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Commercial Airplanes DC10 Service Bulletin Number: DC10-53-109 Original Issue: December 24, 1979 Revision 8: March 10, 2011 ATA System: 5350 SUBJECT: FUSELAGE - Aerodynamic Fairings - Install Electrical Bonding Straps on Extended Wing-to-Fuselage Fillets 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BOEING PROPRIETARY, CONFIDENTIAL, AND/OR TRADE SECRET Copyright © 1989 The Boeing Company Unpublished Work - All Rights Reserved Boeing claims copyright in each page of this document only to the extent that the page contains copyrightable subject matter.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.
BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: December 24, 1979 DC10-53-109Revision 8: March 10, 2011 1 of 122
8.0
BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: December 24, 1979 DC10-53-109Revision 8: March 10, 2011 2 of 122 BOEING SERVICE BULLETIN DC10-53-109
BLANK PAGE
Table of Contents
Revision Transmittal Sheet5
Summary7
1. PLANNING INFORMATION ........................................ 1 1 A. Effectivity ............................................... 1 1
1. Airplanes ............................................ 1 1
2. Spares Affected ........................................ 1 4 B. Concurrent Requirements ...................................... 1 5 C. Reason ................................................ 1 5 D. Description .............................................. 1 5 E. Compliance .............................................. 1 7 F. Approval ............................................... 1 7 G. Manpower .............................................. 1 8 H. Weight and Balance Changes .................................... 2 0 I. Electrical Load Data ......................................... 2 0 J. References .............................................. 2 0
1. Existing Data: ......................................... 2 0
2. Data supplied with this Service Bulletin: ........................... 2 0
3. Installation Drawings Used in the Preparation of this Service Bulletin: ........... 2 0
4. Process Data: ......................................... 2 1 K. Publications Affected ........................................ 2 1 L. Interchangeability and Intermixability of Parts ........................... 2 1
2. MATERIAL INFORMATION ........................................ 2 3 A. Material - Price and Availability ................................... 2 3 B. Industry Support Information .................................... 2 3 C. Parts Necessary For Each Airplane ................................. 2 3
1. Kits/Parts: ........................................... 2 3
2. Parts and Materials Supplied by the Operator: ........................ 3 0
3. Parts Modified and Reidentified: ............................... 3 1
4. Parts Removed and Not Replaced: .............................. 3 1 D. Parts Necessary to Change Spares ................................. 3 1 E. Special Tooling - Price and Availability ............................... 3 1 F. Special Tooling Necessary to do this Service Bulletin ....................... 3 1
3. ACCOMPLISHMENT INSTRUCTIONS .................................. 3 3 A. GENERAL INFORMATION ..................................... 3 3 B. WORK INSTRUCTIONS ....................................... 3 4 FIGURE 1: EXTENDED WING TO FUSELAGE FILLETS - INSTALLATION OF BONDING STRAPS [Group 1-4, Configuration 1] ...................................... 3 8 FIGURE 2: EXTENDED WING TO FUSELAGE FILLETS - REPLACEMENT OF BONDING STRAPS [Group 3-4, Configuration 2] ...................................... 5 7 FIGURE 3: EXTENDED WING TO FUSELAGE FILLETS - REPLACEMENT OF BONDING STRAPS [Group 1-2, Configuration 2] ...................................... 8 3 FIGURE 4: EXTENDED WING TO FUSELAGE FILLETS - REPLACEMENT OF ONE BONDING STRAP [Group 1-4, Configuration 3] ................................. 1 0 7 FIGURE 5: EXTENDED WING TO FUSELAGE FILLETS - EXISTING STRAP INSTALLATION INSPECTION ................................................. 1 1 0
BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: December 24, 1979 DC10-53-109Revision 8: March 10, 2011 3 of 122 BOEING SERVICE BULLETIN DC10-53-109
FIGURE 6: EXTENDED WING TO FUSELAGE FILLETS - INSTALLATION OF ONE BONDING STRAP ................................................. 1 1 3 FIGURE 7: EXTENDED WING TO FUSELAGE FILLETS - INSTALLATION OF ONE BONDING STRAP ................................................. 1 1 7 Appendix A: BONDING STRAP INSTALLATION PROCEDURE ..................... 1 2 2
BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: December 24, 1979 DC10-53-109Revision 8: March 10, 2011 4 of 122 BOEING SERVICE BULLETIN DC10-53-109
Commercial Airplanes DC10 Service Bulletin Revision Transmittal SheetNumber: DC10-53-109Original Issue: December 24, 1979 Revision 8: March 10, 2011 ATA System: 5350 SUBJECT: FUSELAGE - Aerodynamic Fairings - Install Electrical Bonding Straps on Extended Wing-to-Fuselage Fillets This revision includes all pages of the service bulletin.
