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McDonnell DouglasCommercial Airplanes DC10 Service Bulletin Number: DC10-53-109 Original Issue: December 24, 1979 Revision 7: March 03, 2009 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BOEING PROPRIETARY, CONFIDENTIAL, AND/OR TRADE SECRET Copyright © 1989 The Boeing Company Unpublished Work - All Rights Reserved Boeing claims copyright in each page of this document only to the extent that the page contains copyrightable subject matter.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, 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BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.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 7: March 03, 2009 1 of 89
4.0
BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: December 24, 1979 DC10-53-109Revision 7: March 03, 2009 2 of 89 BOEING SERVICE BULLETIN DC10-53-109
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Table of Contents
Revision Transmittal Sheet5
Summary7
1. PLANNING INFORMATION ........................................ 1 1 A. Effectivity ............................................... 1 1
1. Airplanes ............................................ 1 1
2. Spares Affected ........................................ 1 3 B. Concurrent Requirements ...................................... 1 3 C. Reason ................................................ 1 4 D. Description .............................................. 1 4 E. Compliance .............................................. 1 6 F . Approval ............................................... 1 6 G. Manpower .............................................. 1 6 H. Weight and Balance Changes .................................... 1 7 I. Electrical Load Data ......................................... 1 7 J. References .............................................. 1 7
1. Existing Data: .......................................... 1 7
2. Data supplied with this Service Bulletin: ........................... 1 7
3. Installation Drawings Used in the Preparation of this Service Bulletin: ........... 1 8
4. Process Data: ......................................... 1 8 K. Publications Affected ......................................... 1 8 L. Interchangeability and Intermixability of Parts ........................... 1 8
2. MATERIAL INFORMATION ........................................ 1 9 A. Material - Price and Availability ................................... 1 9 B. Industry Support Information .................................... 1 9 C. Parts Necessary For Each Airplane ................................. 1 9
1. Kits/Parts: ............................................ 1 9
2. Parts and Materials Supplied by the Operator: ........................ 2 1
3. Parts Modified and Reidentified: ................................ 2 2
4. Parts Removed and Not Replaced: .............................. 2 2 D. Parts Necessary to Change Spares ................................. 2 2 E. Special Tooling - Price and Availability ............................... 2 2 F . Special Tooling Necessary to do this Service Bulletin ....................... 2 2
3. ACCOMPLISHMENT INSTRUCTIONS .................................. 2 3 A. GENERAL INFORMATION ..................................... 2 3 B. WORK INSTRUCTIONS ....................................... 2 4 FIGURE 1: EXTENDED WING TO FUSELAGE FILLETS - INSTALLATION OF BONDING STRAPS [Group 1-4, Configuration 1] ...................................... 2 7 FIGURE 2: EXTENDED WING TO FUSELAGE FILLETS - REPLACEMENT OF BONDING STRAPS [Group 3-4, Configuration 2] ...................................... 4 4 FIGURE 3: EXTENDED WING TO FUSELAGE FILLETS - REPLACEMENT OF BONDING STRAPS [Group 1-2, Configuration 2] ...................................... 6 6 FIGURE 4: EXTENDED WING TO FUSELAGE FILLETS - REPLACEMENT OF ONE BONDING STRAP [Group 1-4, Configuration 3] .................................. 8 6 Appendix A: BONDING STRAP INSTALLATION PROCEDURE ...................... 8 9 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: December 24, 1979 DC10-53-109Revision 7: March 03, 2009 3 of 89 BOEING SERVICE BULLETIN DC10-53-109
BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: December 24, 1979 DC10-53-109Revision 7: March 03, 2009 4 of 89 BOEING SERVICE BULLETIN DC10-53-109
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McDonnell DouglasCommercial Airplanes DC10 Service Bulletin Revision Transmittal SheetNumber: DC10-53-109Original Issue: December 24, 1979 Revision 7: March 03, 2009 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 No more work is necessary on airplanes changed as shown on revision 5 and 6 of this service bulletin.
More work is necessary on airplanes changed as shown in original release through revision 4 of this service bulletin. Measure electrical resistance of previously installed braided bonding straps. An additional 0.5 hours required.
REASON FOR REVISION This revision is sent to incorporate an electrical resistance check of previously installed braided bonding straps and instructions to correct locations that fail the resistance check. An additional 0.5 hours required.
These sections were changed:
1. In Paragraph 1.D., Description, added instructions to measure electrical resistance of previously installed braided bonding straps and correct any failed resistance checks.
2. In Paragraph 1.F ., Approval, added approval for Revision 7.
3. In Paragraph 1.G., Manpower, added hours for electrical resistance check of previously installed braided bonding straps and correction of electrical bonds that failed.
4. In Paragraph 2.C.1., Kits/Parts, added angles to table previously omitted in error.
5. In Paragraph 3.B.2., Work Instructions, added electrical resistance test and correction of electrical bonds that failed.
