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Commercial Airplanes MD90 Service Bulletin Number: MD90-28-013 Original Issue: September 27, 2013 Revision 1: August 27, 2015 ATA System: 2800 SUBJECT: FUEL - Fuel Systems - Install Ground Fault Interrupter Relays and Change Fuel Pump System Wiring Export of this technology is controlled under the United States Export Administration Regulations (EAR) (15 CFR 300-774). An export license may be required before it is used for development, production or use by foreign persons from specific countries. The controller of this data has the individual responsibility to abide by all export laws.
9E991ECCN:
BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET Copyright © 2013 Boeing.
Unpublished Work. All Rights Reserved.
Treatment of this document and its content is governed by contract with Boeing. Rights to use this document are licensed on a per aircraft basis and such rights may not be transferable. For more information, contact The Boeing Company.
Boeing, the Boeing signature, the Boeing symbol, 707, 717, 727, 737, 747, 757, 767, 777, 787, Dreamliner, BBJ, DC-8, DC-9, DC-10, KC-10, KC-46, KDC-10, MD-10, MD-11, MD-80, MD-88, MD-90, P-8, Poseidon and Boeing liveries are all trademarks owned by The Boeing Company; and no trademark license is granted in connection with this document unless provided in writing by Boeing.
Original Issue: September 27, 2013 MD90-28-013Revision 1: August 27, 2015 1 of 140
2.0
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: September 27, 2013 MD90-28-013Revision 1: August 27, 2015 2 of 140 BOEING SERVICE BULLETIN MD90-28-013
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Table of Contents
Revision Transmittal Sheet5
S u m m a r y7
1. PLANNING INFORMATION ........................................ 1 1 A . E f f e c t i v i t y ............................................... 1 1
1. Airplanes ............................................ 1 1 2 . S p a r e s A f f e c t e d ........................................ 1 3 B. Concurrent Requirements ...................................... 1 4 C. Reason ................................................ 1 4 D. Description .............................................. 1 4 E. Compliance .............................................. 1 5 F . A p p r o v a l ............................................... 1 5 G. Manpower .............................................. 1 5 H. Weight and Balance Changes .................................... 1 7 I. Electrical Load Data ......................................... 1 7 J . R e f e r e n c e s .............................................. 2 2
1. Existing Data: ......................................... 2 2
2. Data Supplied with this Service Bulletin: ........................... 2 2
3. Installation Drawings Used in the Preparation of this Service Bulletin: ........... 2 2 4 . P r o c e s s D a t a : ......................................... 2 3 K. Publications Affected ........................................ 2 3 L. Interchangeability and Intermixability of Parts ........................... 2 3 M. Software Accomplishment Summary ................................ 2 3
2. MATERIAL INFORMATION ........................................ 2 5 A. Material - Price and Availability ................................... 2 5 B. Industry Support Information .................................... 2 5 C. Parts Necessary for Each Airplane ................................. 2 5 1 . K i t s / P a r t s ............................................ 2 5
2. Parts and Materials Supplied by the Operator ........................ 3 1
3. Parts Modified and Reidentified ................................ 3 1
4. Parts Removed and Not Replaced .............................. 3 2 D. Parts Necessary to Change Spares ................................. 3 2 E. Special Tooling - Price and Availability ............................... 3 2 F. Special Tooling Necessary to do this Service Bulletin ....................... 3 3
3. ACCOMPLISHMENT INSTRUCTIONS .................................. 3 5 A. GENERAL INFORMATION ..................................... 3 5 B. WORK INSTRUCTIONS ....................................... 3 7 FIGURE 1: REMOVE RELAYS R2-218 AND R2-219 - FORWARD CARGO COMPARTMENT, LEFT SIDE [Group 3] ............................................ 4 3 FIGURE 2: INSTALL BRACKETS AND TRACK - E/E COMPARTMENT, AFT LEFT RADIO RACK [Group 1 - 2 ] ............................................... 4 5 FIGURE 3: INSTALL BRACKETS AND TRACK - E/E COMPARTMENT, AFT LEFT RADIO RACK [Group 3 ] ................................................ 4 9 FIGURE 4: REMOVE RELAYS R2-336, R2-337 AND RECEPTACLES R5-406, R5-407 - ELECTRICAL POWER CENTER [Group 2] .................................. 5 3 F I G U R E 5 : C E N T E R T A N K F U E L B O O S T W I R E C H A N G E S [ G r o u p 1 ] ................. 5 5 F I G U R E 6 : C E N T E R T A N K F U E L B O O S T W I R E C H A N G E S [ G r o u p 2 ] ................. 6 2 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
