of arcing, and wire integrity tests failure. (a)(b) ACTION 3: Do PART 8: ENGINE 3 THRUST REVERSER CONTROL SYSTEM WIRE HARNESSES DETAILED INSPECTION AND WIRE INTEGRI- TY TESTS for wire chafing damage, riding conditions, signs of arcing, and wire integrity tests failure. (a)(b) ACTION 4: On each of the Engine 1, Engine 2, and Engine 3 junction box assem- bly, do PART 10: JUNCTION BOX ASSEMBLY - DETAILED INSPEC- TION for any wire chafing damage, any sign of arcing and any loose electrical connection. (e) ACTION 5: On each of the Engine 1, Engine 2, and Engine 3 junction box assem- bly, do PART 16: JUNCTION BOX ASSEMBLY - WIRE INTEGRITY TESTS to test for wire integrity tests failure. (b)(e) ACTION 6: Export Controlled ECCN: 9E991 See page 1 for details Original Issue: December 04, 2023 MD11-78A017Revision 1: June 04, 2024 17 of 208 BOEING SERVICE BULLETIN MD11-78A017 ALERTALERT ### Page 18 Table 2: Work Package 2 - Thrust Reverser Control System Wire Harnesses Detailed Inspections and Wire Integrity Tests Repeat Interval (Not to Exceed) Boeing Recommended Compliance Time ActionCondition On each of the Engine 1, Engine 2, and Engine 3 junction box assem- bly, do PART 13: JUNCTION BOX COVER - DETAILED INSPECTION for signs of arcing and fretting to the internal surface of the Junction Box Cover. (e) ACTION 7: On each Engine (Engine 1, Engine 2, and Engine 3), do PART 19: LEFT SIDE AND RIGHT SIDE THRUST REVERSER ELECTRI- CAL HARNESS - DETAILED IN- SPECTION AND WIRE INTEGRITY TESTS for wire chafing damage, signs of arcing, and wire integrity tests failure. (c) ACTION 8: On each Engine (Engine 1, Engine 2, and Engine 3), do PART 24: CORE MISCELLANEOUS WIRE HARNESS ASSEMBLY DETAILED INSPECTION AND WIRE INTEGRI- TY TESTS for wire chafing damage, signs of arcing, and wire integrity tests failure. (b) ACTION 9: On each Engine (Engine 1, Engine 2, and Engine 3), do PART 27: 30 DEGREE BULKHEAD WIRE HAR- NESS ASSEMBLY DETAILED IN- SPECTION AND WIRE INTEGRITY TESTS for wire chafing damage, signs of arcing, and wire integrity tests failure. (b) Export Controlled ECCN: 9E991 See page 1 for details Original Issue: December 04, 2023 MD11-78A017Revision 1: June 04, 2024 18 of 208 BOEING SERVICE BULLETIN MD11-78A017 ALERTALERT ### Page 19 Table 2: Work Package 2 - Thrust Reverser Control System Wire Harnesses Detailed Inspections and Wire Integrity Tests Repeat Interval (Not to Exceed) Boeing Recommended Compliance Time ActionCondition 24 months.-Repeat PART 6: ENGINE 1 THRUST REVERSER CONTROL SYSTEM WIRE HARNESSES DE- TAILED INSPECTION AND WIRE INTEGRITY TESTS for wire chafing damage, riding conditions, signs of arcing, and wire integrity tests fail- ure. (b) CONDITION 3: NO WIRE CHAFING DAMAGE FOUND, NO RIDING CONDI- TIONS FOUND, NO SIGNS OF ARCING FOUND, AND WIRE IN- TEGRITY TESTS PASSED during PART 6: ENGINE 1 THRUST REVERSER CONTROL SYSTEM WIRE HARNESSES DETAILED INSPECTION AND WIRE IN- TEGRITY TESTS. (b) -Before further flight. CONDITION 4 (ACTION 1): Do PART 3: WIRE HARNESS RE- PAIR. CONDITION 4: ANY WIRE CHAFING DAMAGE FOUND, ANY RIDING CONDI- TIONS FOUND, ANY SIGNS OF ARCING FOUND, OR ANY WIRE INTEGRITY TEST FAILED during PART 6: ENGINE 1 THRUST REVERSER CONTROL SYSTEM WIRE HARNESSES DETAILED INSPECTION AND WIRE IN- TEGRITY TESTS. (b) 24 months.-CONDITION 4 (ACTION 2): Repeat PART 6: ENGINE 1 THRUST REVERSER CONTROL SYSTEM WIRE HARNESSES DE- TAILED INSPECTION AND WIRE INTEGRITY TESTS for wire chafing damage, riding conditions, signs of arcing, and wire integrity tests fail- ure. (b) 24 months.-Repeat PART 7: ENGINE 2 THRUST REVERSER CONTROL SYSTEM WIRE HARNESSES IN- SPECTION AND WIRE INTEGRITY TESTS for wire chafing damage, riding conditions, signs of arcing, and wire integrity tests failure. (b) CONDITION 5: NO WIRE CHAFING DAMAGE FOUND, NO RIDING CONDI- TIONS FOUND, NO SIGNS OF ARCING FOUND, AND WIRE IN- TEGRITY TESTS PASSED during PART 7: ENGINE 2 THRUST REVERSER CONTROL SYSTEM WIRE HARNESSES INSPEC- TION AND WIRE INTEGRITY TESTS. (b) Export Controlled ECCN: 9E991 See page 1 for details Original Issue: December 04, 2023 MD11-78A017Revision 1: June 04, 2024 19 of 208 BOEING SERVICE BULLETIN MD11-78A017 ALERTALERT ### Page 20 Table 2: Work Package 2 - Thrust Reverser Control System Wire Harnesses Detailed Inspections and Wire Integrity Tests Repeat Interval (Not to Exceed) Boeing Recommended Compliance Time ActionCondition -Before further flight. CONDITION 6 (ACTION 1): Do PART 3: WIRE HARNESS RE- PAIR. CONDITION 6: ANY WIRE CHAFING DAMAGE FOUND, ANY RIDING CONDI- TIONS FOUND, ANY SIGNS OF ARCING FOUND, OR ANY WIRE INTEGRITY TEST FAILED during PART 7: ENGINE 2 THRUST REVERSER CONTROL SYSTEM WIRE HARNESSES DETAILED INSPECTION AND WIRE IN- TEGRITY TESTS. (b) 24 months.-CONDITION 6 (ACTION 2): Repeat PART 7: ENGINE 2 THRUST REVERSER CONTROL SYSTEM WIRE HARNESSES DE- TAILED INSPECTION AND WIRE INTEGRITY TESTS for wire chafing damage, riding conditions, signs of arcing, and wire integrity tests fail- ure. (b) 24 months.-Repeat PART 8: ENGINE 3 THRUST REVERSER CONTROL SYSTEM WIRE HARNESSES DE- TAILED INSPECTION AND WIRE INTEGRITY TESTS for wire chafing damage, riding conditions, signs of arcing, and wire integrity tests fail- ure. (b) CONDITION 7: NO WIRE CHAFING DAMAGE FOUND, NO RIDING CONDI- TIONS FOUND, NO SIGNS OF ARCING FOUND, AND WIRE IN- TEGRITY TESTS PASSED during PART 8: ENGINE 3 THRUST REVERSER CONTROL SYSTEM WIRE HARNESSES DETAILED INSPECTION AND WIRE IN- TEGRITY TESTS. (b) -Before further flight. CONDITION 8 (ACTION 1): Do PART 3: WIRE HARNESS RE- PAIR. CONDITION 8: ANY WIRE CHAFING DAMAGE FOUND, ANY RIDING CONDI- TIONS FOUND, ANY SIGNS OF ARCING FOUND, OR ANY WIRE INTEGRITY TEST FAILED during PART 8: ENGINE 3 THRUST REVERSER CONTROL SYSTEM WIRE HARNESSES DETAILED INSPECTION AND WIRE IN- TEGRITY TESTS. (b) 24 months.-CONDITION 8 (ACTION 2): Repeat PART 8: ENGINE 3 THRUST REVERSER CONTROL SYSTEM WIRE HARNESSES DE- TAILED INSPECTION AND WIRE INTEGRITY TESTS for wire chafing damage, riding conditions, signs of arcing, continuity test failure, and wire integrity tests failure. (b) 24 months.-Repeat PART 10: JUNCTION BOX ASSEMBLY - DETAILED INSPEC- TION for any wire chafing damage, any sign of arcing, and any loose electrical connection. CONDITION 9: NO WIRE CHAFING DAMAGE FOUND, NO SIGN OF ARCING FOUND, AND NO LOOSE ELEC- TRICAL CONNECTION FOUND during PART 10: JUNCTION BOX ASSEMBLY - DETAILED INSPEC- TION. Export Controlled ECCN: 9E991 See page 1 for details Original Issue: December 04, 2023 MD11-78A017Revision 1: June 04, 2024 20 of 208 BOEING SERVICE BULLETIN MD11-78A017 ALERTALERT ### Page 21 Table 2: Work Package 2 - Thrust Reverser Control System Wire Harnesses Detailed Inspections and Wire Integrity Tests Repeat Interval (Not to Exceed) Boeing Recommended Compliance Time ActionCondition -Before further flight. CONDITION 10 OPTION 1 (ACTION 1): CONDITION 10: ANY WIRE CHAFING DAMAGE FOUND, ANY SIGN OF ARCING FOUND OR ANY LOOSE ELEC- TRICAL CONNECTION FOUND during PART 10: JUNCTION BOX ASSEMBLY - DETAILED INSPEC- TION. Do PART 11: JUNCTION BOX AS- SEMBLY - WIRE REPAIR. 24 months.-CONDITION 10 OPTION 1 (ACTION 2): Repeat PART 10: JUNCTION BOX ASSEMBLY - DETAILED INSPEC- TION for any wire chafing damage, any sign of arcing and any loose electrical connection. -Before further flight. CONDITION 10 OPTION 2 (ACTION 1): Do PART 18: ENGINE 1, ENGINE 2, AND ENGINE 3 PYLON JUNC- TION BOX ASSEMBLY - INSTAL- LATION to replace damaged Junc- tion Box Assembly with a new or serviceable Junction Box Assembly. (d)(e) 24 months.-CONDITION 10 OPTION 2 (ACTION 2): Repeat PART 10: JUNCTION BOX ASSEMBLY - DETAILED INSPEC- TION for any wire chafing damage, any sign of arcing and any loose electrical connection. 24 months.-Repeat PART 16: JUNCTION BOX ASSEMBLY - WIRE INTEGRITY TEST. (b) CONDITION 11: WIRE INTEGRI- TY TESTS PASSED during PART 16: JUNCTION BOX ASSEMBLY - WIRE INTEGRITY TEST. (b) Export Controlled ECCN: 9E991 See page 1 for details Original Issue: December 04, 2023 MD11-78A017Revision 1: June 04, 2024 21 of 208 BOEING SERVICE BULLETIN MD11-78A017 ALERTALERT ### Page 22 Table 2: Work Package 2 - Thrust Reverser Control System Wire Harnesses Detailed Inspections and Wire Integrity Tests Repeat Interval (Not to Exceed) Boeing Recommended Compliance Time ActionCondition -Before further flight. CONDITION 12 OPTION 1 (ACTION 1): CONDITION 12: ANY WIRE INTEGRITY TEST FAILED during PART 16: JUNC- TION BOX ASSEMBLY - WIRE INTEGRITY TESTS. (b) Do PART 18: ENGINE 1, ENGINE 2, AND ENGINE 3 PYLON JUNC- TION BOX ASSEMBLY - INSTAL- LATION to replace the failed Junc- tion Box Assembly with a new or serviceable Junction Box Assembly. (d)(e) 24 months.CONDITION 12 OPTION 1 (ACTION 2): Repeat PART 16: JUNCTION BOX ASSEMBLY - WIRE INTEGRITY TESTS. (b) -Before further flight. CONDITION 12 OPTION 2 (ACTION 1): Do PART 11: JUNCTION BOX AS- SEMBLY - WIRE REPAIR and make sure the wire integrity test is passed. (b)(e) 24 months.