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Commercial Airplanes DC10 Service Bulletin Number: DC10-28-264 Original Issue: May 15, 2015 ATA System: 2822 SUBJECT: FUEL - Engine Fuel Supply - Replace Fuel Pump Housing Electrical Connectors 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 © 2015 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Unpublished Work.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: May 15, 2015 DC10-28-264 1 of 207
2.0
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: May 15, 2015 DC10-28-264 2 of 207 BOEING SERVICE BULLETIN DC10-28-264
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Table of Contents
S u m m a r y5
1. PLANNING INFORMATION9
A . E f f e c t i v i t y9
1. Airplanes9
2 . S p a r e s A f f e c t e d ........................................ 1 5 B. Concurrent Requirements ...................................... 1 5 C. Reason ................................................ 1 5 D. Description .............................................. 1 6 E. Compliance .............................................. 1 7 F . A p p r o v a l ............................................... 1 7 G. Manpower .............................................. 1 9 H. Weight and Balance Changes .................................... 3 3 I. Electrical Load Data ......................................... 3 4 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 5
3. Installation Drawings Used in the Preparation of this Service Bulletin: ........... 3 5 K. Publications Affected ........................................ 3 5 L. Interchangeability and Intermixability of Parts ........................... 3 6 M. Software Accomplishment Summary ................................ 3 6
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 ........................ 4 1
3. Parts Modified and Reidentified ................................ 4 3
4. Parts Removed and Not Replaced .............................. 4 3 D. Parts Necessary to Change Spares ................................. 4 3 E. Special Tooling - Price and Availability ............................... 4 3 F. Special Tooling Necessary to do this Service Bulletin ....................... 4 3
3. ACCOMPLISHMENT INSTRUCTIONS .................................. 4 5 A. GENERAL INFORMATION ..................................... 4 5 B. WORK INSTRUCTIONS ....................................... 4 8 FIGURE 1: FUEL PUMP HOUSING - IDENTIFY PROTECTIVE CAP TYPE .............. 6 8 FIGURE 2: BENCH WORK - MAKE ALIGNMENT PINS ......................... 7 1 FIGURE 3: LEFT WING REAR SPAR - DISCONNECT FUEL PUMP WIRES .............. 7 2 FIGURE 4: LEFT WING FORWARD SPAR - DISCONNECT FUEL PUMP WIRES ........... 7 5 FIGURE 5: RIGHT WING FORWARD SPAR - DISCONNECT FUEL PUMP WIRES .......... 7 9 FIGURE 6: RIGHT WING REAR SPAR - DISCONNECT FUEL PUMP WIRES ............. 8 3 FIGURE 7: CENTER WING REAR SPAR (UPPER AUX TANK) - DISCONNECT FUEL PUMP WIRES [Group 1-4] ........................................... 8 6 FIGURE 8: CENTER WING REAR SPAR (LOWER AUX TANK) - DISCONNECT FUEL PUMP WIRES [Group 2-4] ........................................... 8 9 F I G U R E 9 : A F T A U X T A N K - D I S C O N N E C T F U E L P U M P W I R E S [ G r o u p 3 ] .............. 9 3 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
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F I G U R E 1 0 : F O R W A R D F U S E L A G E T A N K - D I S C O N N E C T F U E L P U M P W I R E S [ G r o u p 4 ] ..... 9 7 FIGURE 11: AFT FUSELAGE TANK - DISCONNECT FUEL PUMP WIRES [Group 4] ......... 1 0 0 FIGURE 12: LEFT WING TANK 1 TIP - DISCONNECT FUEL PUMP WIRES [Group 4] ........ 1 0 3 F I G U R E 1 3 : R I G H T W I N G T A N K 3 T I P - D I S C O N N E C T F U E L P U M P W I R E S [ G r o u p 4 ] ....... 1 0 6 FIGURE 14: CHANGE FUEL PUMP HOUSING ELECTRICAL CONNECTOR OPTION 1, CONDITION 1 - A L L P U M P S .......................................... 