COMPLIANCE INFORMATION RELATED TO THIS REVISION Federal Aviation Administration (FAA) Airworthiness Directive AD 2009-26-17 is related to this service bulletin.
More work is necessary on all airplanes changed in accordance with all previous revisions of this service bulletin.
The more work required installs a new braided bonding strap omitted from previous revisions of this service bulletin. An additional 8.8 task hours are required to do the work.
REASON FOR REVISION This revision is sent to include the requirement for a new braided bonding strap omitted from previous releases of this service bulletin and to reinstate airplanes inadvertently dropped from the effectivity.
These sections were changed:
1. In Paragraph 1.A., Effectivity, re-instated airplanes inadvertently dropped from effectivity, and added new Configurations for Groups 1 through 4.
2. In Paragraph 1.D., Description, added new Group/Configuration data, and description of additional work.
3. In Paragraph 1.E., Compliance, added new Federal Aviation Administration (FAA) Airworthiness Directive (AD).
4. In Paragraph 1.F., Approval, changed statement to reflect new revision, and added new Airworthiness Directive.
5. In Paragraph 1.G., Manpower, Changed Table for Configuration 3, added tables for new Group/Configuration data.
6. In Paragraph 1.J.1., Existing Data, added new AD.
7. In Paragraph 1.J.2., Data supplied with this Service Bulletin, changed drawing revision letter.
8. In Paragraph 1.J.3., Installation Drawings Used In the Preparation of This Service Bulletin, changed drawing revision letter.
BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: December 24, 1979 DC10-53-109Revision 8: March 10, 2011 5 of 122
9. In Paragraph 2.C., Parts Necessary for Each Airplane, added new tables for Group/Configuration identification, added new part number and changed supplier address.
10. In Paragraph 2.C.2., Parts and Materials Supplied by Operator, revised one part number quantity and changed supplier address.
11. In Paragraph 3.A., General Information, added new note.
12. In Paragraph 3.B., Work Instructions, added new work instructions for existing Group/Configurations and new Group/Configuration.
13. In Figure 1, changed illustrations and added new work steps to show additional work.
14. In Figure 2, changed illustrations and added new work steps to show additional work.
15. In Figure 3, changed illustrations and added new work steps to show additional work.
16. In Figure 4, added parts inadvertently omitted from previous revisions to work step table.
17. Added new Figures 5, 6 and 7 to show additional work.
18. In Appendix, clarified work requirements.
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 December 24, 1979Original Issue:
August 14, 1981Revision 1:
October 28, 1983Revision 2:
November 14, 1986Revision 3:
October 07, 1992Revision 4:
March 19, 2008Revision 5:
July 10, 2008Revision 6:
March 03, 2009Revision 7:
March 10, 2011Revision 8:
BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: December 24, 1979 DC10-53-109Revision 8: March 10, 2011 6 of 122 BOEING SERVICE BULLETIN DC10-53-109
Commercial Airplanes DC10 Service Bulletin SummaryNumber: DC10-53-109Original Issue: December 24, 1979 Revision 8: March 10, 2011 ATA System: 5350 SUBJECT: FUSELAGE - Aerodynamic Fairings - Install Electrical Bonding Straps on Extended Wing-to-Fuselage Fillets
CONCURRENT REQUIREMENTS This service bulletin may be accomplished in conjunction with Service Bulletin DC10-53-103 or Service Bulletin DC10-53-119 for convenience of maintenance.
