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McDonnell DouglasCommercial Airplanes DC8 Service Bulletin Number: DC8-28-090 Original Issue: October 09, 2009 ATA System: 2820 SUBJECT: FUEL - Fuel Tank Fill Control Indicating System - Install Fuel Tank Float Switch In-Line Fuses 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BOEING PROPRIETARY, CONFIDENTIAL, AND/OR TRADE SECRET Copyright © 2009 The Boeing Company Unpublished Work - All Rights Reserved Boeing claims copyright in each page of this document only to the extent that the page contains copyrightable subject matter.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.
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4.0
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BLANK PAGE
Table of Contents
Summary5
1. PLANNING INFORMATION7
A. Effectivity7
1. Airplanes7
2. Spares Affected ........................................ 1 1 B. Concurrent Requirements ...................................... 1 1 C. Reason ................................................ 1 1 D. Description .............................................. 1 1 E. Compliance .............................................. 1 2 F. Approval ............................................... 1 2 G. Manpower .............................................. 1 2 H. Weight and Balance Changes .................................... 1 3 I. Electrical Load Data ......................................... 1 4 J. References .............................................. 1 4
1. Existing Data .......................................... 1 4
2. Data supplied with this Service Bulletin ............................ 1 4
3. Installation Drawings Used in the Preparation of this Service Bulletin ............ 1 4 K. Publications Affected ........................................ 1 4 L. Interchangeability and Intermixability of Parts ........................... 1 4
2. MATERIAL INFORMATION ........................................ 1 5 A. Material - Price and Availability ................................... 1 5 B. Industry Support Information .................................... 1 5 C. Parts Necessary For Each Airplane ................................. 1 5
1. Kits/Parts ............................................ 1 5
2. Parts and Materials Supplied by the Operator ........................ 1 8
3. Parts Modified and Reidentified ................................ 2 0
4. Parts Removed and Not Replaced .............................. 2 0 D. Parts Necessary to Change Spares ................................. 2 0 E. Special Tooling - Price and Availability ............................... 2 1 F. Special Tooling Necessary to do this Service Bulletin ....................... 2 1
3. ACCOMPLISHMENT INSTRUCTIONS .................................. 2 3 A. GENERAL INFORMATION ..................................... 2 3 B. WORK INSTRUCTIONS ....................................... 2 4 FIGURE 1: IN-LINE FUSE (EQUIPMENT ITEM NUMBER F1-115) - INSTALLATION [Group 1, 3] . . 28 FIGURE 2: IN-LINE FUSE (EQUIPMENT ITEM NUMBER F1-101) - INSTALLATION [Group 1] .... 3 2 FIGURE 3: IN-LINE FUSE (EQUIPMENT ITEM NUMBER F1-117) - INSTALLATION [Group 1, 3] . . 36 FIGURE 4: IN-LINE FUSE (EQUIPMENT ITEM NUMBER F1-116) - INSTALLATION [Group 1, 3] . . 39 FIGURE 5: IN-LINE FUSE (EQUIPMENT ITEM NUMBER F1-102) - INSTALLATION [Group 1] .... 4 3 FIGURE 6: IN-LINE FUSE (EQUIPMENT ITEM NUMBER F1-118) - INSTALLATION [Group 1, 3] . . 47 FIGURE 7: IN-LINE FUSE (EQUIPMENT ITEM NUMBERS F1-101, F1-103 AND F1-105) - INSTALLATION [Group 2] ............................................ 5 0 FIGURE 8: IN-LINE FUSE (EQUIPMENT ITEM NUMBER F1-107) - INSTALLATION [Group 2] .... 5 4 FIGURE 9: IN-LINE FUSE (EQUIPMENT ITEM NUMBER F1-109) - INSTALLATION [Group 2] .... 5 7 FIGURE 10: IN-LINE FUSE (EQUIPMENT ITEM NUMBERS F1-111 AND F1-112) - INSTALLATION [Group 2 ] ................................................ 6 0