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FIGURE 7: CENTER AND AUX FUEL BOOST AND TRANSFER WIRE CHANGES [Group 3] .... 6 8 FIGURE 8: INSTALL GFI RELAYS AND RECEPTACLES - E/E COMPARTMENT, AFT LEFT RADIO RACK [Group 1] ............................................ 8 1 FIGURE 9: INSTALL GFI RELAYS AND RECEPTACLES - E/E COMPARTMENT, AFT LEFT RADIO RACK [Group 2] ............................................ 8 4 FIGURE 10: INSTALL GFI RELAYS AND RECEPTACLES - E/E COMPARTMENT, AFT LEFT RADIO RACK [Group 3] ............................................ 8 7 APPENDIX A: GFI CENTER FUEL TANK PUMPS CONTROL CIRCUIT, AND CENTER FUEL TANK PUMPS LOW PRESSURE INDICATION SYSTEM TEST PROCEDURES [Group 1] ........ 9 2 APPENDIX B: GFI CENTER FUEL TANK PUMPS CONTROL CIRCUIT, AND CENTER FUEL TANK PUMPS LOW PRESSURE INDICATION SYSTEM TEST PROCEDURES [Group 2] ....... 1 0 5 APPENDIX C: GFI CENTER/AUX FUEL TANK PUMPS CONTROL CIRCUIT, AND CENTER/AUX FUEL TANK PUMPS LOW PRESSURE INDICATION SYSTEM TEST PROCEDURES [Group 3] . . . 119 APPENDIX D: BOEING PART DEMAND INTENT ............................. 1 4 0 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
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Commercial Airplanes MD90 Service Bulletin Revision Transmittal SheetNumber: MD90-28-013Original Issue: September 27, 2013 Revision 1: August 27, 2015 ATA System: 2800 SUBJECT: FUEL - Fuel Systems - Install Ground Fault Interrupter Relays and Change Fuel Pump System Wiring This revision includes all pages of the service bulletin.
COMPLIANCE INFORMATION RELATED TO THIS REVISION Federal Aviation Administration (FAA) Airworthiness Directive AD 2012-18-05 is related to this service bulletin.
Effects of this Revision on airplanes on which Original Issue was previously done:
None.
REASON FOR REVISION This revision is sent to incorporate engineering released after the original issue of this service bulletin to address the no work conditions due to Ground Fault Interrupter (GFI) panel washers, GFI panel mounting holes too small, wire assembly routing and process issues encountered during validation of the original issue of this service bulletin.
The data given in Information Notice MD90-28-013 IN 01 is included in this revision.
As a part of a service bulletin validation program, this installation was completed on airplane fuselage number 2097 by Service Bulletin MD90-28-013 Original Issue before the release of Revision 1 of this service bulletin.
The installation/change completed on airplane fuselage number 2097 by Service Bulletin MD90-28-013 Original Issue is equivalent to the release of Revision 1 of this service bulletin. Airplane fuselage number 2097 has the configuration of a Group 1 airplane.
These sections were changed:
1. In Background, added Boeing Fleet Team Digest (FTD) statement.
2. In Background, added Summary Evaluation Table.
3. In Paragraph 1.C., Reason, added statements.
4. In Paragraph 1.D., Description, added Compliance statement.
5. In Paragraph 1.G., Manpower, updated Manpower.
6. In Paragraph 1.H., Weight and Balance Changes, updated Group 1 through Group 3, information.
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: September 27, 2013 MD90-28-013Revision 1: August 27, 2015 5 of 140
7. In Paragraph 1.J.1., Existing Data: added additional references.
8. In Paragraph 1.J.2.a., Drawings: changed drawing revision.
9. In Paragraph 1.J.3., Installation Drawings Used in the preparation of this Service Bulletin: changed drawing revision.
10. In Paragraph 1.K.1., Publications: updated information.
11. In Paragraph 2.A., Material - Price and Availability, added survey information.
12. In Paragraph 2.C.1., Kits/Parts, Group 1 through Group 3, Service KIt, updated information.
13. In Paragraph 2.C.2., Parts and Materials Supplied by the Operator, added part information.
14. In Paragraph 2.C.3., Parts Modified and Reidentified, Group 1 through Group 3, added parts.
15. In Paragraph 3.A., General Information, Note: added new note.
16. In paragraph 3.B., Work Instructions, Group 1 through Group 3, added instructions.
17. In Figure 5 through Figure 7, added a reference.
18. In Figure 8, changed view A and B and added view C.
19. In Figure 8, changed part number and added footnotes (b), (c), (d) and (e).
20. In Figure 9, changed view A and B and added view C.
21. In Figure 9, changed part number and added footnotes (b), (c), (d) and (e).
22. In Figure 10, changed view A and B and added view C.
23. In Figure 10, changed part number and added footnotes (b), (c), (d) and (e).
24. Added Appendix D.
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 September 27, 2013Original Issue:
August 27, 2015Revision 1:
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
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Commercial Airplanes MD90 Service Bulletin SummaryNumber: MD90-28-013Original Issue: September 27, 2013 Revision 1: August 27, 2015 ATA System: 2800 SUBJECT: FUEL - Fuel Systems - Install Ground Fault Interrupter Relays and Change Fuel Pump System Wiring
CONCURRENT REQUIREMENTS None.