-CONDITION 12 OPTION 2 (ACTION 2): Repeat PART 16: JUNCTION BOX ASSEMBLY - WIRE INTEGRITY TESTS to test for wire integrity tests failure. (b) -Before further flight. CONDITION 13 (ACTION 1): Do PART 14: JUNCTION BOX COVER - INSTALLATION CONDITION 13: NO SIGNS OF ARCING FOUND AND NO FRETTING FOUND ON THE INTERNAL SURFACE OF THE JUNCTION BOX COVER during PART 13: JUNCTION BOX COVER - DETAILED INSPEC- TION. -Before further flight. CONDITION 13 (ACTION 2): Do PART 18: ENGINE 1, ENGINE 2, AND ENGINE 3 PYLON JUNC- TION BOX ASSEMBLY - INSTAL- LATION. 24 months.-CONDITION 13 (ACTION 3): Repeat PART 13: JUNCTION BOX COVER - DETAILED INSPECTION for signs of arcing and fretting to the internal surface of the Junction Box Cover. Export Controlled ECCN: 9E991 See page 1 for details Original Issue: December 04, 2023 MD11-78A017Revision 1: June 04, 2024 22 of 208 BOEING SERVICE BULLETIN MD11-78A017 ALERTALERT ### Page 23 Table 2: Work Package 2 - Thrust Reverser Control System Wire Harnesses Detailed Inspections and Wire Integrity Tests Repeat Interval (Not to Exceed) Boeing Recommended Compliance Time ActionCondition -Before further flight. CONDITION 14 (ACTION 1): Do PART 15: JUNCTION BOX COVER - REPLACEMENT. CONDITION 14: ANY SIGNS OF ARCING FOUND OR FRETTING FOUND ON THE INTERNAL SURFACE OF THE JUNCTION BOX COVER during PART 13: JUNCTION BOX COV- ER - DETAILED INSPECTION. -Before further flight. CONDITION 14 (ACTION 2): Do PART 18: ENGINE 1, ENGINE 2, AND ENGINE 3 PYLON JUNC- TION BOX ASSEMBLY - INSTAL- LATION. 24 months.-CONDITION 14 (ACTION 3): Repeat PART 13: JUNCTION BOX COVER - DETAILED INSPECTION for signs of arcing and fretting to the internal surface of the Junction Box Cover. 24 months.-Repeat PART 19: LEFT SIDE AND RIGHT SIDE THRUST REVERSER ELECTRICAL HARNESS - DE- TAILED INSPECTION AND WIRE INTEGRITY TESTS for wire chafing damage, signs of arcing, and wire integrity tests failure. (c) CONDITION 15: NO WIRE CHAFING DAMAGE FOUND, NO SIGNS OF ARCING FOUND, AND WIRE INTEGRITY TESTS PASSED, ON BOTH THE LEFT SIDE AND RIGHT SIDE THRUST REVERSER ELECTRI- CAL HARNESS, during PART 19: LEFT SIDE AND RIGHT SIDE THRUST REVERSER ELECTRI- CAL HARNESS - DETAILED IN- SPECTION AND WIRE INTEGRI- TY TESTS. (c) Export Controlled ECCN: 9E991 See page 1 for details Original Issue: December 04, 2023 MD11-78A017Revision 1: June 04, 2024 23 of 208 BOEING SERVICE BULLETIN MD11-78A017 ALERTALERT ### Page 24 Table 2: Work Package 2 - Thrust Reverser Control System Wire Harnesses Detailed Inspections and Wire Integrity Tests Repeat Interval (Not to Exceed) Boeing Recommended Compliance Time ActionCondition -Before further flight. CONDITION 16 OPTION 1 (ACTION 1): CONDITION 16: ANY WIRE CHAFING DAMAGE FOUND, ANY SIGNS OF ARC- ING FOUND, OR WIRE INTEGRI- TY TESTS FAILED ON THE RIGHT SIDE THRUST REVERS- ER ELECTRICAL HARNESS during PART 19: LEFT SIDE AND RIGHT SIDE THRUST REVERS- ER ELECTRICAL HARNESS - DETAILED INSPECTION. Do PART 20: RIGHT SIDE THRUST REVERSER ELECTRI- CAL HARNESS - REPLACEMENT. 24 months.-CONDITION 16 OPTION 1 (ACTION 2): Repeat PART 19: LEFT SIDE AND RIGHT SIDE THRUST REVERSER ELECTRICAL HARNESS - DE- TAILED INSPECTION AND WIRE INTEGRITY TESTS for wire chafing damage, signs of arcing, and wire integrity tests failure. (c) AND WIRE INTEGRITY TESTS AND NO WIRE CHAFING DAMAGE FOUND, NO SIGNS OF ARCING FOUND, AND WIRE INTEGRITY TESTS PASSED ON THE LEFT SIDE THRUST REVERSER ELECTRICAL HARNESS. (c) -Before further flight. CONDITION 16 OPTION 2 (ACTION 1): Do PART 22: RIGHT SIDE THRUST REVERSER ELECTRI- CAL HARNESS - REPAIR. 24 months.-CONDITION 16 OPTION 2 (ACTION 2): Repeat PART 19: LEFT SIDE AND RIGHT SIDE THRUST REVERSER ELECTRICAL HARNESS - DE- TAILED INSPECTION AND WIRE INTEGRITY TESTS for wire chafing damage, signs of arcing, and wire integrity tests failure. (c) Export Controlled ECCN: 9E991 See page 1 for details Original Issue: December 04, 2023 MD11-78A017Revision 1: June 04, 2024 24 of 208 BOEING SERVICE BULLETIN MD11-78A017 ALERTALERT ### Page 25 Table 2: Work Package 2 - Thrust Reverser Control System Wire Harnesses Detailed Inspections and Wire Integrity Tests Repeat Interval (Not to Exceed) Boeing Recommended Compliance Time ActionCondition -Before further flight. CONDITION 17 OPTION 1 (ACTION 1): CONDITION 17: ANY WIRE CHAFING DAMAGE FOUND, ANY SIGNS OF ARC- ING FOUND, OR WIRE INTEGRI- TY TESTS FAILED ON THE LEFT SIDE THRUST REVERSER ELECTRICAL HARNESS during PART 19: LEFT SIDE AND RIGHT SIDE THRUST REVERS- ER ELECTRICAL HARNESS - DETAILED INSPECTION AND WIRE INTEGRITY TESTS AND NO WIRE CHAFING DAMAGE FOUND, NO SIGNS OF ARCING FOUND, AND WIRE INTEGRITY TESTS PASSED ON THE RIGHT SIDE THRUST REVERSER ELECTRICAL HARNESS. (c) Do PART 21: LEFT SIDE THRUST REVERSER ELECTRICAL HAR- NESS - REPLACEMENT. 24 months.-CONDITION 17 OPTION 1 (ACTION 2): Repeat PART 19: THRUST RE- VERSER ELECTRICAL HARNESS - INSPECTION AND WIRE IN- TEGRITY TESTS for wire chafing damage, signs of arcing, and wire integrity tests failure. (c) -Before further flight. CONDITION 17 OPTION 2 (ACTION 1): Do PART 23: LEFT SIDE THRUST REVERSER ELECTRICAL HAR- NESS REPAIR. 24 months.-CONDITION 17 OPTION 2 (ACTION 2): Repeat PART 19: LEFT SIDE AND RIGHT SIDE THRUST REVERSER ELECTRICAL HARNESS - DE- TAILED INSPECTION AND WIRE INTEGRITY TESTS for wire chafing damage, signs of arcing, and wire integrity tests failure. (c) Export Controlled ECCN: 9E991 See page 1 for details Original Issue: December 04, 2023 MD11-78A017Revision 1: June 04, 2024 25 of 208 BOEING SERVICE BULLETIN MD11-78A017 ALERTALERT ### Page 26 Table 2: Work Package 2 - Thrust Reverser Control System Wire Harnesses Detailed Inspections and Wire Integrity Tests Repeat Interval (Not to Exceed) Boeing Recommended Compliance Time ActionCondition -Before further flight. CONDITION 18 OPTION 1 (ACTION 1): CONDITION 18: ANY WIRE CHAFING DAMAGE FOUND, ANY SIGNS OF ARC- ING FOUND. Do PART 21: LEFT SIDE THRUST REVERSER ELECTRICAL HAR- NESS - REPLACEMENT.OR WIRE INTEGRITY TESTS FAILED ON BOTH THE LEFT SIDE AND RIGHT SIDE THRUST REVERSER ELECTRICAL HAR- NESSES during PART 19: LEFT SIDE AND RIGHT SIDE THRUST REVERSER ELECTRICAL HAR- NESS - DETAILED INSPECTION AND WIRE INTEGRITY TESTS. (c) -Before further flight. CONDITION 18 OPTION 1 (ACTION 2): Do PART 20: RIGHT SIDE THRUST REVERSER ELECTRI- CAL HARNESS - REPLACEMENT. 24 months.-CONDITION 18 OPTION 1 (ACTION 3): Repeat PART 19: LEFT SIDE AND RIGHT SIDE THRUST REVERSER ELECTRICAL HARNESS - DE- TAILED INSPECTION AND WIRE INTEGRITY TESTS for wire chafing damage, signs of arcing, and wire integrity tests failure. (c) -Before further flight. CONDITION 18 OPTION 2 (ACTION 1): Do PART 23: LEFT SIDE THRUST REVERSER ELECTRICAL HAR- NESS - REPAIR. -Before further flight. CONDITION 18 OPTION 2 (ACTION 2): Do PART 22: RIGHT SIDE THRUST REVERSER ELECTRI- CAL HARNESS - REPAIR. 24 months.-CONDITION 18 OPTION 2 (ACTION 3): Repeat PART 19: LEFT SIDE AND RIGHT SIDE THRUST REVERSER ELECTRICAL HARNESS - DE- TAILED INSPECTION AND WIRE INTEGRITY TESTS for wire chafing damage, signs of arcing, and wire integrity tests failure. (c) -Before further flight. CONDITION 18 OPTION 3 (ACTION 1): Export Controlled ECCN: 9E991 See page 1 for details Original Issue: December 04, 2023 MD11-78A017Revision 1: June 04, 2024 26 of 208 BOEING SERVICE BULLETIN MD11-78A017 ALERTALERT ### Page 27 Table 2: Work Package 2 - Thrust Reverser Control System Wire Harnesses Detailed Inspections and Wire Integrity Tests Repeat Interval (Not to Exceed) Boeing Recommended Compliance Time ActionCondition Do PART 23: LEFT SIDE THRUST REVERSER ELECTRICAL HAR- NESS REPAIR. -Before further flight. CONDITION 18 OPTION 3 (ACTION 2): Do PART 20: RIGHT SIDE THRUST REVERSER ELECTRI- CAL HARNESS - REPLACEMENT. 24 months.-CONDITION 18 OPTION 3 (ACTION 3): Repeat PART 19: LEFT SIDE AND RIGHT SIDE THRUST REVERSER ELECTRICAL HARNESS - DE- TAILED INSPECTION AND WIRE INTEGRITY TESTS for wire chafing damage, signs of arcing, and wire integrity tests failure. (c) -Before further flight. CONDITION 18 OPTION 4 (ACTION 1): Do PART 21: LEFT SIDE THRUST REVERSER ELECTRICAL HAR- NESS - REPLACEMENT. -Before further flight. CONDITION 18 OPTION 4 (ACTION 2): Do PART 22: RIGHT SIDE THRUST REVERSER ELECTRI- CAL HARNESS - REPAIR. 