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:
BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: December 24, 1979 DC10-53-109Revision 7: March 03, 2009 5 of 89
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:
BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: December 24, 1979 DC10-53-109Revision 7: March 03, 2009 6 of 89 BOEING SERVICE BULLETIN DC10-53-109
McDonnell DouglasCommercial Airplanes DC10 Service Bulletin SummaryNumber: DC10-53-109Original Issue: December 24, 1979 Revision 7: March 03, 2009 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 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.
ACTION This service bulletin provides instructions to accomplish the following on the left and right wings:
1. Group 1-4, Configuration 1:
(Airplanes that have not Previously done Service Bulletin DC10-53-109) Install six 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) Remove and replace six metal bonding straps with six 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 metal bonding straps were installed in production) Remove and replace six metal bonding straps with six new braided bonding straps between the metallic frame of the fillet and the wing leading edge ribs installed in production.
4. Group 1-4, Configuration 3:
(Airplanes that have Previously done Service Bulletin DC10-53-109 Revision 4) BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: December 24, 1979 DC10-53-109Revision 7: March 03, 2009 7 of 89
Replaces one existing braided bonding strap with one new longer braided bonding strap 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.
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 Boeing recommends that operators do this service bulletin at the earliest scheduled maintenance period.
Federal Aviation Administration (FAA) Airworthiness Directive (AD) 2006-16-03 is related to this service bulletin.
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
6.613.3DC-10 and MD-10 Group 1-4, Configuration 2 Elapsed HoursTotal Task HoursAirplanes
9.118.2DC-10 and MD-10 Group 1-4, Configuration 3 Elapsed HoursTotal Task HoursAirplanes
5.5 - 9.510.5 - 18.5DC-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 7: March 03, 2009 8 of 89 BOEING SERVICE BULLETIN DC10-53-109
BOEING SERVICE BULLETIN DC10-53-109 GROUPS 1-4, CONFIG 1
INSTALL SIX NEW BRAIDED BONDING STRAPS GROUPS 1-4, CONFIG 2
REPLACE SIX METAL BONDING STRAPS WITH SIX
BRAIDED BONDING STRAPS GROUPS 1-4, CONFIG 3
REPLACE ONE EXISTING BRAIDED BONDING STRAP
WITH ONE NEW LONGER BRAIDED BONDING STRAP
LEFT SIDE SHOWN
RIGHT SIDE OPPOSITE Original Issue: December 24, 1979 Revision 7: March 03, 2009 DC10-53-109 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 9 of 89
BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: December 24, 1979 DC10-53-109Revision 7: March 03, 2009 10 of 89 BOEING SERVICE BULLETIN DC10-53-109
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McDonnell DouglasCommercial Airplanes DC10 Service Bulletin Number: DC10-53-109 Original Issue: December 24, 1979 Revision 7: March 03, 2009 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 previously accomplished Service Bulletin DC10-53-109. Install six new braided bonding straps.
1 Airplanes that have previously accomplished Service Bulletin DC10-53-109 at Revision 3 or a prior revision. Replace six metal bonding straps with six braided bonding straps.
2 Airplanes that have previously accomplished Service Bulletin DC10-53-109 Revision 4. Replace one existing braided bonding strap with one new longer braided bonding strap.
3 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: December 24, 1979 DC10-53-109Revision 7: March 03, 2009 11 of 89
DESCRIPTIONCONFIGURATIONGROUP Airplane fuselage number 300 only.-2 Airplanes that have not previously accomplished Service Bulletin DC10-53-109. Install six new braided bonding straps.
1 Airplanes that have previously accomplished Service Bulletin DC10-53-109 at Revision 3 or a prior revision. Replace six metal bonding straps with six braided bonding straps.
2 Airplanes that have previously accomplished Service Bulletin DC10-53-109 Revision 4. Replace one existing braided bonding strap with one new longer braided bonding strap.
3 Airplane fuselage numbers 260 through 299 excluding 268, 277, 280 through 282, 289 and 295 through 298.
-3 Airplanes that have not previously accomplished Service Bulletin DC10-53-109. Install six new braided bonding straps.
1 Airplanes that have previously accomplished Service Bulletin DC10-53-109 at Revision 3 or a prior revision or metal bonding straps were installed in production. Replace six metal bonding straps with six braided bonding straps.
2 Airplanes that have previously accomplished Service Bulletin DC10-53-109 Revision 4. Replace one existing braided bonding strap with one new longer braided bonding strap.
3 Airplane fuselage numbers 301 through 422.-4 Airplanes that have not previously accomplished Service Bulletin DC10-53-109. Install six new braided bonding straps.
1 Airplanes that have previously accomplished Service Bulletin DC10-53-109 at Revision 3 or a prior revision or metal bonding straps were installed in production. Replace six metal bonding straps with six braided bonding straps.
2 Airplanes that have previously accomplished Service Bulletin DC10-53-109 Revision 4. Replace one existing braided bonding strap with one new longer braided bonding strap.
3 Airplane Models:
DC-10-10, DC-10-15, DC-10-30, DC-10-30F , DC-10-30F (KC-10A), DC-10-40, DC-10-40F , MD-10-10F , MD-10-30F BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: December 24, 1979 DC10-53-109Revision 7: March 03, 2009 12 of 89 BOEING SERVICE BULLETIN DC10-53-109