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FIGURE 11: IN-LINE FUSE (EQUIPMENT ITEM NUMBERS F1-102, F1-104 AND F1-106) - INSTALLATION [Group 2] ............................................ 6 3 FIGURE 12: IN-LNE FUSE (EQUIPMENT ITEM NUMBER F1-108) - INSTALLATION [Group 2] .... 6 7 FIGURE 13: IN-LINE FUSE (EQUIPMENT ITEM NUMBER F1-110) - INSTALLATION [Group 2] .... 7 0 FIGURE 14: IN-LINE FUSE (EQUIPMENT ITEM NUMBERS F1-113 AND F1-114) - INSTALLATION [Group 2 ] ................................................ 7 3 FIGURE 15: [Group 1] ............................................ 7 6 FIGURE 16: [Group 2] ............................................ 8 0 FIGURE 17: [Group 3] ............................................ 8 8 APPENDIX A: DC-8 SERVICE BULLETIN FUEL LEVEL FLOAT SWITCH TEST PROCEDURE [Group 1] . 91 APPENDIX B: DC-8 SERVICE BULLETIN FUEL LEVEL FLOAT SWITCH TEST PROCEDURE [Group 2] . 92 APPENDIX C: DC-8 SERVICE BULLETIN FUEL LEVEL FLOAT SWITCH TEST PROCEDURE [Group 3] . 93
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McDonnell DouglasCommercial Airplanes DC8 Service Bulletin SummaryNumber: DC8-28-090Original Issue: October 09, 2009 ATA System: 2820 SUBJECT: FUEL - Fuel Tank Fill Control Indicating System - Install Fuel Tank Float Switch In-Line Fuses
CONCURRENT REQUIREMENTS None.
BACKGROUND An analysis by Boeing has determined that float switch wires located on the left and right wing leading edge at the front spar are routed in the same bundles as power lines. If a short circuit between a float switch wire and a power wire occurs, an over current can cause excessive temperatures in the float switch wires, resulting in damage. Adding an in-line fuse as a self-contained component in each float switch circuit will minimize the possibility of excessive temperatures in the float switch wires. If not corrected, and there is a short circuit of the float switch wire to a power wire, possible damage to the float switch wire could occur, and become a potential ignition source into the 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.
Critical Design Configuration Control Limitation (CDCCL) 20-10 from Report MDC-02K9030 affects airplane maintenance documents.
ACTION This service bulletin installs fuel tank float switch in-line fuses in the left and right wing leading edge front spar.
EFFECTIVITY DC-8-33, DC-8-42, DC-8-43, DC-8-51, DC-8-52, DC-8-53, DC-8F-54, DC-8-55, DC-8F-55, DC-8-61, DC-8-61F, DC-8-62, DC-8-62F, DC-8-63, DC-8-63F, DC-8-71F, DC-8-72, DC-8-72F, DC-8-73F. Refer to Paragraph 1.A.1., Airplanes, for the list of affected airplanes.
COMPLIANCE The Federal Aviation Administration (FAA) will possibly release an Airworthiness Directive related to this service bulletin. The Airworthiness Directive will make the compliance tasks and times given in this service bulletin mandatory.
Boeing recommends that the change given in this service bulletin be done within 5 years after the original issue date of this service bulletin.
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INDUSTRY SUPPORT INFORMATION Boeing warranty remedies are not available for the configuration changes given in this service bulletin.
MANPOWER Refer to Paragraph 1.G., for Manpower information.
MATERIAL INFORMATION Boeing Supplied Kits/Parts.
Refer to Paragraph 2.A., Material - Price and Availability.
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McDonnell DouglasCommercial Airplanes DC8 Service Bulletin Number: DC8-28-090 Original Issue: October 09, 2009 ATA System: 2820 SUBJECT: FUEL - Fuel Tank Fill Control Indicating System - Install Fuel Tank Float Switch In-Line Fuses
1. PLANNING INFORMATION A. Effectivity
1. Airplanes
DESCRIPTIONCONFIGURATIONGROUP Applicable to Airplanes with Intermediate Fuel Level Float Switch and 2 Fuel Level Float Switch Alert.
-1 Applicable to Airplanes with Intermediate Fuel Level Float Switch and 6 Fuel Level Float Switch Alert.
-2 Applicable to Airplanes without Intermediate Fuel Level Float Switch and 2 Fuel Level Float Switch Alert.