24 months.-CONDITION 18 OPTION 4 (ACTION 3): Repeat PART 19: LEFT SIDE AND RIGHT SIDE THRUST REVERSER ELECTRICAL HARNESS - DE- TAILED INSPECTION AND WIRE INTEGRITY TESTS for wire chafing damage, signs of arcing, and wire integrity tests failure. (c) Export Controlled ECCN: 9E991 See page 1 for details Original Issue: December 04, 2023 MD11-78A017Revision 1: June 04, 2024 27 of 208 BOEING SERVICE BULLETIN MD11-78A017 ALERTALERT ### Page 28 Table 2: Work Package 2 - Thrust Reverser Control System Wire Harnesses Detailed Inspections and Wire Integrity Tests Repeat Interval (Not to Exceed) Boeing Recommended Compliance Time ActionCondition 24 months.-Repeat PART 24: CORE MISCEL- LANEOUS WIRE HARNESS AS- SEMBLY - DETAILED INSPEC- TION AND WIRE INTEGRITY TESTS for wire chafing damage, signs of arcing, and wire integrity tests failure. (b) CONDITION 19: NO WIRE CHAFING DAMAGE FOUND, NO SIGNS OF ARCING FOUND, AND WIRE INTEGRITY TESTS PASSED during PART 24: CORE MISCELLANEOUS WIRE HARNESS ASSEMBLY - DE- TAILED INSPECTION AND WIRE INTEGRITY TESTS. (b) -Before further flight. CONDITION 20 OPTION 1 (ACTION 1): CONDITION 20: ANY WIRE CHAFING DAMAGE FOUND, ANY SIGNS OF ARC- ING FOUND, OR ANY WIRE IN- TEGRITY TEST FAILED during PART 24: CORE MISCELLA- NEOUS WIRE HARNESS ASSEM- BLY DETAILED INSPECTION AND WIRE INTEGRITY TESTS. (b) Do PART 25: CORE MISCELLA- NEOUS WIRE HARNESS ASSEM- BLY - REPLACEMENT. 24 months.-CONDITION 20 OPTION 1 (ACTION 2): Repeat PART 24: CORE MISCEL- LANEOUS WIRE HARNESS AS- SEMBLY - DETAILED INSPEC- TION AND WIRE INTEGRITY TESTS for wire chafing damage, signs of arcing, and wire integrity tests failure. (b) -Before further flight. CONDITION 20 OPTION 2 (ACTION 1): Do PART 26: CORE MISCELLA- NEOUS WIRE HARNESS ASSEM- BLY - REPAIR. 24 months.-CONDITION 20 OPTION 2 (ACTION 2): Repeat PART 24: CORE MISCEL- LANEOUS WIRE HARNESS AS- SEMBLY - DETAILED INSPEC- TION AND WIRE INTEGRITY TESTS for wire chafing damage, signs of arcing, and wire integrity tests failure. (b) Export Controlled ECCN: 9E991 See page 1 for details Original Issue: December 04, 2023 MD11-78A017Revision 1: June 04, 2024 28 of 208 BOEING SERVICE BULLETIN MD11-78A017 ALERTALERT ### Page 29 Table 2: Work Package 2 - Thrust Reverser Control System Wire Harnesses Detailed Inspections and Wire Integrity Tests Repeat Interval (Not to Exceed) Boeing Recommended Compliance Time ActionCondition -Before further flight. CONDITION 21 (ACTION 1): Do PART 30: WORK PACKAGE 2 - RETURN TO SERVICE TESTS AND CLOSE ACCESS. CONDITION 21: NO WIRE CHAFING DAMAGE FOUND, NO SIGNS OF ARCING FOUND, AND WIRE INTEGRITY TESTS PASSED during PART 27: 30 DEGREE BULKHEAD WIRE HARNESS ASSEMBLY - DE- TAILED INSPECTION AND WIRE INTEGRITY TESTS. (b) 24 months.-CONDITION 21 (ACTION 2): Repeat PART 27: 30 DEGREE BULKHEAD WIRE HARNESS AS- SEMBLY - DETAILED INSPEC- TION AND WIRE INTEGRITY TESTS. (b) Export Controlled ECCN: 9E991 See page 1 for details Original Issue: December 04, 2023 MD11-78A017Revision 1: June 04, 2024 29 of 208 BOEING SERVICE BULLETIN MD11-78A017 ALERTALERT ### Page 30 Table 2: Work Package 2 - Thrust Reverser Control System Wire Harnesses Detailed Inspections and Wire Integrity Tests Repeat Interval (Not to Exceed) Boeing Recommended Compliance Time ActionCondition -Before further flight. CONDITION 22 OPTION 1 (ACTION 1): CONDITION 22: ANY WIRE CHAFING DAMAGE FOUND, ANY SIGNS OF ARC- ING FOUND, OR ANY WIRE IN- TEGRITY TEST FAILED during PART 27: 30 DEGREE BULK- HEAD WIRE HARNESS ASSEM- BLY - DETAILED INSPECTION AND WIRE INTEGRITY TESTS. (b) Do PART 28: 30 DEGREE BULK- HEAD WIRE HARNESS ASSEM- BLY - REPLACEMENT. -Before further flight. CONDITION 22 OPTION 1 (ACTION 2): Do PART 30: WORK PACKAGE 2 - RETURN TO SERVICE TESTS AND CLOSE ACCESS. 24 months.-CONDITION 22 OPTION 1 (ACTION 3): Repeat PART 27: 30 DEGREE BULKHEAD WIRE HARNESS AS- SEMBLY - DETAILED INSPEC- TION AND WIRE INTEGRITY TESTS for wire chafing damage, signs of arcing, and wire integrity tests failure. (b) -Before further flight. CONDITION 22 OPTION 2 (ACTION 1): Do PART 29: 30 DEGREE BULK- HEAD WIRE HARNESS - ASSEM- BLY REPAIR. -Before further flight. CONDITION 22 OPTION 2 (ACTION 2): Do PART 30: WORK PACKAGE 2 - RETURN TO SERVICE TESTS AND CLOSE ACCESS. 24 months.-CONDITION 22 OPTION 2 (ACTION 3): Repeat PART 27: 30 DEGREE BULKHEAD WIRE HARNESS AS- SEMBLY - DETAILED INSPEC- TION AND WIRE INTEGRITY TESTS for wire chafing damage, signs of arcing, and wire integrity tests failure. (b) (a) Accomplishing the initial ACTION 1 through 3 inclusive specified in Work Package 2 terminates the Work Package 1 PART 2: ENGINE 1, ENGINE 2, AND ENGINE 3 PYLON WIRE HARNESS DETAILED IN- SPECTION requirement. (b) Wire integrity tests consist of a continuity test and an insulation resistance test. Export Controlled ECCN: 9E991 See page 1 for details Original Issue: December 04, 2023 MD11-78A017Revision 1: June 04, 2024 30 of 208 BOEING SERVICE BULLETIN MD11-78A017 ALERTALERT ### Page 31 Table 2: Work Package 2 - Thrust Reverser Control System Wire Harnesses Detailed Inspections and Wire Integrity Tests Repeat Interval (Not to Exceed) Boeing Recommended Compliance Time ActionCondition (c) Wire integrity tests consist of a continuity test, a conductivity test, and an insulation resistance. (d) A serviceable Junction Box Assembly is a Junction Box Assembly that has complied with all of the following: – Passed PART 12 continuity test and insulation resistance test in this service bulletin. – Done PART 12 Detailed Inspection for wire chafing damage and signs of arcing in this bulletin and all applicable on-condition corrective action have been done. – Done PART 12 Detailed Inspection for signs of arcing and fretting to the internal surface of the Junction Box Cover and all applicable on-condition corrective action have been done. – Does not have any loose electrical connections. Refer to SWPM 20-30-03 GENERAL INSTRUCTIONS HARDWARE - MAINTENANCE PRACTICES as an accepted procedure. (e) For operators that accomplish PART 10, PART 16, and PART 13 concurrently: If, during any inspection or test specified in PART 10, PART 16, or PART 13, a damaged Junction Box Assembly is replaced with a new or serviceable Junction Box Assembly as specified in Part 18, it is not required to do the other inspections and tests specified in PART 10, PART 16 and PART 13, except the repeat inspections and tests specified in PART 10, PART 16 and PART 13 must still be done at the specified repeat intervals. Report any finding to The Boeing Company in accordance with APPENDIX C, APPENDIX D and APPENDIX E as applicable within 90 days after the completion of this service bulletin. 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. 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 See page 1 for details Original Issue: December 04, 2023 MD11-78A017Revision 1: June 04, 2024 31 of 208 BOEING SERVICE BULLETIN MD11-78A017 ALERTALERT ### Page 32 G. Manpower The tables below show an estimate of the task hours necessary to do this modification for each airplane. This estimate is for direct labor only, done by an experienced crew. Adjust the estimate with the 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. Table 1: Work Package 1 - Engine 1, Engine 2, and Engine 3 Pylon Thrust Reverser Control System Wire Harnesses Detailed Inspection Elapsed HoursTask HoursNumber of PersonsTask 1.532PART 1 362PART 2 ---PART 3 (a) 1.532PART 4 --TOTAL FOR EACH AIRPLANE (b) (a) The task and elapsed hours are not given as the work necessary for repairs varies depend- ing on condition. (b) The total task hours and elapsed hours are not given as the work necessary for each air- plane is variable. Table 2: Work Package 2 - Thrust Reverser Control System Wire Harnesses Detailed Inspections and Wire Integrity Tests Elapsed HoursTask HoursNumber of PersonsTask ---PART 3 (a) 8162PART 5 242PART 6 242PART 7 242PART 8 1.532PART 9 111PART 10 ---PART 11 (a) 111PART 12 (c) 0.750.751PART 13 (c) Export Controlled ECCN: 9E991 See page 1 for details Original Issue: December 04, 2023 MD11-78A017Revision 1: June 04, 2024 32 of 208 BOEING SERVICE BULLETIN MD11-78A017 ALERTALERT ### Page 33 Table 2: Work Package 2 - Thrust Reverser Control System Wire Harnesses Detailed Inspections and Wire Integrity Tests Elapsed HoursTask HoursNumber of PersonsTask 0.250.251PART 14 (c) 