1 0 9 FIGURE 15: CHANGE FUEL PUMP HOUSING ELECTRICAL CONNECTOR OPTION 1, CONDITION 2 ( R E Q U I R E S T A N K E N T R Y ) - A L L P U M P S ......................... 1 1 3 FIGURE 16: CHANGE FUEL PUMP HOUSING OPTION 2 (REQUIRES TANK ENTRY) - ALL PUMPS . 117 FIGURE 17: LEFT WING REAR SPAR - ROUTE AND CLIP FUEL PUMP WIRES ........... 1 2 2 FIGURE 18: LEFT WING FWD SPAR - ROUTE AND CLIP FUEL PUMP WIRES ........... 1 2 5 FIGURE 19: RIGHT WING FWD SPAR - ROUTE AND CLIP FUEL PUMP WIRES ........... 1 2 9 FIGURE 20: RIGHT WING REAR SPAR - ROUTE AND CLIP FUEL PUMP WIRES .......... 1 3 3 FIGURE 21: CENTER WING REAR SPAR (UPPER AUX TANK) - ROUTE AND CLIP FUEL PUMP WIRES [Group 1-4] .......................................... 1 3 6 FIGURE 22: CENTER WING REAR SPAR (LOWER AUX TANK) - ROUTE AND CLIP FUEL PUMP WIRES [Group 2-4] .......................................... 1 3 9 FIGURE 23: AFT AUX TANK - ROUTE AND CLIP FUEL PUMP WIRES [Group 3] ........... 1 4 3 FIGURE 24: FORWARD FUSELAGE TANK- ROUTE AND CLIP FUEL PUMP WIRES [Group 4] . . . 147 FIGURE 25: AFT FUSELAGE TANK - ROUTE AND CLIP FUEL PUMP WIRES [Group 4] ....... 1 5 1 F I G U R E 2 6 : L E F T W I N G T A N K 1 T I P - R O U T E A N D C L I P F U E L P U M P W I R E S [ G r o u p 4 ] ...... 1 5 5 FIGURE 27: RIGHT WING TANK 3 TIP - ROUTE AND CLIP FUEL PUMP WIRES [Group 4] ..... 1 5 8 FIGURE 28: LEFT WING REAR SPAR - TERMINATE FUEL PUMP WIRES .............. 1 6 1 FIGURE 29: LEFT WING FORWARD SPAR - TERMINATE FUEL PUMP WIRES ........... 1 6 5 FIGURE 30: RIGHT WING FORWARD SPAR - TERMINATE FUEL PUMP WIRES .......... 1 6 8 FIGURE 31: RIGHT WING REAR SPAR - TERMINATE FUEL PUMP WIRES ............. 1 7 1 FIGURE 32: CENTER WING REAR SPAR UPPER AUXILIARY TANK - TERMINATE FUEL PUMP WIRES [Group 1-4] .......................................... 1 7 5 FIGURE 33: CENTER WING REAR SPAR LOWER AUXILIARY TANK - TERMINATE FUEL PUMP WIRES [Group 2-4] .......................................... 1 7 8 F I G U R E 3 4 : A F T A U X I L I A R Y T A N K - T E R M I N A T E F U E L P U M P W I R E S [ G r o u p 3 ] .......... 1 8 1 FIGURE 35: FORWARD FUSELAGE TANK - TERMINATE FUEL PUMP WIRES [Group 4] ...... 1 8 4 F I G U R E 3 6 : A F T F U S E L A G E T A N K - T E R M I N A T E F U E L P U M P W I R E S [ G r o u p 4 ] .......... 1 8 6 F I G U R E 3 7 : L E F T W I N G T A N K 1 T I P - T E R M I N A T E F U E L P U M P W I R E S [ G r o u p 4 ] ......... 1 8 8 FIGURE 38: RIGHT WING TANK 3 TIP - TERMINATE FUEL PUMP WIRES [Group 4] ........ 1 9 0 APPENDIX A: 24 MONTH REPETITIVE INSPECTION ........................... 1 9 2 APPENDIX B: BOEING PART DEMAND INTENT - SURVEY ....................... 2 0 7 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
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Commercial Airplanes DC10 Service Bulletin SummaryNumber: DC10-28-264Original Issue: May 15, 2015 ATA System: 2822 SUBJECT: FUEL - Engine Fuel Supply - Replace Fuel Pump Housing Electrical Connectors
CONCURRENT REQUIREMENTS Refer to Paragraph 1.B., Concurrent Requirements.
BACKGROUND MD-11 and DC-10 operators have reported instances of fuel pump housing electrical connector failures related to ingress of airplane fluids. Currently installed fuel pump housing electrical connectors have 18 month repetitive inspection requirements related to Federal Aviation Administration (FAA) Airworthiness Directive (AD) 2011-11-05 and AD 2002-13-10. An improved fuel pump housing electrical connector has been developed in conjunction with Hydro-Aire to supersede the currently installed fuel pump housing electrical connectors. In addition to the new fuel pump housing electrical connector, the use of environmentally sealed terminal lugs will help to prevent the wicking of airplane fluids into the fuel pump wires and the fuel pump housing electrical connector. If not corrected, failure of the fuel pump housing electrical connector could result in a potential source of ignition in a fuel tank and consequent fire or explosion.