BACKGROUND Frictional heating or sparking may develop from fuel pump failure, wear of fuel pump rotating components, or ingestion of debris by the pump. Electrical faults in a fuel pump may result in electrical arc burn through of a fuel pump. Frictional heating or sparking and electrical arc burn through in fuel pump inlets or priming system outlets exposed (i.e. not covered by fuel) to the tank ullage in combination with the ullage being flammable, may result in a fuel tank ignition event. A fuel tank ignition event could develop with a pump running in an empty tank if the normal shutoff command is delayed or as a result of control system failures that keep the pump in a latent uncommanded running condition. Center wing fuel tanks and auxiliary fuel tank may be subject to this condition since they are normally pumped dry over the course of a flight. If not corrected frictional heating or sparking, electrical arc burn through, or a fuel tank pump running in an empty fuel tank may result in a fuel tank ignition event.
This service bulletin is the result of the safety assessments conducted by Boeing under a Special Federal Aviation Regulation (SFAR) 88, Fuel Tank System Fault Tolerance Evaluation Requirements.
Boeing Fleet Team Digest (FTD) MD90 FTD 28-03001 and MD90 FTD 28-12002 are related to this service bulletin.
This table is provided to operators for planning purposes only. Refer to the applicable sections for more information.
ReferenceAffectedPlanning Data Paragraph 1.A.2., Spares AffectedNoSpares Affected Paragraph 1.E., Compliance and Paragraph
1.F., Approval YesAD Related Paragraph 1.H., Weight and Balance ChangesYesWeight and Balance Change Paragraph 1.I., Electrical Load DataYesElectrical Load Changed Paragraph 1.K., Publications AffectedYesPublications Affected Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
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ReferenceAffectedPlanning Data Paragraph 1.K., Publications AffectedYesAirplane Flight Operations Affected (Flight Crew Operations Manual and/or FAA Approved Airplane Flight Manual) Paragraph 2.C.1., Kits/PartsYesKits/Parts Required Paragraph 2.C.2., Parts and Materials Supplied by the Operator YesOperator Supplied Parts/Material Paragraph 2.F., Special Tooling Necessary to do this Service Bulletin NoSpecial Tooling Required ACTION This service bulletin installs Ground Fault Interrupter (GFI) relays and cuts/coils/stows wires to center wing and auxiliary fuel tank pump motor neutral circuits.
EFFECTIVITY MD90-30 Airplanes. Refer to Paragraph 1.A.1., Airplanes, for the list of affected airplanes.
COMPLIANCE Federal Aviation Administration (FAA) Airworthiness Directive AD 2012-18-05 is related to this service bulletin.
Boeing recommends that the change given in this service bulletin be done within 60 months after the effective date of AD 2012-18-05.
INDUSTRY SUPPORT INFORMATION Boeing warranty remedies are not available for the configuration changes given in this service bulletin.
MANPOWER Elapsed HoursTotal Task HoursGroup
31.058.01
24.445.32
73.7142.73
MATERIAL INFORMATION Boeing Supplied Kits/Parts.
Refer to Paragraph 2.A., Material - Price and Availability.
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
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BOEING SERVICE BULLETIN MD90-28-013
INSTALL GROUND FAULT INTERRUPTER RELAYS
AND CHANGE FUEL PUMP SYSTEM WIRING 1885979 Original Issue: September 27, 2013 Revision 1: August 27, 2015 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished MD90-28-013 Work - See page 1 for details. 9 of 140
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
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Commercial Airplanes MD90 Service Bulletin Number: MD90-28-013 Original Issue: September 27, 2013 Revision 1: August 27, 2015 ATA System: 2800 SUBJECT: FUEL - Fuel Systems - Install Ground Fault Interrupter Relays and Change Fuel Pump System Wiring
1. PLANNING INFORMATION A. Effectivity
1. Airplanes This service bulletin is for the airplanes shown below.
DESCRIPTIONCONFIGURATIONGROUP Airplanes that install GFI relays for center fuel tank boost pumps which are affected by SR90280011-7001 drawing configuration.
-1 Airplanes that install GFI relays for center fuel tank boost pumps which are affected by SR90280011-7003 drawing configuration.
-2 Airplanes that install GFI relays for center fuel tank and forward auxiliary fuel tank boost pumps which are affected by SR90280011-7005 drawing configuration.
-3 Airplane Models:
MD-90-30 GroupFuselage Number 12094 - 2099 12100 12115 12117 12120 12122 - 2123 12125 - 2126 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: September 27, 2013 MD90-28-013Revision 1: August 27, 2015 11 of 140
GroupFuselage Number 12129 12131 12133 12136 12138 12140 - 2144 12146 - 2147 12149 - 2150 12153 - 2154 12156 - 2159 12161 - 2166 12169 - 2171 12173 12175 12177 12179 12181 - 2182 12184 12186 12190 22191 12193 - 2195 12197 - 2198 12200 12202 - 2203 22205 12207 22209 12210 - 2212 22213 22215 - 2216 12217 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
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