111PART 15 (c) 111PART 16 (c) ---PART 17 (NOT USED) 1.532PART 18 6122PART 19 1.532PART 20 (b) 1.532PART 21 (b) ---PART 22 (a) ---PART 23 (a) 6122PART 24 (b) 362PART 25 (b) ---PART 26 (a) 6122PART 27 (b) 111PART 28 (c) ---PART 29 (a) 8162PART 30 --TOTAL FOR EACH AIRPLANE (d) (a) The task and elapsed hours are not given as the work necessary for repairs varies depend- ing on condition. (b) This task is done on each engine or engine pylon. Task hours is for all three locations. (c) The task and elapsed hours are given for one engine only. (d) The total task hours and elapsed hours are not given as the work necessary for each air- plane is variable. H. Weight and Balance Changes None. I. Electrical Load Data Not changed. Export Controlled ECCN: 9E991 See page 1 for details Original Issue: December 04, 2023 MD11-78A017Revision 1: June 04, 2024 33 of 208 BOEING SERVICE BULLETIN MD11-78A017 ALERTALERT ### Page 34 J. References 1. Existing Data: a. Boeing Service Related Problem (SRP) MD11-78-0117 b. Component Maintenance Manual (CMM), ROHR, Inc CMM 71-50-07 c. Component Maintenance Manual (CMM), MRAS CMM 78-31-35 (MR 92514) d. Federal Aviation Administration (FAA) Notice of Proposed Rule Making (NPRM)AD-2023-00888-T e. Service Bulletin Index D624N001 f. Standard Overhaul Practices Manual (SOPM) 20-10-24 g. Standard Wiring Practices Manual (SWPM)20-00-06, 20-00-09, 20-10-01, 20-20-03, 20-50-01 h. MD-11 Aircraft Maintenance Manual (AMM) 06-24-00, 20-50-02, 24-00-00, 36-11-07, 36-13-01, 36-13-03, 71-00-00, 71-10-00, 71-50-04, 71-50-05, 76-11-10, 78-30-00, 78-31-10, 78-31-22 i. MD-11 Fleet Team Digest (FTD) 78-23001 j. MD-11 Wiring Diagram Manual (WDM) 71-51-11, 71-51-12, 71-51-13, 78-34-01, 78-34-02, 78-34-03 2. Data Supplied with this Service Bulletin: None. 3. Installation Drawings Used in the Preparation of this Service Bulletin: None. 4. Process Data: Douglas Process Specifications referred to on the drawings are not given in this service bulletin since these procedures are frequently used as standard shop practices. K. Publications Affected 1. Publications: None. 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. Export Controlled ECCN: 9E991 See page 1 for details Original Issue: December 04, 2023 MD11-78A017Revision 1: June 04, 2024 34 of 208 BOEING SERVICE BULLETIN MD11-78A017 ALERTALERT ### Page 35 L. Interchangeability and Intermixability of Parts Accomplishment of this service bulletin does not affect interchangeability or intermixability of parts. M. Software Accomplishment Summary Not affected. Export Controlled ECCN: 9E991 See page 1 for details Original Issue: December 04, 2023 MD11-78A017Revision 1: June 04, 2024 35 of 208 BOEING SERVICE BULLETIN MD11-78A017 ALERTALERT ### Page 36 Export Controlled ECCN: 9E991 See page 1 for details Original Issue: December 04, 2023 MD11-78A017Revision 1: June 04, 2024 36 of 208 BOEING SERVICE BULLETIN MD11-78A017 ALERTALERT BLANK PAGE ### Page 37 2. MATERIAL INFORMATION A. Material - Price and Availability The operator can supply the parts and materials shown in Paragraph 2.C., Parts Necessary for Each Airplane. 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: None. 2. Parts and Materials Supplied by the Operator: The following parts or materials are necessary to do the change in this service bulletin. Parts and materials in the manuals given in Paragraph 1.J., References, can also be necessary. Examine operator part and material supply to make sure all necessary parts and materials are available. NotesExisting Part NumberNameQTYPart Number / Specification (a)(g)AUN7613-( )JUNCTION BOX ASSEMBLY1AUN7613-( ) (a)(h)AUN8602JUNCTION BOX COVER1AUN8602 (a)(b)224W9721-50( ) OR 224W9921-50( ) CORE MISCELLANEOUS WIRE HARNESS ASSEMBLY 1224W9721-50( ) OR 224W9921-50( ) (a)(b)224W9731-50( )30 DEGREE BULKHEAD WIRE HARNESS ASSEMBLY 1224W9731-50( ) (a)(c)7116M20G( )FAN REVERSER ELECTRICAL CABLE 17116M20G( ) (a)(c)7116M21G( )FAN REVERSER ELECTRICAL CABLE 17116M21G( ) (d)(e)(f)-CHEMICAL CONVERSION COAT- ING 0.25 Pint SOPM 20-10-24 CLASS B, TYPE 2 (a) If necessary. This is the number of parts for one engine. (b) Can be repaired, refer to Rohr, Inc CMM 71-50-07 as an accepted procedure. Export Controlled ECCN: 9E991 See page 1 for details Original Issue: December 04, 2023 MD11-78A017Revision 1: June 04, 2024 37 of 208 BOEING SERVICE BULLETIN MD11-78A017 ALERTALERT ### Page 38 NotesExisting Part NumberNameQTYPart Number / Specification (c) Can be supplied by: Middle River Aerospace Systems (MRAS) (CAGE: 1B6R3). For customers based in the Americas: (including Canada, South America, and the continental US including the Hawaiian Islands, and the US Territories in the Caribbean and Pacific Territory), contact Middle River Aerostructure Systems at: Website: https://aerohub.stengg.com/us (If stock is not available, contact a Customer Account Representative at MRAS_CF6_Customer_Support@mras.com). For customers based in the Rest of the World, contact ST Engineering Aerospace Systems Pte. Ltd at: Website: https://aerohub.stengg.com/sg (If stock is not available, contact a Customer Support Repre- sentative at aerohub_support@stengg.com). AOG contact: aeroline@stengg.com; AOG Helpline: +1 410-346-0502 or +65 3129-2468 MRAS Customer Call Center/ Support: aeroline@stengg.com; Helpline: +1 410-346-0502 or +65 3129-2468. (d) Refer to the Qualified Products List at the end of the Boeing Material Specification (BMS) for supplier data. (e) Some conversion coatings contain Chromium trioxide/Chromic acid and will not be available in the Eu- ropean Union after September 2017 without an authorization. EU operators are encouraged to ensure their suppliers are authorized to provide the material after the sunset date and that downstream users comply with the risk mitigation measures and operational conditions. (f) May be purchased from: Boeing Distribution Incorporated (Cage 22819) 2750 Regent Boulevard, Dallas, Texas 75261 Website: https://shop.boeing.com/aviation-supply (g) New or serviceable part. Refer to Paragraph 3.A.17, General Information for serviceable Junction Box Assembly requirements. (h) New or serviceable part. Refer to Paragraph 3.A.18, General Information for serviceable Junction Box Cover requirements. 3. Parts Modified and Reidentified: None. 4. Parts Removed and Not Replaced: None. D. Parts Necessary to Change Spares None. E. Special Tooling - Price and Availability None. Export Controlled ECCN: 9E991 See page 1 for details Original Issue: December 04, 2023 MD11-78A017Revision 1: June 04, 2024 38 of 208 BOEING SERVICE BULLETIN MD11-78A017 ALERTALERT ### Page 39 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. Export Controlled ECCN: 9E991 See page 1 for details Original Issue: December 04, 2023 MD11-78A017Revision 1: June 04, 2024 39 of 208 BOEING SERVICE BULLETIN MD11-78A017 ALERTALERT ### Page 40 Export Controlled ECCN: 9E991 See page 1 for details Original Issue: December 04, 2023 MD11-78A017Revision 1: June 04, 2024 40 of 208 BOEING SERVICE BULLETIN MD11-78A017 ALERTALERT BLANK PAGE ### Page 41 3. ACCOMPLISHMENT INSTRUCTIONS A. GENERAL INFORMATION IF ELECTRICAL POWER IS APPLIED TO THE AIRPLANE, MAKE SURE YOU OBEY ALL PRECAUTIONS WHILE YOU DO WORK. IF YOU DO NOT OBEY THE PRECAUTIONS, DEATH OR INJURY TO PERSONS, AND DAMAGE TO THE AIRPLANE CAN OCCUR.WARNING ELECTRICALLY GROUND THE AIRPLANE. THIS WILL HELP TO PREVENT DAMAGE TO THE AIRPLANE OR EQUIPMENT.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 TO ENSURE THE INTEGRITY OF WIRING AND COMPONENTS, INCLUDING INSTALLED DIODES, IT IS RECOMMENDED THAT INSULATION RESISTANCE TEST VOLTAGE DO NOT EXCEED 500 VOLTS.CAUTION NOTE: 1. Manual titles are referred to by acronyms. Refer to Paragraph 1.J., References, for definition of the acronyms. 2. Equivalent parts are listed in the AEPL, Drawing 7595071. 3. The work instructions are divided into work packages. Each work package can be completed independently during separate maintenance visits. Task Hours and Elapsed Hours for each work package are given in Paragraph 1.G., Manpower. 4. 