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) DC-10 FTD 28-11002, DC-10 FTD 28-12001 and DC-10 FTD 28-13003 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 AffectedYesSpares Affected Paragraph 1.E., Compliance and Paragraph
1.F., Approval YesAD Related 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 AffectedYesAirplane Flight Operations Affected (Flight Crew Operations Manual and/or FAA Approved Airplane Flight Manual) Paragraph 2.C.1., Kits/PartsYesKits/Parts Required Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: May 15, 2015 DC10-28-264 5 of 207
ReferenceAffectedPlanning Data 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 provides instructions to change/replace fuel pump housing electrical connectors or fuel pump housings, associated wires, feed-through components and install sealed terminal lugs on fuel pump wires as follows:
1. Remove fuel boost/transfer pumps (AC Pumping Units).
2. Do Option 1 or Option 2.
Option 1 (Replace Fuel Pump Housing Electrical Connector)
a. Identify the fuel pump housing protective cap type.
Condition 1 (Spring Mounted Protective Cap - Tank Entry Not Required)
(1) Change the fuel pump housing electrical connector, associated wires, fuel tank feed through components and install sealed terminal lugs on fuel pump wiring.
Condition 2 (No Spring Mounted Protective Cap - Tank Entry Required)
(1) Change the fuel pump housing electrical connector, associated wires, fuel tank feed through components and install sealed terminal lugs on fuel pump wiring.
Option 2 (Replace Fuel Pump Housing - Tank Entry Required)
a. Replace the fuel pump housing, associated wires, fuel tank feed through components and install sealed terminal lugs on fuel pump wiring (Tank entry required).
3. Install previously removed fuel boost/transfer pumps (AC Pumping Units).
EFFECTIVITY All DC-10-10, DC-10-10F, DC-10-15, DC-10-30, DC-10-30F, DC-10-30F (KC-10A), DC-10-30F (KDC-10), DC-10-40, DC-10-40F, MD-10-10F and MD-10-30F Airplanes. Refer to Paragraph 1.A.1., Airplanes, for the list of affected airplane(s).
Refer to Paragraph 1.A.2., Spares Affected for the list of affected components.
COMPLIANCE Boeing recommends that the change given in this service bulletin be done within 36 months after the original issue date of this service bulletin.
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: May 15, 2015 DC10-28-264 6 of 207 BOEING SERVICE BULLETIN DC10-28-264
The FAA will possibly release an AD related to this service bulletin. The AD will make the compliance tasks and times given in this service bulletin mandatory.
INDUSTRY SUPPORT INFORMATION Boeing warranty remedies are not available for the configuration changes 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.
Operators are encouraged to complete the survey provided in APPENDIX B of this service bulletin to help Boeing predict the quantity and timing of the Boeing Supplied Kits/Parts.
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: May 15, 2015 DC10-28-264 7 of 207 BOEING SERVICE BULLETIN DC10-28-264
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: May 15, 2015 DC10-28-264 8 of 207 BOEING SERVICE BULLETIN DC10-28-264
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Commercial Airplanes DC10 Service Bulletin Number: DC10-28-264 Original Issue: May 15, 2015 ATA System: 2822 SUBJECT: FUEL - Engine Fuel Supply - Replace Fuel Pump Housing Electrical Connectors
1. PLANNING INFORMATION A. Effectivity
1. Airplanes This service bulletin is for the airplanes shown below.
DESCRIPTIONCONFIGURATIONGROUP Airplanes with Auxiliary Upper Fuel Tank.-1 Airplanes with Auxiliary Upper and Lower Fuel Tanks.-2 Airplanes with Auxiliary Fuel Tanks and Aft Fuel Tank.-3 Airplanes with Auxiliary Fuel Tanks, Fwd and Aft Fuel Tanks.-4 Airplanes with Tank No. 1, Tank No. 2, and Tank No. 3 only.-5 Airplane Models:
DC-10-10, DC-10-10F, DC-10-15, DC-10-30, DC-10-30F, DC-10-30F (KC-10A), DC-10-30F (KDC-10), DC-10-40, DC-10-40F, MD-10-10F, MD-10-30F GroupFuselage Number 12 56 58 515 517 525 526 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
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GroupFuselage Number 527 532 533 534 535 539 540 541 542 543 555 559 260 561 562 165 570 271 172 576 578 183 586 589 290 296 299 2100 2103 2106 2110 5112 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
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GroupFuselage Number 2114 - 115 2117 5119 2122 - 123 2127 2129 2131 - 135 2137 5138 - 139 5140 5142 5144 - 145 2146 - 147 5148 2150 2152 5153 - 155 2156 - 158 2160 5162 2165 - 166 5169 2170 - 171 5173 2174 5177 2178 - 179 2183 - 184 2187 - 189 2190 2192 5194 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
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GroupFuselage Number 2195 - 196 5198 2199 2201 5203 2204 5205 2206 5207 - 209 5210 2211 - 216 2219 2220 - 221 2223 - 227 2229 2230 2232 2234 - 236 2239 2240 2242 2244 - 246 5247 2248 5249 5250 1251 - 252 2253 - 257 2261 - 268 5269 5270 - 273 2274 - 275 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
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