Boeing ASB MD90-29A021: U.S. DOT/FAA - SB-MD90-29A021-02, text

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Commercial Airplanes MD90 Service Bulletin ALERT Number: MD90-29A021 Original Issue: May 15, 2007 Revision 2: March 16, 2010 ATA System: 2920 SUBJECT: HYDRAULIC POWER - Auxiliary Hydraulic Power System - Replaces the Auxiliary Hydraulic Pump Wire Harness and Changes Routing Installation Export of this technology is controlled under the United States Export Administration Regulations (EAR) (15 CFR 730-774). An export license may be required before it is used for development, production or use by foreign persons from specific countries. The controller of this data has the individual responsibility to abide by all export laws.

9E991ECCN:

BOEING PROPRIETARY, CONFIDENTIAL, AND/OR TRADE SECRET Copyright © 2007 The Boeing Company Unpublished Work - All Rights Reserved Boeing claims copyright in each page of this document only to the extent that the page contains copyrightable subject matter. Boeing also claims copyright in this document as a compilation and/or collective work.

This document includes proprietary information owned by The Boeing Company and/or one or more third parties.

Treatment of the document and the information it contains is governed by contract with Boeing. For more information, contact The Boeing Company, P.O. Box 3707, Seattle, Washington 98124.

Boeing, the Boeing signature, the Boeing symbol, 707, 717, 727, 737, 747, 757, 767, 777, 787, Dreamliner, BBJ, DC-8, DC-9, DC-10, KC-10, KDC-10, MD-10, MD-11, MD-80, MD-88, MD-90, P-8A, Poseidon and the Boeing livery are all trademarks owned by The Boeing Company; and no trademark license is granted in connection with this document unless provided in writing by Boeing.

Original Issue: May 15, 2007 MD90-29A021Revision 2: March 16, 2010 1 of 81

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Original Issue: May 15, 2007 MD90-29A021Revision 2: March 16, 2010 2 of 81 BOEING SERVICE BULLETIN MD90-29A021

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Table of Contents

Revision Transmittal Sheet5

Summary7

1. PLANNING INFORMATION9

A. Effectivity9

1. Airplanes9

2. Spares Affected ........................................ 1 2 B. Concurrent Requirements ...................................... 1 2 C. Reason ................................................ 1 2 D. Description .............................................. 1 2 E. Compliance .............................................. 1 3 F. Approval ............................................... 1 3 G. Manpower .............................................. 1 3 H. Weight and Balance Changes .................................... 1 5 I. Electrical Load Data ......................................... 1 5 J. References .............................................. 1 6

1. Existing Data: ......................................... 1 6

2. Data supplied with this Service Bulletin: ........................... 1 6

3. Installation Drawings Used in the Preparation of this Service Bulletin: ........... 1 6 K. Publications Affected ........................................ 1 6 L. Interchangeability and Intermixability of Parts ........................... 1 7

2. MATERIAL INFORMATION ........................................ 1 9 A. Material - Price and Availability ................................... 1 9 B. Industry Support Information .................................... 2 0 C. Parts Necessary For Each Airplane ................................. 2 0

1. Kits/Parts: ........................................... 2 0

2. Parts and Materials Supplied by the Operator: ........................ 2 3

3. Parts Modified and Reidentified: ............................... 2 4

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

3. ACCOMPLISHMENT INSTRUCTIONS .................................. 2 5 A. GENERAL INFORMATION ..................................... 2 5 B. WORK INSTRUCTIONS ....................................... 2 6 FIGURE 1: AUXILIARY HYDRAULIC PUMP WIRE HARNESS - REMOVAL [Group 1, Configuration 1-2;

Group 2, Configuration 1] ................................... 3 4 FIGURE 2: AUXILIARY HYDRAULIC PUMP WIRE HARNESS - SUPPORT BRACKETS - INSTALL [Group 1, Configuration 1-2; Group 2, Configuration 1] ........................ 3 7 FIGURE 3: AUXILIARY HYDRAULIC PUMP WIRE HARNESS - INSTALL [Group 1, Configuration 2; Group 2, Configuration 1] ....................................... 4 1 FIGURE 4: ELECTRICAL WIRING DIAGRAM - TERMINATE WIRE HARNESS [Group 1, Configuration 1-2;