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 MD-11 Structural Repair Manual (SRM) Chapter 51. – Torque Values: — Values for structural fasteners are included in Chapter 20 of MD-11 Aircraft Maintenance Manual (AMM). — Values for airframe maintenance tasks are included in Chapter 20 of MD-11 Aircraft Maintenance Manual (AMM). — Values for electrical maintenance tasks are included in Chapter 20 of Standard Wiring Practices Manual (SWPM). Export Controlled ECCN: 9E991 See page 1 for details Original Issue: December 04, 2023 MD11-78A017Revision 1: June 04, 2024 41 of 208 BOEING SERVICE BULLETIN MD11-78A017 ALERTALERT ### Page 42 — Values for engine maintenance tasks are included in Chapter 70 of MD-11 Aircraft Maintenance Manual (AMM). — Non-standard torque values for maintenance tasks are included in the applicable installation step. 5. Refer to the SWPM 20-10-01 as accepted wire installation procedures. Refer to these SWPM chapters for applicable operations, as accepted procedures: – TITLECHAPTER INSPECTION INSTRUCTIONS FOR STANDARD WIRING INSTALLATIONS SWPM 20-00-06 GENERAL MAINTENANCE PRACTICES - ELECTRICALSWPM 20-00-09 6. Obey all of the warnings and cautions given in the specified manual sections. 7. Refer to APPENDIX A and APPENDIX B for logic diagram(s). Logic diagrams are provided as an aid only. Information contained in Paragraph 1.E., Compliance is the primary source for compliance times. Information contained in Paragraph 3.B., Work Instructions is the primary source for tasks required for compliance. 8. A Detailed Inspection is defined as: An intensive examination of a specific item, installation, or assembly to detect damage, failure, or irregularity. This could include tactile assessment in which a component or assembly can be checked for tightness/security. Available lighting is normally supplemented with a direct source of good lighting at an intensity deemed appropriate. Inspection aids such as mirrors, magnifying lenses, borescopes, etc. may be necessary. Surface cleaning and elaborate procedures may be required. 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. 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. 11. This service bulletin includes functional test procedures for the systems changed by this service bulletin. More functional tests can possibly be necessary in accordance with standard maintenance practices because of interruption to other airplane systems. 12. Use of colors in Figures is based on guidance from the ATA e-Business Program (ATA) iSpec 2200. 13. 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 or an OPTION, do all of the ACTION numbers for that CONDITION or OPTION. Export Controlled ECCN: 9E991 See page 1 for details Original Issue: December 04, 2023 MD11-78A017Revision 1: June 04, 2024 42 of 208 BOEING SERVICE BULLETIN MD11-78A017 ALERTALERT ### Page 43 14. The compliance times for the actions in Paragraph 3.B., WORK INSTRUCTIONS are in Paragraph 1.E., Compliance. 15. Some steps in the Work Instructions are labeled as Required for Compliance (RC). If this service bulletin is mandated by an Airworthiness Directive (AD), then the steps labeled as RC, including sub-steps under an RC step and any figures identified in an RC step, must be done to comply with the AD. If a step or sub-step is labeled "RC Exempt," then the RC requirement is removed from that step or sub-step. An Alternative Method of Compliance (AMOC) is required for any deviations to RC steps, including sub-steps and identified figures. Steps not labeled as RC may be deviated from using accepted methods in accordance with the operator's maintenance or inspection program without obtaining approval of an AMOC. This is provided that the RC steps, including sub-steps and identified figures, can still be done as specified, and the airplane can be put back in an airworthy condition. 16. Send to The Boeing Company via Boeing Communication System (BCS) general information on the inspected airplane, report of found damage, test failures, repairs, location and nature of damage on the airplane, pylons, engine, and thrust reversers. Refer to APPENDIX C, APPENDIX D and APPENDIX E for additional guidance. 17. A serviceable Junction Box Assembly is a Junction Box Assembly that complied with all of the following: – Passed PART 12 continuity test and insulation resistance test in this service bulletin. – Done PART 12 Detailed Inspection for wire chafing damage and signs of arcing in this bulletin and all applicable on-condition corrective action have been done. – Done PART 12 Detailed Inspection for signs of arcing and fretting to the internal surface of the Junction Box Cover and all applicable on-condition corrective action have been done. – Does not have any loose electrical connections. Refer to SWPM 20-20-03 GENERAL INSTRUCTIONS HARDWARE - MAINTENANCE PRACTICES as an accepted procedure. 18. A serviceable Junction Box Cover is a Junction Box Cover that do not have any sign of arcing and fretting to the internal surface of the Junction Box Cover. 19. An asterisk ( * ) symbol shown next to a Pin letter denotes lower case letter. B. WORK INSTRUCTIONS Work Package 1 - Engine 1, Engine 2, and Engine 3 Pylon Thrust Reverser Control System Wire Harnesses Detailed Inspection 1. Do PART 1: WORK PACKAGE 1 - OPEN ACCESS. 2. RC - Do PART 2: ENGINE 1, ENGINE 2, AND ENGINE 3 PYLON WIRE HARNESS DETAILED INSPECTION for wire chafing damage, signs of arcing, and riding conditions. NOTE: Accomplishing the initial ACTION 1 through 3 inclusive specified in Work Package 2 terminates the Work Package 1 PART 2: ENGINE 1, ENGINE 2, AND ENGINE 3 PYLON WIRE HARNESS DETAILED INSPECTION requirement. Export Controlled ECCN: 9E991 See page 1 for details Original Issue: December 04, 2023 MD11-78A017Revision 1: June 04, 2024 43 of 208 BOEING SERVICE BULLETIN MD11-78A017 ALERTALERT ### Page 44 a. CONDITION 1: NO WIRE CHAFING DAMAGE FOUND, NO SIGNS OF ARCING, AND NO RIDING CONDITIONS FOUND during PART 2: ENGINE 1, ENGINE 2, AND ENGINE 3 PYLON WIRE HARNESS - DETAILED INSPECTION. (1) CONDITION 1 (ACTION 1): Do PART 4: WORK PACKAGE 1 - RETURN TO SERVICE TESTS AND CLOSE ACCESS. (2) CONDITION 1 (ACTION 2): Do the actions specified in Work Package 2. b. CONDITION 2: ANY WIRE CHAFING DAMAGE FOUND, ANY SIGNS OF ARCING, OR ANY RIDING CONDITIONS FOUND during PART 2: ENGINE 1, ENGINE 2, AND ENGINE 3 PYLON WIRE HARNESS - DETAILED INSPECTION. (1) CONDITION 2 (ACTION 1): Do PART 3: WIRE HARNESS REPAIR. (2) CONDITION 2 (ACTION 2): Do PART 4: WORK PACKAGE 1 - RETURN TO SERVICE TESTS AND CLOSE ACCESS. (3) CONDITION 2 (ACTION 3): Do the actions specified in Work Package 2. 3. Put the airplane back to a serviceable condition. 4. Report any finding to The Boeing Company in accordance with APPENDIX C, APPENDIX D and APPENDIX E after the completion of this service bulletin. Work Package 2 - Thrust Reverser Control System Wire Harnesses Detailed Inspections and Wire Integrity Tests 1. Do PART 5: WORK PACKAGE 2 - OPEN ACCESS. 2. RC - ACTION 1: Do PART 6: ENGINE 1 THRUST REVERSER CONTROL SYSTEM WIRE HARNESSES - DETAILED INSPECTION AND WIRE INTEGRITY TESTS for wire chafing damage, riding conditions, signs of arcing, and wire integrity tests failure. NOTE: Accomplishing the initial ACTION 1 through 3 inclusive specified in Work Package 2 terminates the Work Package 1 PART 2: ENGINE 1, ENGINE 2, AND ENGINE 3 PYLON WIRE HARNESS DETAILED INSPECTION requirement. NOTE: Wire integrity tests consist of a continuity test and an insulation resistance test. a. CONDITION 3: NO WIRE CHAFING DAMAGE FOUND, NO RIDING CONDITIONS FOUND, NO SIGNS OF ARCING FOUND, AND WIRE INTEGRITY TESTS PASSED during PART 6: ENGINE 1 THRUST REVERSER CONTROL SYSTEM WIRE HARNESSES - DETAILED INSPECTION AND WIRE INTEGRITY TESTS. (1) Repeat PART 6: ENGINE 1 THRUST REVERSER CONTROL SYSTEM WIRE HARNESSES - DETAILED INSPECTION AND WIRE INTEGRITY TESTS. b. CONDITION 4: ANY WIRE CHAFING DAMAGE FOUND, ANY RIDING CONDITIONS FOUND, ANY SIGNS OF ARCING FOUND, OR ANY WIRE INTEGRITY TEST FAILED during PART 6: ENGINE 1 THRUST REVERSER CONTROL SYSTEM WIRE HARNESSES - DETAILED INSPECTION AND WIRE INTEGRITY TESTS. Export Controlled ECCN: 9E991 See page 1 for details Original Issue: December 04, 2023 MD11-78A017Revision 1: June 04, 2024 44 of 208 BOEING SERVICE BULLETIN MD11-78A017 ALERTALERT ### Page 45 (1) CONDITION 4 (ACTION 1): Do PART 3: WIRE HARNESS REPAIR. (2) CONDITION 4 (ACTION 2): Repeat PART 6: ENGINE 1 THRUST REVERSER CONTROL SYSTEM WIRE HARNESSES DETAILED INSPECTION AND WIRE INTEGRITY TESTS. 