-3 Airplane Models:
DC-8-33, DC-8-42, DC-8-43, DC-8-51, DC-8-52, DC-8-53, DC-8-55, DC-8-61, DC-8-61F, DC-8-62, DC-8-62F, DC-8-63, DC-8-63F, DC-8-71F, DC-8-72, DC-8-72F, DC-8-73F, DC-8F-54, DC-8F-55 GroupFuselage Number 3107 3115 3122 3134 3139 3153 3163
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GroupFuselage Number 3182 3185 3187 3189 3202 - 203 3207 - 208 321 3218 3223 3233 - 234 3241 3246 - 247 3251 3254 3259 3261 - 262 3274 3276 - 277 3283 - 284 2286 3288 3290 3292 3294 - 295 2298 3305 2307 2309 3316 2319 3320 - 321 2322 - 323
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GroupFuselage Number 3326 2327 3329 - 331 2333 - 335 3337 1338 2344 2347 - 348 1351 1354 3358 1360 2361 3363 2371 3372 3374 2375 - 377 2379 - 380 3381 - 382 2385 3387 2389 2392 - 396 2401 2403 1405 2407 3408 3410 2411 2413
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GroupFuselage Number 2416 - 417 1418 - 419 3420 2421 - 423 3425 - 426 2427 - 428 2431 - 432 2434 1435 - 436 2437 - 440 2442 - 447 3449 - 450 2451 2453 - 456 2458 3459 - 460 2463 - 469 3477 2478 - 483 2485 2487 - 491 3492 2493 3495 2496 2500 - 504 2508 - 509 2511 2515 - 516 2519 - 525 2527 - 531 2534 - 535
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GroupFuselage Number 2538 - 540 2542 2546 - 549 2551 2554 - 556 379
2. Spares Affected None.
B. Concurrent Requirements None.
C. Reason An analysis by Boeing has determined that float switch wires located on the left and right wing leading edge at the front spar are routed in the same bundles as power lines. If a short circuit between a float switch wire and a power wire occurs, an over current can cause excessive temperatures in the float switch wires, resulting in damage. Adding an in-line fuse as a self-contained component in each float switch circuit will minimize the possibility of excessive temperatures in the float switch wires. If not corrected, and there is a short circuit of the float switch wire to a power wire, possible damage to the float switch wire could occur, and become a potential ignition source into the 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.
Critical Design Configuration Control Limitation (CDCCL) 20-10 from Report MDC-02K9030 affects airplane maintenance documents.
D. Description This service bulletin installs fuel tank float switch in-line fuses in the left and right wing leading edge front spar.
The work in this service bulletin is done in the maintenance zone(s) given below.
Group 1:
Affected Maintenance Zones ZoneModel 107, 108, 112, 115, 116DC-8-61, DC-8-61F, DC-8-71F
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Group 2:
Affected Maintenance Zones ZoneModel 107, 108, 112, 115, 116DC-8-62, DC-8-62F, DC-8-63, DC-8-63F, DC-8-72, DC-8-72F, DC-8-73F Group 3:
Affected Maintenance Zones ZoneModel 107, 108, 112, 115, 116DC-8-33, DC-8-42, DC-8-43, DC-8-51, DC-8-52, DC-8-53, DC-8-55, DC-8-61, DC-8-61F, DC-8-71F, DC-8F-54, DC-8F-55 E. Compliance The Federal Aviation Administration (FAA) will possibly release an Airworthiness Directive related to this service bulletin. The Airworthiness Directive will make the compliance tasks and times given in this service bulletin mandatory.
Boeing recommends that the change given in this service bulletin be done within 5 years after the original issue date of this service bulletin.
F. Approval This service bulletin was examined by the Federal Aviation Administration (FAA). The changes specified in this service bulletin comply with the applicable regulations and are FAA approved, as well as European Aviation Safety Agency (EASA)/Joint Aviation Authorities (JAA) approved for all EASA/JAA approved airplanes listed in the service bulletin effectivity. This service bulletin and its approval were based on the airplane in its original Boeing delivery configuration or as modified by other approved Boeing changes.
If an airplane has a non-Boeing modification or repair that affects a component or system also affected by this service bulletin, the operator is responsible for obtaining appropriate regulatory agency approval before incorporating this service bulletin.
G. Manpower The table below shows an estimate of the task hours necessary to do this change for each airplane.
This estimate is for direct labor only, done by an experienced crew. Adjust the estimate with operator task hour data if necessary. The estimate does not include lost time. These are some examples of lost time:
Time to adjust to the workplace Time to schedule the work Time to inspect the work
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