BACKGROUND An engineering review of the extended wing to fuselage fillet by Boeing revealed an increase in the non metallic area of the fillet. In the event of a severe lightning strike, induced transients could be imposed on wiring in the root area. Installation of the new bonding straps to electrically connect the metallic frame of the fillet to the metal ribs of the wing leading edge will substantially reduce the induced electrical transients.
Service Bulletin Revision 5 was the result of the safety assessments conducted by Boeing under a Special Federal Aviation Regulation (SFAR) 88, Fuel Tank System Fault Tolerance Evaluation Requirements.
ACTION This service bulletin provides instructions to accomplish the work as follows on the left and right wings:
1. Group 1-4, Configuration 1:
(Airplanes that have not previously done Service Bulletin DC10-53-109) Installs seven new braided bonding straps between the metallic frame of the fillet and the wing leading edge ribs.
2. Group 1-2, Configuration 2:
(Airplanes that have previously done Service Bulletin DC10-53-109 Revision 3 or a Prior Revision) Removes and replaces seven solid metal bonding straps with seven new braided bonding straps between the metallic frame of the fillet and the wing leading edge ribs.
3. Group 3-4, Configuration 2:
(Airplanes that have previously done Service Bulletin DC10-53-109 Revision 3 or a Prior Revision or solid metal bonding straps were installed in production) Removes and replaces seven solid metal bonding straps with seven new braided bonding straps between the metallic frame of the fillet and the wing leading edge ribs installed in production.
BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: December 24, 1979 DC10-53-109Revision 8: March 10, 2011 7 of 122
4. Group 1-4, Configuration 3:
(Airplanes that have previously done Service Bulletin DC10-53-109 Revision 4) Replaces one existing braided bonding strap with a longer braided bonding strap and installs a new braided bonding strap on each side between the metallic frame of the fillet and the wing leading edge ribs. Measures electrical resistance of previously installed braided bonding straps and if resistance check fails, removes braided bonding strap assembly, cleans mating surfaces, installs bonding strap assembly and measures resistance.
5. Group 1-4, Configuration 4:
(Airplanes that have previously done Service Bulletin DC10-53-109 Revisions 5 and/or 6) Installs a new braided bonding strap on each side between the metallic frame of the fillet and the wing leading edge ribs, and measures electrical resistance of previously installed braided bonding straps and if resistance check fails, removes braided bonding strap assembly, cleans mating surfaces, installs bonding strap assembly and measures resistance. .
6. Group 1-4, Configuration 5:
(Airplanes that have previously done Service Bulletin DC10-57-109 Revision 7) Installs a new braided bonding strap on each side between the metallic frame of the fillet and the wing leading edge ribs.
EFFECTIVITY DC-10 and MD-10 airplanes with extended wing to fuselage fillets. Refer to Paragraph 1.A.1., Airplanes for the list of affected airplanes.
COMPLIANCE Federal Aviation Administration (FAA) Airworthiness Directive AD 2009-26-17 is related to this service bulletin.
Boeing recommends that operators do this service bulletin at the earliest scheduled maintenance period.
INDUSTRY SUPPORT INFORMATION Boeing warranty remedies are not available for the configuration changes given in this service bulletin.
MANPOWER Group 1-4, Configuration 1 Elapsed HoursTotal Task HoursAirplanes
7.514.9DC-10 and MD-10 Group 1-4, Configuration 2 Elapsed HoursTotal Task HoursAirplanes
9.919.8DC-10 and MD-10
BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: December 24, 1979 DC10-53-109Revision 8: March 10, 2011 8 of 122 BOEING SERVICE BULLETIN DC10-53-109
Group 1-4, Configuration 3 Elapsed HoursTotal Task HoursAirplanes
6.3 - 10.312.1 - 20.1DC-10 and MD-10 Group 1-4, Configuration 4 Elapsed HoursTotal Task HoursAirplanes
5.9 - 9.510.5 - 18.5DC-10 and MD-10 Group 1-4, Configuration 5 Elapsed HoursTotal Task HoursAirplanes
6.28.8DC-10 and MD-10
MATERIAL INFORMATION Boeing Supplied Kits/Parts.