3. RC - ACTION 2: Do PART 7: ENGINE 2 THRUST REVERSER CONTROL SYSTEM WIRE HARNESSES - DETAILED INSPECTION AND WIRE INTEGRITY TESTS for wire chafing damage, riding conditions, signs of arcing, and wire integrity tests failure. NOTE: Accomplishing the initial ACTION 1 through 3 inclusive specified in Work Package 2 terminates the Work Package 1 PART 2: ENGINE 1, ENGINE 2, AND ENGINE 3 PYLON WIRE HARNESS DETAILED INSPECTION requirement. NOTE: Wire integrity tests consist of a continuity test and an insulation resistance test. a. CONDITION 5: NO WIRE CHAFING DAMAGE FOUND, NO RIDING CONDITIONS FOUND, NO SIGNS OF ARCING FOUND, AND WIRE INTEGRITY TESTS PASSED during PART 7: ENGINE 2 THRUST REVERSER CONTROL SYSTEM WIRE HARNESSES - DETAILED INSPECTION AND WIRE INTEGRITY TESTS. (1) Repeat PART 7: ENGINE 2 THRUST REVERSER CONTROL SYSTEM WIRE HARNESSES - DETAILED INSPECTION AND WIRE INTEGRITY TESTS. b. CONDITION 6: ANY WIRE CHAFING DAMAGE FOUND, ANY RIDING CONDITIONS FOUND, ANY SIGNS OF ARCING FOUND, OR ANY WIRE INTEGRITY TEST FAILED during PART 7: ENGINE 2 THRUST REVERSER CONTROL SYSTEM WIRE HARNESSES - DETAILED INSPECTION AND WIRE INTEGRITY TESTS. (1) CONDITION 6 (ACTION 1): Do PART 3: WIRE HARNESS REPAIR. (2) CONDITION 6 (ACTION 2): Repeat PART 7: ENGINE 2 THRUST REVERSER CONTROL SYSTEM WIRE HARNESSES - DETAILED INSPECTION AND WIRE INTEGRITY TESTS. 4. RC - ACTION 3: Do PART 8: ENGINE 3 THRUST REVERSER CONTROL SYSTEM WIRE HARNESSES - DETAILED INSPECTION AND WIRE INTEGRITY TESTS for wire chafing damage, riding conditions, signs of arcing, and wire integrity tests failure. NOTE: Accomplishing the initial ACTION 1 through 3 inclusive specified in Work Package 2 terminates the Work Package 1 PART 2: ENGINE 1, ENGINE 2, AND ENGINE 3 PYLON WIRE HARNESS DETAILED INSPECTION requirement. NOTE: Wire integrity tests consist of a continuity test and an insulation resistance test. a. CONDITION 7: NO WIRE CHAFING DAMAGE FOUND, NO RIDING CONDITIONS FOUND, NO SIGNS OF ARCING FOUND, AND WIRE INTEGRITY TESTS PASSED during PART 8: ENGINE 3 THRUST REVERSER CONTROL SYSTEM WIRE HARNESSES - DETAILED INSPECTION AND WIRE INTEGRITY TESTS. (1) Repeat PART 8: ENGINE 3 THRUST REVERSER CONTROL SYSTEM WIRE HARNESSES - DETAILED INSPECTION AND WIRE INTEGRITY TESTS. Export Controlled ECCN: 9E991 See page 1 for details Original Issue: December 04, 2023 MD11-78A017Revision 1: June 04, 2024 45 of 208 BOEING SERVICE BULLETIN MD11-78A017 ALERTALERT ### Page 46 b. CONDITION 8: ANY WIRE CHAFING DAMAGE FOUND, ANY RIDING CONDITIONS FOUND, ANY SIGNS OF ARCING FOUND, OR ANY WIRE INTEGRITY TEST FAILED during PART 8: ENGINE 3 THRUST REVERSER CONTROL SYSTEM WIRE HARNESSES - DETAILED INSPECTION AND WIRE INTEGRITY TESTS. (1) CONDITION 8 (ACTION 1): Do PART 3: WIRE HARNESS REPAIR. (2) CONDITION 8 (ACTION 2): Repeat PART 8: ENGINE 3 THRUST REVERSER CONTROL SYSTEM WIRE HARNESSES - DETAILED INSPECTION AND WIRE INTEGRITY TESTS. 5. Do PART 9: ENGINE 1, ENGINE 2, AND ENGINE 3 PYLON JUNCTION BOX ASSEMBLY REMOVAL. 6. RC - On each of the Engine 1, Engine 2, and Engine 3 pylon Junction Box Assembly do as follows: a. ACTION 4: Do PART 10: JUNCTION BOX ASSEMBLY - DETAILED INSPECTION for any chafing damage, any sign of arcing, and any loose electrical connection. NOTE: For operators that accomplish PART 10, PART 16, and PART 13 concurrently: If, during any inspection or test specified in PART 10, PART 16, or PART 13, a damaged Junction Box Assembly is replaced with a new or serviceable Junction Box Assembly as specified in Part 18, it is not required to do the other inspections and tests specified in PART 10, PART 16 and PART 13, except the repeat inspections and tests specified in PART 10, PART 16 and PART 13 must still be done at the specified repeat intervals. (1) CONDITION 9: NO WIRE CHAFING DAMAGE FOUND, NO SIGN OF ARCING FOUND AND NO LOOSE ELECTRICAL CONNECTION FOUND during PART 10: JUNCTION BOX ASSEMBLY - DETAILED INSPECTION. (a) Repeat PART 10: JUNCTION BOX ASSEMBLY - DETAILED INSPECTION. (2) CONDITION 10: ANY WIRE CHAFING DAMAGE FOUND, ANY SIGN OF ARCING FOUND OR ANY LOOSE ELECTRICAL CONNECTION FOUND during PART 10: JUNCTION BOX ASSEMBLY - DETAILED INSPECTION. (a) CONDITION 10 OPTION 1 (ACTION 1): Do PART 11: JUNCTION BOX ASSEMBLY - WIRE REPAIR. (b) CONDITION 10 OPTION 1 (ACTION 2): Repeat PART 10: JUNCTION BOX ASSEMBLY - DETAILED INSPECTION. (c) CONDITION 10 OPTION 2 (ACTION 1): Do PART 18: ENGINE 1, ENGINE 2, AND ENGINE 3 PYLON JUNCTION BOX ASSEMBLY - INSTALLATION to replace damaged Junction Box Assembly with a new or serviceable Junction Box Assembly. (d) CONDITION 10 OPTION 2 (ACTION 2): Repeat PART 10: JUNCTION BOX ASSEMBLY - DETAILED INSPECTION. b. ACTION 5: Do PART 16: JUNCTION BOX ASSEMBLY - WIRE INTEGRITY TESTS to test for wire integrity tests failure. Export Controlled ECCN: 9E991 See page 1 for details Original Issue: December 04, 2023 MD11-78A017Revision 1: June 04, 2024 46 of 208 BOEING SERVICE BULLETIN MD11-78A017 ALERTALERT ### Page 47 NOTE: For operators that accomplish PART 10, PART 16, and PART 13 concurrently: If, during any inspection or test specified in PART 10, PART 16, or PART 13, a damaged Junction Box Assembly is replaced with a new or serviceable Junction Box Assembly as specified in Part 18, it is not required to do the other inspections and tests specified in PART 10, PART 16 and PART 13, except the repeat inspections and tests specified in PART 10, PART 16 and PART 13 must still be done at the specified repeat intervals. NOTE: Wire integrity tests consist of a continuity test and an insulation resistance test. (1) CONDITION 11: WIRE INTEGRITY TESTS PASSED during PART 16: JUNCTION BOX ASSEMBLY - WIRE INTEGRITY TESTS. (a) Repeat PART 16: JUNCTION BOX ASSEMBLY - WIRE INTEGRITY TESTS. (2) CONDITION 12: ANY WIRE INTEGRITY TEST FAILED during PART 16: JUNCTION BOX ASSEMBLY - WIRE INTEGRITY TESTS. (a) CONDITION 12 OPTION 1 (ACTION 1): Do PART 18: ENGINE 1, ENGINE 2, AND ENGINE 3 PYLON JUNCTION BOX ASSEMBLY - INSTALLATION to replace the failed Junction Box Assembly with a new or serviceable Junction Box Assembly. (b) CONDITION 12 OPTION 1 (ACTION 2): Repeat PART 16: JUNCTION BOX ASSEMBLY - WIRE INTEGRITY TESTS. NOTE: Wire integrity tests consist of a continuity test and an insulation resistance test. (c) CONDITION 12 OPTION 2 (ACTION 1): Do PART 11: JUNCTION BOX ASSEMBLY - REPAIR and make sure the wire integrity tests is passed. (d) CONDITION 12 OPTION 2 (ACTION 2): Repeat PART 16: JUNCTION BOX ASSEMBLY - WIRE INTEGRITY TESTS. c. ACTION 6: Do PART 13: JUNCTION BOX COVER - DETAILED INSPECTION for signs of arcing and fretting to the internal surface of the Junction Box Cover. NOTE: For operators that accomplish PART 10, PART 16, and PART 13 concurrently: If, during any inspection or test specified in PART 10, PART 16, or PART 13, a damaged Junction Box Assembly is replaced with a new or serviceable Junction Box Assembly as specified in Part 18, it is not required to do the other inspections and tests specified in PART 10, PART 16 and PART 13, except the repeat inspections and tests specified in PART 10, PART 16 and PART 13 must still be done at the specified repeat intervals. (1) CONDITION 13: NO SIGNS OF ARCING FOUND AND NO FRETTING FOUND ON THE INTERNAL SURFACE OF THE JUNCTION BOX COVER during PART 13: JUNCTION BOX COVER - DETAILED INSPECTION. (a) CONDITION 13 (ACTION 1): Do PART 14: JUNCTION BOX COVER - INSTALLATION. Export Controlled ECCN: 9E991 See page 1 for details Original Issue: December 04, 2023 MD11-78A017Revision 1: June 04, 2024 47 of 208 BOEING SERVICE BULLETIN MD11-78A017 ALERTALERT ### Page 48 (b) CONDITION 13 (ACTION 2): Do PART 18: ENGINE 1, ENGINE 2, AND ENGINE 3 PYLON JUNCTION BOX ASSEMBLY - INSTALLATION. (c) CONDITION 13 (ACTION 3): Repeat PART 13: JUNCTION BOX COVER - DETAILED INSPECTION for signs of arcing and fretting to the internal surface of the Junction Box Cover. (2) CONDITION 14: ANY SIGNS OF ARCING FOUND OR FRETTING FOUND ON THE INTERNAL SURFACE OF THE JUNCTION BOX COVER during PART 13: JUNCTION BOX COVER - DETAILED INSPECTION. (a) CONDITION 14 (ACTION 1): Do PART 15: JUNCTION BOX COVER - REPLACEMENT. (b) CONDITION 14 (ACTION 2): Do PART 18: ENGINE 1, ENGINE 2, AND ENGINE 3 PYLON JUNCTION BOX ASSEMBLY - INSTALLATION. (c) CONDITION 14 (ACTION 3): Repeat PART 13: JUNCTION BOX COVER - DETAILED INSPECTION for signs of arcing and fretting to the internal surface of the Junction Box Cover. 