Group 2, Configuration 1] ................................... 4 7 FIGURE 5: CLAMPS COMMON TO EXISTING WIRE HARNESSES - INSTALL [Group 1, Configuration 1-2; Group 2, Configuration 1] ................................. 4 8 FIGURE 6: AUXILIARY HYDRAULIC PUMP WIRE HARNESS - SUPPORT BRACKET AND CLAMP - INSTALLATION [Group 1, Configuration 3] .......................... 5 1

Original Issue: May 15, 2007 MD90-29A021Revision 2: March 16, 2010 3 of 81 BOEING SERVICE BULLETIN MD90-29A021

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FIGURE 7: AUXILIARY HYDRAULIC PUMP WIRE HARNESS - SUPPORT BRACKET AND CLAMP - INSTALLATION [Group 1, Configuration 3-4; Group 2, Configuration 2] .......... 5 7 FIGURE 8: AUXILIARY HYDRAULIC PUMP WIRE HARNESS - WIRE HARNESS - INSTALLATION [Group 1, Configuration 1] ....................................... 6 1 FIGURE 9: AUXILIARY HYDRAULIC PUMP WIRE HARNESS - SUPPORT CLAMP - INSTALLATION [Group 1, Configuration 3-5; Group 2, Configuration 2-3] .................. 7 3 FIGURE 10: AUXILIARY HYDRAULIC PUMP WIRE HARNESS - CHECK ELECTRICAL RESISTANCE [Group 1, Configuration 3-5; Group 2, Configuration 2-3] .................. 7 5 FIGURE 11: AUXILIARY HYDRAULIC PUMP WIRE HARNESS - SLEEVING - INSPECTION/INSTALLATION [Group 1, Configuration 3-5; Group 2, Configuration 2-3] .................. 7 9

Original Issue: May 15, 2007 MD90-29A021Revision 2: March 16, 2010 4 of 81 BOEING SERVICE BULLETIN MD90-29A021

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Commercial Airplanes MD90 Service Bulletin ALERT Revision Transmittal SheetNumber: MD90-29A021Original Issue: May 15, 2007 Revision 2: March 16, 2010 ATA System: 2920 SUBJECT: HYDRAULIC POWER - Auxiliary Hydraulic Power System - Replaces the Auxiliary Hydraulic Pump Wire Harness and Changes Routing Installation This Revision includes all pages of the service bulletin.

COMPLIANCE INFORMATION RELATED TO THIS REVISION More work is necessary on airplanes changed in accordance with the original issue or Revision 1 of this service bulletin. The additional work involves checking electrical resistance, adding new clamps at two positions, adding sleeving to the wire harness if its missing, and adding red tape to the connector end of the wire harness if its missing. An additional 3.0 hours is required to complete the additional work described in this revision of this service bulletin.

Federal Aviation Administration (FAA) Airworthiness Directive AD 2009-07-04 is related to this service bulletin.

REASON FOR REVISION This revision is sent to incorporate engineering released subsequent to Revision 1 of this service bulletin, which changes the wire harness clamp and sleeving installation. The data given in Information Notices MD90-29A021 IN 03 and MD90-29A021 IN 04 are included in this revision.

These sections were changed:

1. In Paragraph 1.A., Effectivity, changed group configuration table to reflect correct requirements.

2. In Paragraph 1.E., Compliance, added FAA Airworthiness Directive AD 2009-07-04 and changed compliance time.

3. In Paragraph 1.F., Approval, changed approval statement.

4. In Paragraph 1.G., Manpower, changed manpower tables.

5. In Paragraph 1.J.1., Existing Data, added FAA Airworthiness Directive AD 2009-07-04 and Boeing Multiple Operator Message (MOM) MOM-MOM-10-0034.

6. In Paragraph 1.J.3., Installation Drawings Used in the Preparation of this Service Bulletin, changed drawing revision level.

7. In Paragraph 1.K., Publications, added Damage Tolerance Based Structural Inspections statement.

Original Issue: May 15, 2007 MD90-29A021Revision 2: March 16, 2010 5 of 81

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8. In Paragraph 2.A., Material - Price and Availability, changed kit numbers, kit pricing and expiration date.

9. In Paragraph 2.C.1., Kits/Parts, changed kit applicability and parts lists to reflect correct requirements.

10. In Paragraph 2.C.2., Parts and Materials Supplied by the Operator, added new required materials.

11. In Paragraph 3., Accomplishment Instructions:

a. Added new General Information notes.

b. Changed Work Instructions to reflect correct requirements.

c. Changed Figures 1, 2, 3, 5, 6, 7, 8, 9 to reflect correct requirements.

d. Changed Figure 10.

e. Added Figure 11.