Refer to Paragraph 2.A., Material - Price and Availability.
BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: December 24, 1979 DC10-53-109Revision 8: March 10, 2011 9 of 122 BOEING SERVICE BULLETIN DC10-53-109
BOEING SERVICE BULLETIN DC10-53-109 000000 |000000a 1000000 as GROUPS 1-4, CONFIG 1
AIRPLANES THAT HAVE NOT DONE SERVICE BULLETIN DC10-53-109 GROUPS 1-4, CONFIG 2
AIRPLANES THAT HAVE PREVIOUSLY DONE SERVICE BULLETIN DC10-53-109 REVISION 3 OR A PRIOR REVISION GROUPS 1-4, CONFIG 3
AIRPLANES THAT HAVE PREVIOUSLY DONE SERVICE BULLETIN DC10-53-109 REVISION 4 GROUPS 1-4, CONFIG 4
AIRPLANES THAT HAVE PREVIOUSLY DONE SERVICE BULLETIN DC10-53-109 REVISION 5 AND/OR 6 GROUPS 1-4, CONFIG 5
AIRPLANES THAT HAVE PREVIOUSLY DONE SERVICE BULLETIN DC10-53-109 REVISION 7
LEFT SIDE SHOWN
RIGHT SIDE OPPOSITE Original Issue: December 24, 1979 Revision 8: March 10, 2011 BOEING PROPRIETARY - DC10-53-109 Copyright © Unpublished Work - See page 1 for details. 10 of 122
Commercial Airplanes DC10 Service Bulletin Number: DC10-53-109 Original Issue: December 24, 1979 Revision 8: March 10, 2011 ATA System: 5350 SUBJECT: FUSELAGE - Aerodynamic Fairings - Install Electrical Bonding Straps on Extended Wing-to-Fuselage Fillets
1. PLANNING INFORMATION A. Effectivity
1. Airplanes This service bulletin is for the airplanes shown below.
NOTE: This service bulletin is applicable only to airplanes with extended wing-to-fuselage fillets.
DESCRIPTIONCONFIGURATIONGROUP Airplane fuselage numbers 268, 277, 280 through 282, 289, 295 through 298, 423 through 446.
-1 Airplanes that have not done Service Bulletin DC10-53-109.1 Airplanes that have previously done Service Bulletin DC10-53-109 Revision 3 or a prior revision.
2 Airplanes that have previously done Service Bulletin DC10-53-109 Revision 4.
3 Airplanes that have previously done Service Bulletin DC10-53-109 Revision 5 and/or 6.
4 Airplanes that have previously done Service Bulletin DC10-53-109 Revision 7.
BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: December 24, 1979 DC10-53-109Revision 8: March 10, 2011 11 of 122
DESCRIPTIONCONFIGURATIONGROUP Airplane fuselage number 300 only.-2 Airplanes that have not done Service Bulletin DC10-53-109.1 Airplanes that have previously done Service Bulletin DC10-53-109 Revision 3 or a prior revision.
2 Airplanes that have previously done Service Bulletin DC10-53-109 Revision 4.
3 Airplanes that have previously done Service Bulletin DC10-53-109 Revision 5 and/or 6.
4 Airplanes that have previously done Service Bulletin DC10-53-109 Revision 7.
5 Airplane fuselage numbers 260 through 299 excluding 268, 277, 280 through 282, 289 and 295 through 298, and the effectivities of Service Bulletins DC10-53-103 and DC10-53-119.
-3 Airplanes that have not done Service Bulletin DC10-53-109.1 Airplanes that have previously done Service Bulletin DC10-53-109 Revision 3 or a prior revision.
2 Airplanes that have previously done Service Bulletin DC10-53-109 Revision 4.
3 Airplanes that have previously done Service Bulletin DC10-53-109 Revision 5 and/or 6.
4 Airplanes that have previously done Service Bulletin DC10-53-109 Revision 7.
BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: December 24, 1979 DC10-53-109Revision 8: March 10, 2011 12 of 122 BOEING SERVICE BULLETIN DC10-53-109