7. RC - On each Engine (Engine 1, Engine 2, and Engine 3), do as follows: a. ACTION 7: Do PART 19: LEFT SIDE AND RIGHT SIDE THRUST REVERSER ELECTRICAL HARNESS - DETAILED INSPECTION AND WIRE INTEGRITY TESTS for wire chafing damage, signs of arcing, and wire integrity tests failure. NOTE: Wire integrity tests consist of a continuity test, a conductivity test, and an insulation resistance. (1) CONDITION 15: NO WIRE CHAFING DAMAGE FOUND, NO SIGNS OF ARCING FOUND, AND WIRE INTEGRITY TESTS PASSED, ON BOTH THE LEFT SIDE AND RIGHT SIDE THRUST REVERSER ELECTRICAL HARNESS, during PART 19: LEFT SIDE AND RIGHT SIDE THRUST REVERSER ELECTRICAL HARNESS - DETAILED INSPECTION AND WIRE INTEGRITY TESTS. (a) Repeat PART 19: LEFT SIDE AND RIGHT SIDE THRUST REVERSER ELECTRICAL HARNESS - DETAILED INSPECTION AND WIRE INTEGRITY TESTS. (2) CONDITION 16: ANY WIRE CHAFING DAMAGE FOUND, ANY SIGNS OF ARCING FOUND, OR WIRE INTEGRITY TESTS FAILED ON THE RIGHT SIDE THRUST REVERSER ELECTRICAL HARNESS during PART 19: LEFT SIDE AND RIGHT SIDE THRUST REVERSER ELECTRICAL HARNESS - DETAILED INSPECTION AND WIRE INTEGRITY TESTS AND NO WIRE CHAFING DAMAGE FOUND, NO SIGNS OF ARCING FOUND, AND WIRE INTEGRITY TESTS PASSED ON THE LEFT SIDE THRUST REVERSER ELECTRICAL HARNESS. (a) CONDITION 16 OPTION 1 (ACTION 1): Do PART 20: RIGHT SIDE THRUST REVERSER ELECTRICAL HARNESS - REPLACEMENT. (b) CONDITION 16 OPTION 1 (ACTION 2): Repeat PART 19: LEFT SIDE AND RIGHT SIDE THRUST REVERSER ELECTRICAL HARNESS - DETAILED INSPECTION AND WIRE INTEGRITY TESTS. Export Controlled ECCN: 9E991 See page 1 for details Original Issue: December 04, 2023 MD11-78A017Revision 1: June 04, 2024 48 of 208 BOEING SERVICE BULLETIN MD11-78A017 ALERTALERT ### Page 49 (c) CONDITION 16 OPTION 2 (ACTION 1): Do PART 22: RIGHT SIDE THRUST REVERSER ELECTRICAL HARNESS - REPAIR. (d) CONDITION 16 OPTION 2 (ACTION 2): Repeat PART 19: LEFT SIDE AND RIGHT SIDE THRUST REVERSER ELECTRICAL HARNESS - DETAILED INSPECTION AND WIRE INTEGRITY TESTS. (3) CONDITION 17: ANY WIRE CHAFING DAMAGE FOUND, ANY SIGNS OF ARCING FOUND, OR WIRE INTEGRITY TESTS FAILED ON THE LEFT SIDE THRUST REVERSER ELECTRICAL HARNESS during PART 19: LEFT SIDE AND RIGHT SIDE THRUST REVERSER ELECTRICAL HARNESS DETAILED INSPECTION AND WIRE INTEGRITY TESTS AND NO WIRE CHAFING DAMAGE FOUND, NO SIGNS OF ARCING FOUND, AND WIRE INTEGRITY TESTS PASSED ON THE RIGHT SIDE THRUST REVERSER ELECTRICAL HARNESS. (a) CONDITION 17 OPTION 1 (ACTION 1): Do PART 21: LEFT SIDE THRUST REVERSER ELECTRICAL HARNESS - REPLACEMENT. (b) CONDITION 17 OPTION 1 (ACTION 2): Repeat PART 19: LEFT SIDE AND RIGHT SIDE THRUST REVERSER ELECTRICAL HARNESS - DETAILED INSPECTION AND WIRE INTEGRITY TESTS. (c) CONDITION 17 OPTION 2 (ACTION 1): Do PART 23: LEFT SIDE THRUST REVERSER ELECTRICAL HARNESS - REPAIR. (d) CONDITION 17 OPTION 2 (ACTION 2): Repeat PART 19: LEFT SIDE AND RIGHT SIDE THRUST REVERSER ELECTRICAL HARNESS - DETAILED INSPECTION AND WIRE INTEGRITY TESTS. (4) CONDITION 18: ANY WIRE CHAFING DAMAGE FOUND, ANY SIGNS OF ARCING FOUND, OR WIRE INTEGRITY TESTS FAILED ON BOTH THE LEFT SIDE AND RIGHT SIDE THRUST REVERSER ELECTRICAL HARNESSES during PART 19: LEFT SIDE AND RIGHT SIDE THRUST REVERSER ELECTRICAL HARNESS - DETAILED INSPECTION AND WIRE INTEGRITY TESTS. (a) CONDITION 18 OPTION 1 (ACTION 1): Do PART 21: LEFT SIDE THRUST REVERSER ELECTRICAL HARNESS - REPLACEMENT. (b) CONDITION 18 OPTION 1 (ACTION 2): Do PART 20: RIGHT SIDE THRUST REVERSER ELECTRICAL HARNESS - REPLACEMENT. (c) CONDITION 18 OPTION 1 (ACTION 3): Repeat PART 19: LEFT SIDE AND RIGHT SIDE THRUST REVERSER ELECTRICAL HARNESS - DETAILED INSPECTION AND WIRE INTEGRITY TESTS. (d) CONDITION 18 OPTION 2 (ACTION 1): Do PART 23: LEFT SIDE THRUST REVERSER ELECTRICAL HARNESS - REPAIR. (e) CONDITION 18 OPTION 2 (ACTION 2): Do PART 22: RIGHT SIDE THRUST REVERSER ELECTRICAL HARNESS - REPAIR. Export Controlled ECCN: 9E991 See page 1 for details Original Issue: December 04, 2023 MD11-78A017Revision 1: June 04, 2024 49 of 208 BOEING SERVICE BULLETIN MD11-78A017 ALERTALERT ### Page 50 (f) CONDITION 18 OPTION 2 (ACTION 3): Repeat PART 19: LEFT SIDE AND RIGHT SIDE THRUST REVERSER ELECTRICAL HARNESS - DETAILED INSPECTION AND WIRE INTEGRITY TESTS. (g) CONDITION 18 OPTION 3 (ACTION 1): Do PART 23: LEFT SIDE THRUST REVERSER ELECTRICAL HARNESS - REPAIR. (h) CONDITION 18 OPTION 3 (ACTION 2): Do PART 20: RIGHT SIDE THRUST REVERSER ELECTRICAL HARNESS - REPLACEMENT. (i) CONDITION 18 OPTION 3 (ACTION 3): Repeat PART 19: LEFT SIDE AND RIGHT SIDE THRUST REVERSER ELECTRICAL HARNESS - DETAILED INSPECTION AND WIRE INTEGRITY TESTS. (j) CONDITION 18 OPTION 4 (ACTION 1): Do PART 21: LEFT SIDE THRUST REVERSER ELECTRICAL HARNESS - REPLACEMENT. (k) CONDITION 18 OPTION 4 (ACTION 2): Do PART 22: RIGHT SIDE THRUST REVERSER ELECTRICAL HARNESS - REPAIR. (l) CONDITION 18 OPTION 4 (ACTION 3): Repeat PART 19: LEFT SIDE AND RIGHT SIDE THRUST REVERSER ELECTRICAL HARNESS - DETAILED INSPECTION AND WIRE INTEGRITY TESTS. b. ACTION 8: Do PART 24: CORE MISCELLANEOUS WIRE HARNESS ASSEMBLY - DETAILED INSPECTION AND WIRE INTEGRITY TESTS for wire chafing damage, signs of arcing, and wire integrity tests failure. NOTE: Wire integrity tests consist of a continuity test and an insulation resistance test. (1) CONDITION 19: NO WIRE CHAFING DAMAGE FOUND, NO SIGNS OF ARCING FOUND, AND WIRE INTEGRITY TESTS PASSED during PART 24: CORE MISCELLANEOUS WIRE HARNESS ASSEMBLY - DETAILED INSPECTION AND WIRE INTEGRITY TESTS. (a) Repeat PART 24: CORE MISCELLANEOUS WIRE HARNESS ASSEMBLY - DETAILED INSPECTION AND WIRE INTEGRITY TESTS. (2) CONDITION 20: ANY WIRE CHAFING DAMAGE FOUND, ANY SIGNS OF ARCING FOUND, OR ANY WIRE INTEGRITY TEST FAILED during PART 24: CORE MISCELLANEOUS WIRE HARNESS ASSEMBLY - DETAILED INSPECTION AND WIRE INTEGRITY TESTS. (a) CONDITION 20 OPTION 1 (ACTION 1): Do PART 25: CORE MISCELLANEOUS WIRE HARNESS ASSEMBLY - REPLACEMENT. (b) CONDITION 20 OPTION 1 (ACTION 2): Repeat PART 24: CORE MISCELLANEOUS WIRE HARNESS ASSEMBLY - DETAILED INSPECTION AND WIRE INTEGRITY TESTS. (c) CONDITION 20 OPTION 2 (ACTION 1): Do PART 26: CORE MISCELLANEOUS WIRE HARNESS ASSEMBLY - REPAIR. Export Controlled ECCN: 9E991 See page 1 for details Original Issue: December 04, 2023 MD11-78A017Revision 1: June 04, 2024 50 of 208 BOEING SERVICE BULLETIN MD11-78A017 ALERTALERT ### Page 51 (d) CONDITION 20 OPTION 2 (ACTION 2): Repeat PART 24: CORE MISCELLANEOUS WIRE HARNESS ASSEMBLY - DETAILED INSPECTION AND WIRE INTEGRITY TESTS. c. ACTION 9: Do PART 27: 30 DEGREE BULKHEAD WIRE HARNESS ASSEMBLY - DETAILED INSPECTION AND WIRE INTEGRITY TESTS for wire chafing damage, signs of arcing, and wire integrity tests failure. NOTE: Wire integrity tests consist of a continuity test and an insulation resistance test. (1) CONDITION 21: NO WIRE CHAFING DAMAGE FOUND, NO SIGNS OF ARCING FOUND, AND WIRE INTEGRITY TESTS PASSED during PART 27: 30 DEGREE BULKHEAD WIRE HARNESS ASSEMBLY - DETAILED INSPECTION AND WIRE INTEGRITY TESTS. (a) CONDITION 21 (ACTION 1): Do PART 30: WORK PACKAGE 2 - RETURN TO SERVICE TESTS AND CLOSE ACCESS. (b) CONDITION 21 (ACTION 2): Repeat PART 27: 30 DEGREE BULKHEAD WIRE HARNESS ASSEMBLY - DETAILED INSPECTION AND WIRE INTEGRITY TESTS. (2) CONDITION 22: ANY WIRE CHAFING DAMAGE FOUND, ANY SIGNS OF ARCING FOUND, OR ANY WIRE INTEGRITY TEST FAILED during PART 27: 30 DEGREE BULKHEAD WIRE HARNESS ASSEMBLY - DETAILED INSPECTION AND WIRE INTEGRITY TESTS. (a) CONDITION 22 OPTION 1 (ACTION 1): Do PART 28: 30 DEGREE BULKHEAD WIRE HARNESS ASSEMBLY - REPLACEMENT. (b) CONDITION 22 OPTION 1 (ACTION 2): Do PART 30: WORK PACKAGE 2 - RETURN TO SERVICE TESTS AND CLOSE ACCESS. (c) CONDITION 22 OPTION 1 (ACTION 3): Repeat PART 27: 30 DEGREE BULKHEAD WIRE HARNESS ASSEMBLY - DETAILED INSPECTION AND WIRE INTEGRITY TESTS. (d) CONDITION 22 OPTION 2 (ACTION 1): Do PART 29: 30 DEGREE BULKHEAD WIRE HARNESS ASSEMBLY - REPAIR. (e) CONDITION 22 OPTION 2 (ACTION 2): Do PART 30: WORK PACKAGE 2 - RETURN TO SERVICE TESTS AND CLOSE ACCESS. (f) CONDITION 22 OPTION 2 (ACTION 3): Repeat PART 27: 30 DEGREE BULKHEAD WIRE HARNESS ASSEMBLY - DETAILED INSPECTION AND WIRE INTEGRITY TESTS. 8. Put the airplane back to a serviceable condition. 9. Report any finding to The Boeing Company in accordance with APPENDIX C, APPENDIX D and APPENDIX E after the completion of this service bulletin. Export Controlled ECCN: 9E991 See page 1 for details Original Issue: December 04, 2023 MD11-78A017Revision 1: June 04, 2024 51 of 208 BOEING SERVICE BULLETIN MD11-78A017 ALERTALERT ### Page 52 PART 1: WORK PACKAGE 1 - OPEN ACCESS 1. Make sure that the thrust reverser on Engine 1, Engine 2, and Engine 3 is fully stowed. Refer to MD-11 AMM 78-31-22 as an accepted procedure. 2. Remove electrical power from the airplane. Refer to MD-11 AMM 24-00-00 as an accepted procedure. 