Vertical lines are put on the left edge of each page, except in Paragraph 1.A., Effectivity, to show the location of important changes.

Pages with no vertical lines have no important changes.

REVISION HISTORY May 15, 2007Original Issue:

August 29, 2008Revision 1:

March 16, 2010Revision 2:

Original Issue: May 15, 2007 MD90-29A021Revision 2: March 16, 2010 6 of 81 BOEING SERVICE BULLETIN MD90-29A021

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Commercial Airplanes MD90 Service Bulletin ALERT SummaryNumber: MD90-29A021Original Issue: May 15, 2007 Revision 2: March 16, 2010 ATA System: 2920 SUBJECT: HYDRAULIC POWER - Auxiliary Hydraulic Power System - Replaces the Auxiliary Hydraulic Pump Wire Harness and Changes Routing Installation

THIS BULLETIN IS SENT TO THE OPERATORS OF RECORD OF THE AIRPLANES SHOWN IN PARAGRAPH

1.A., EFFECTIVITY. IF AN AIRPLANE HAS BEEN LEASED OR SOLD, SEND THIS SERVICE BULLETIN TO THE NEW OPERATOR. IF APPLICABLE SPARES HAVE BEEN SOLD, SEND THIS SERVICE BULLETIN TO THE NEW OWNER.

CONCURRENT REQUIREMENTS None.

BACKGROUND On MD-80 airplanes three operators have reported three instances of electrically shorted wires in the right wheel well and evidence of arcing on the auxiliary hydraulic pump power cables. One incident resulted in a fire in the wheel well. Investigation revealed damage to the power cables was caused by structural chafing. In addition, the Special Federal Aviation Regulation (SFAR) 88 analysis determined that extra protection is required on the auxiliary hydraulic pump wire harness assembly where it comes in close proximity to the center fuel tank. MD-90 airplanes have a similar installation and Boeing analysis determined that the existing auxiliary hydraulic pump wire harness assembly is routed within the tire burst area. A new and longer auxiliary hydraulic pump wire harness assembly installed and routed outside the "tire burst" area will minimize the possibility of chaffing and electrical wire arcing damage. If not corrected, electrical arcing and/or shorted wires could result in a wheel well fire and/or hazard to the adjacent fuel tank.

This service bulletin is the result of the safety assessments conducted by Boeing under SFAR 88, "Fuel Tank System Fault Tolerance Evaluation Requirements".

ACTION This service bulletin provides instructions to install a new auxiliary hydraulic pump wire harness assembly and route it outside of the "tire burst" area.

EFFECTIVITY MD-90-30 Airplanes. Refer to Paragraph 1.A.1., Airplanes, for the list of affected airplanes.

COMPLIANCE Federal Aviation Administration (FAA) Airworthiness Directive AD 2009-07-04 is related to this service bulletin.

Original Issue: May 15, 2007 MD90-29A021Revision 2: March 16, 2010 7 of 81

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Boeing recommends that operators accomplish this service bulletin within 18 months after the date of Revision 2 on this service bulletin.

INDUSTRY SUPPORT INFORMATION Boeing warranty remedies are available only for installation of the missing support bracket and installation of an additional wire harness assembly support clamp for the affected airplanes (described in MD90-29A021 Revision 1) in warranty as of January 1, 2000. Please refer to Paragraph 2.B., Industry Support Information.

MANPOWER Refer to Paragraph 1.G., Manpower.

MATERIAL INFORMATION Boeing supplied Parts/Materials.

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

Original Issue: May 15, 2007 MD90-29A021Revision 2: March 16, 2010 8 of 81 BOEING SERVICE BULLETIN MD90-29A021

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THIS BULLETIN IS SENT TO THE OPERATORS OF RECORD OF THE AIRPLANES SHOWN IN PARAGRAPH

1.A., EFFECTIVITY. IF AN AIRPLANE HAS BEEN LEASED OR SOLD, SEND THIS SERVICE BULLETIN TO THE NEW OPERATOR. IF APPLICABLE SPARES HAVE BEEN SOLD, SEND THIS SERVICE BULLETIN TO THE NEW OWNER.

1. PLANNING INFORMATION A. Effectivity

1. Airplanes This service bulletin is for the airplanes shown below.

NOTE: The intent of this service bulletin was accomplished on fuselage number 2094 prior to the release of the original issue, at an operator's facility during a service bulletin validation.