3. Open access to the thrust reverser control system wire harnesses as shown in Table 1. Refer to MD-11 AMM 06-24-00 as an accepted procedure. Table 1: Open Pylon Access Panels LOCATIONACCESS NUMBER LEFT WING PYLON (ENGINE 1)437AL 437AR 437BL 437BR 437DL 437EL 437FL 438AL 438AR 438BL 438CL 438CR 438DL 438GL Export Controlled ECCN: 9E991 See page 1 for details Original Issue: December 04, 2023 MD11-78A017Revision 1: June 04, 2024 52 of 208 BOEING SERVICE BULLETIN MD11-78A017 ALERTALERT ### Page 53 Table 1: Open Pylon Access Panels LOCATIONACCESS NUMBER TAIL PYLON (ENGINE 2)457AL 457AR 457BL 457BR 457CL 457CR 457DL 457DR 457EL 457ER 457FR 457GR RIGHT WING PYLON (ENGINE 3)487AL 487AR 487BL 487BR 487DL 487EL 487FL 488AL 488AR 488BL 488CL 488CR 488DL 488GL PART 2: ENGINE 1, ENGINE 2, AND ENGINE 3 PYLON WIRE HARNESS - DETAILED INSPECTION 1. RC - Do a Detailed Inspection of the Engine 1 pylon thrust reverser control system wire harnesses for wire chafing damage, signs of arcing, and riding conditions in accordance with FIGURE 1. 2. RC - Do a Detailed Inspection of the Engine 2 pylon thrust reverser control system wire harnesses for wire chafing damage, signs of arcing, and riding conditions in accordance with FIGURE 2. Export Controlled ECCN: 9E991 See page 1 for details Original Issue: December 04, 2023 MD11-78A017Revision 1: June 04, 2024 53 of 208 BOEING SERVICE BULLETIN MD11-78A017 ALERTALERT ### Page 54 3. RC - Do a Detailed Inspection of the Engine 3 pylon thrust reverser control system wire harnesses for wire chafing damage, signs of arcing, and riding conditions in accordance with FIGURE 3. PART 3: WIRE HARNESS REPAIR 1. RC - Repair or replace any wire that has wire chafing damage, signs of arcing, or riding conditions. Refer to SWPM 20-10-01 as an accepted procedure. PART 4: WORK PACKAGE 1 - RETURN TO SERVICE TESTS AND CLOSE ACCESS 1. RC Exempt - Close access to the thrust reverser control system wire harnesses as shown in Table 2. Refer to MD-11 AMM 06-24-00 as an accepted procedure. Table 2: Close Pylon Access Panels LOCATIONACCESS NUMBER LEFT WING PYLON437AL 437AR 437BL 437BR 437DL 437EL 437FL 438AL 438AR 438BL 438CL 438CR 438DL 438GL Export Controlled ECCN: 9E991 See page 1 for details Original Issue: December 04, 2023 MD11-78A017Revision 1: June 04, 2024 54 of 208 BOEING SERVICE BULLETIN MD11-78A017 ALERTALERT ### Page 55 Table 2: Close Pylon Access Panels LOCATIONACCESS NUMBER RIGHT WING PYLON487AL 487AR 487BL 487BR 487DL 487EL 487FL 488AL 488AR 488BL 488CL 488CR 488DL 488GL TAIL PYLON457AL 457AR 457BL 457BR 457CL 457CR 457DL 457DR 457EL 457ER 457FR 457GR 2. RC Exempt - Restore electrical power to the airplane. Refer to MD-11 AMM 24-00-00 as an accepted procedure. 3. RC - Do a minimum and approach idle power test and a functional test of the thrust reverser system. Refer to MD-11 AMM 71-00-00 and MD-11 AMM 78-30-00 as accepted procedures. Export Controlled ECCN: 9E991 See page 1 for details Original Issue: December 04, 2023 MD11-78A017Revision 1: June 04, 2024 55 of 208 BOEING SERVICE BULLETIN MD11-78A017 ALERTALERT ### Page 56 PART 5: WORK PACKAGE 2 - OPEN ACCESS 1. Make sure that the thrust reverser on Engine 1, Engine 2, and Engine 3 is fully stowed. Refer to MD-11 AMM 78-31-22 as an accepted procedure. 2. Remove electrical power from the airplane. Refer to MD-11 AMM 24-00-00 as an accepted procedure. 3. Open access to the thrust reverser control system wire harnesses as shown in Table 3. Refer to MD-11 AMM 06-24-00 as an accepted procedure. Table 3: Open Pylon Access Panels LOCATIONACCESS NUMBER LEFT WING PYLON437AL 437AR 437BL 437BR 437DL 437EL 437FL 438AL 438AR 438BL 438CL 438CR 438DL 438GL Export Controlled ECCN: 9E991 See page 1 for details Original Issue: December 04, 2023 MD11-78A017Revision 1: June 04, 2024 56 of 208 BOEING SERVICE BULLETIN MD11-78A017 ALERTALERT ### Page 57 Table 3: Open Pylon Access Panels LOCATIONACCESS NUMBER RIGHT WING PYLON487AL 487AR 487BL 487BR 487DL 487EL 487FL 488AL 488AR 488BL 488CL 488CR 488DL 488GL TAIL PYLON457AL 457AR 457BL 457BR 457CL 457CR 457DL 457DR 457EL 457ER 457FR 457GR 4. On each of the Engine 1 and Engine 3 pylon, do the following: a. Remove and keep the D1-8051 pneumatic intermediate temperature sensor from the pylon pneumatic duct. Refer to MD-11 AMM 36-11-07 as an accepted procedure. b. Remove and keep the D1-8052 pneumatic manifold temperature sensor from the pylon pneumatic duct. Refer to MD-11 AMM 36-13-03 as an accepted procedure. Export Controlled ECCN: 9E991 See page 1 for details Original Issue: December 04, 2023 MD11-78A017Revision 1: June 04, 2024 57 of 208 BOEING SERVICE BULLETIN MD11-78A017 ALERTALERT ### Page 58 TO PREVENT INJURY AND COMPONENT DAMAGE IT IS RECOMMENDED THAT TWO TECHNICIANS REMOVE THE BLEED AIR PRECOOLER FROM THE PYLON.WARNING DO NOT DISPLACE THE HEADER DUCT SEAL WHEN REMOVING THE BLEED AIR PRECOOLER.CAUTION c. Remove the bleed air precooler. Refer to MD-11 AMM 36-13-01 as an accepted procedure. 5. On the Engine 2 pylon, do the following: MAKE SURE THE INTEGRATED DRIVE GENERATOR (IDG) ELECTRICAL HARNESS IS PROTECTED AGAINST CHAFING WHEN DOING THE FOLLOWING PROCEDURES.CAUTION a. Locate the plenum assembly. Disconnect the wire-harness P-clamps from the plenum assembly. Remove and keep the bolts and washers from the plenum assembly. Remove and keep the plenum assembly from the tail pylon. Refer to MD-11 AMM 36-13-01 as an accepted procedure. b. Remove and keep the D1-8251 pneumatic intermediate temperature sensor from the pylon pneumatic duct. Refer to MD-11 AMM 36-11-07 as an accepted procedure. c. Remove and keep the D1-8252 pneumatic manifold temperature sensor from the pylon pneumatic duct. Refer to MD-11 AMM 36-13-03 as an accepted procedure. TO PREVENT INJURY AND COMPONENT DAMAGE IT IS RECOMMENDED THAT TWO TECHNICIANS REMOVE THE BLEED AIR PRECOOLER FROM THE PYLON.WARNING DO NOT DISPLACE THE HEADER DUCT SEAL WHEN REMOVING THE BLEED AIR PRECOOLER.CAUTION d. Remove the bleed air precooler. Refer to MD-11 AMM 36-13-01 as an accepted procedure. 6. Open the fan cowl and thrust reverser doors. Refer to MD-11 AMM 71-10-00 as an accepted procedure. Export Controlled ECCN: 9E991 See page 1 for details Original Issue: December 04, 2023 MD11-78A017Revision 1: June 04, 2024 58 of 208 BOEING SERVICE BULLETIN MD11-78A017 ALERTALERT ### Page 59 7. On each of Engine 1, Engine 2, and Engine 3, disconnect the Line Replaceable Units (LRUs) shown in Table 4. Table 4: Engine - Line Replaceable Unit (LRU) Disconnection Refer to WIRING DIAGRAM CONNECTORLRU PART NAMELRU MD-11 WDM 71-51-11P1-8505ATHRUST REVERSER (T/R) DIRECTION- AL PILOT VALVE U1-8505 P1-8505B P1-8506T/R TRANSCOWL INDICATING SWITCH LEFT HAND SIDE S1-8506 P1-8508T/R TRANSCOWL INDICATING SWITCH RIGHT HAND SIDE S1-8508 P1-8157STARTER AIR VALVES2-8157 P1-8161NACELLE EXIT TEMP SENSORT2-8161 P1-8245ANTI-ICE VALVE INLET COWLS2-8245 P1-8154BYPASS SOLENOID (OUTBOUND) PRIMARY HYDRAULIC PUMP S2-8154 P1-8153BYPASS SOLENOID (INBOUND) STANDBY HYDRAULIC PUMP S2-8153 P1-8525CHIGH PRESSURE FUEL SHUTOFF VALVE U1-8525 P1-8525D 8. On Engine 1 and Engine 3, disconnect the connectors shown in Table 5. Table 5: Engine 1 and Engine 3 - Connector Disconnection Refer to WIRING DIAGRAM CONNECTOR (RECEPTACLE)CONNECTOR (PLUG) MD-11 WDM 71-51-11R5-8510P1-8510 R5-8509P1-8509 R5-8057P1-8057 R5-8011P1-8011 Export Controlled ECCN: 9E991 See page 1 for details Original Issue: December 04, 2023 MD11-78A017Revision 1: June 04, 2024 59 of 208 BOEING SERVICE BULLETIN MD11-78A017 ALERTALERT ### Page 60 9. On Engine 2, disconnect the connectors shown in Table 6. Table 6: Engine 2 - Connector Disconnection Refer to WIRING DIAGRAM CONNECTOR (RECEPTACLE)CONNECTOR (PLUG) MD-11 WDM 71-51-11R5-8510P1-8510 R5-8509P1-8509 R5-8257P1-8257 R5-8211P1-8211 10. On Engine 1, Engine 2 and Engine 3, disconnect the connectors shown in Table 7. Table 7: Engine 1, Engine 2 and Engine 3 - Thrust Control Module Connector Disconnec- tion Refer to WIRING DIAGRAM CONNECTOR (RECEPTACLE)CONNECTOR (PLUG) MD-11 WDM 78-34-01-P1-5904 -P1-567 R5-5165- MD-11 WDM 78-34-02R5-5905P1-5905 R5-565P1-565 R5-5266- MD-11 WDM 78-34-03R5-570P1-570 R5-5906P1-5906 R5-5265- Export Controlled ECCN: 9E991 See page 1 for details Original Issue: December 04, 2023 MD11-78A017Revision 1: June 04, 2024 60 of 208 BOEING SERVICE BULLETIN MD11-78A017 ALERTALERT The text continues at https://openairdocs.org/service-documents/boeing/md11-78a017/file/69d5826ed559.md?from=61 --- OpenAirDocs.org is an independent research project of [Contrail Labs](https://contraillabs.com/). It is not affiliated with the FAA or the NTSB. Source documents are U.S. government works in the public domain, except the copies of manufacturers’ service documents, which belong to their rights holders.