The intent of this service bulletin was accomplished on fuselage number 2117 prior to the release of Revision 2, at an operator's facility during a service bulletin validation.

Original Issue: May 15, 2007 MD90-29A021Revision 2: March 16, 2010 9 of 81

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DESCRIPTIONCONFIGURATIONGROUP MD-90 Airplanes with fuselage numbers 2018 through 2249.-1 Airplanes that have not accomplished the original issue or Revision 1 of this service bulletin and have not accomplished Service Bulletin MD90-29-012.

1 Airplanes that have not accomplished the original issue or Revision 1 of this service bulletin and have accomplished Service Bulletin MD90-29-012.

2 Airplanes that have accomplished the original issue of this service bulletin and have not accomplished Service Bulletin MD90-29-012.

3 Airplanes that have accomplished the original issue of this service bulletin and have accomplished Service Bulletin MD90-29-012.

4 Airplanes that have accomplished Revision 1 of this service bulletin.5 MD-90 Airplanes with fuselage numbers 2250 and higher.-2 Airplanes that have not accomplished the original issue or Revision 1 of this service bulletin.

1 Airplanes that have accomplished the original issue of this service bulletin.

2 Airplanes that have accomplished Revision 1 of this service bulletin.3 Airplane Models:

MD-90-30 GroupFuselage Number 12094 - 2100 12115 12117 12120 12122 - 2123 12125 - 2126 12129 12131 12133

Original Issue: May 15, 2007 MD90-29A021Revision 2: March 16, 2010 10 of 81 BOEING SERVICE BULLETIN MD90-29A021

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GroupFuselage Number 12136 12138 12140 - 2144 12146 - 2147 12149 - 2150 12153 - 2154 12156 - 2159 12161 - 2166 12169 - 2171 12173 12175 12177 12179 12181 12184 12186 12190 - 2191 12193 - 2195 12197 - 2198 12200 12202 - 2203 12205 12207 12209 - 2213 12215 - 2217 12219 - 2233 12235 - 2237 12240 12243 12245 12248 22250 - 2251

Original Issue: May 15, 2007 MD90-29A021Revision 2: March 16, 2010 11 of 81 BOEING SERVICE BULLETIN MD90-29A021

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GroupFuselage Number 22253 22255 - 2263 22288 - 2290 24001 - 4002

2. Spares Affected None.

B. Concurrent Requirements None.

C. Reason On MD-80 airplanes three operators have reported three instances of electrically shorted wires in the right wheel well and evidence of arcing on the auxiliary hydraulic pump power cables. One incident resulted in a fire in the wheel well. Investigation revealed damage to the power cables was caused by structural chafing. In addition, the Special Federal Aviation Regulation (SFAR) 88 analysis determined that extra protection is required on the auxiliary hydraulic pump wire harness assembly where it comes in close proximity to the center fuel tank. MD-90 airplanes have a similar installation and Boeing analysis determined that the existing auxiliary hydraulic pump wire harness assembly is routed within the tire burst area. A new and longer auxiliary hydraulic pump wire harness assembly installed and routed outside the "tire burst" area will minimize the possibility of chaffing and electrical wire arcing damage.

If not corrected, electrical arcing and/or shorted wires could result in a wheel well fire and/or hazard to the adjacent fuel tank.

This service bulletin is the result of the safety assessments conducted by Boeing under SFAR 88, "Fuel Tank System Fault Tolerance Evaluation Requirements".

Revision 1 was sent to give instructions to install a wire harness assembly support bracket in the right wheel well on all MD-90 airplanes if/when it is missing, install an additional wire harness assembly support clamp, install a support and bracket for Group 1 airplanes that have not accomplished Service Bulletin MD90-29-012, and to inspect wire harness assembly protective sleeving dimensions. The data given in Information Notices MD90-29A021 IN 01 and MD90-29A021 IN 02 are included in this revision.

Revision 2 is sent to incorporate engineering released subsequent to Revision 1 of this service bulletin, which changes the wire harness clamp and sleeving installation. The data given in Information Notices MD90-29A021 IN 03 and MD90-29A021 IN 04 are included in this revision.

D. Description This service bulletin provides instructions to install a new auxiliary hydraulic pump wire harness assembly and route it outside of the "tire burst" area.

Original Issue: May 15, 2007 MD90-29A021Revision 2: March 16, 2010 12 of 81 BOEING SERVICE BULLETIN MD90-29A021

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