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Commercial Airplanes DC9 Service Bulletin Number: DC9-28-217 Original Issue: December 01, 2009 Revision 1: August 12, 2010 ATA System: 2821 2822 SUBJECT: FUEL - Switch Fuel Level Float - Fuel Level Float and Pressure Switch In-Line Fuse 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BOEING PROPRIETARY, CONFIDENTIAL, AND/OR TRADE SECRET Copyright © 2009 The Boeing Company Unpublished Work - All Rights Reserved Boeing claims copyright in each page of this document only to the extent that the page contains copyrightable subject matter.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.
BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: December 01, 2009 DC9-28-217Revision 1: August 12, 2010 1 of 166
2.0
BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: December 01, 2009 DC9-28-217Revision 1: August 12, 2010 2 of 166 BOEING SERVICE BULLETIN DC9-28-217
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 ........................................ 2 6 B. Concurrent Requirements ...................................... 2 7 C. Reason ................................................ 2 7 D. Description .............................................. 2 7 E. Compliance .............................................. 3 0 F. Approval ............................................... 3 0 G. Manpower .............................................. 3 0 H. Weight and Balance Changes .................................... 3 6 I. Electrical Load Data ......................................... 3 8 J. References .............................................. 3 8
1. Existing Data .......................................... 3 8
2. Data supplied with this Service Bulletin ............................ 3 8
3. Installation Drawings Used in the Preparation of this Service Bulletin ............ 3 9
4. Process Data: ......................................... 3 9 K. Publications Affected ........................................ 3 9 L. Interchangeability and Intermixability of Parts ........................... 3 9
2. MATERIAL INFORMATION ........................................ 4 1 A. Material - Price and Availability ................................... 4 1 B. Industry Support Information .................................... 4 1 C. Parts Necessary For Each Airplane ................................. 4 2
1. Kits/Parts ............................................ 4 2
2. Parts and Materials Supplied by the Operator ........................ 5 5
3. Parts Modified and Reidentified ................................ 5 8
4. Parts Removed and Not Replaced .............................. 5 8 D. Parts Necessary to Change Spares ................................. 5 8 E. Special Tooling - Price and Availability ............................... 5 8 F. Special Tooling Necessary to do this Service Bulletin ....................... 5 9
3. ACCOMPLISHMENT INSTRUCTIONS .................................. 6 1 A. GENERAL INFORMATION ..................................... 6 1 B. WORK INSTRUCTIONS ....................................... 6 2 FIGURE 1: FUEL LEVEL FLOAT SWITCH IN-LINE FUSE INSTALLATION [Group 1] ......... 8 8 FIGURE 2: FUEL LEVEL FLOAT SWITCH IN-LINE FUSE INSTALLATION [Group 2] ......... 9 1 FIGURE 3: FUEL LEVEL FLOAT SWITCH IN-LINE FUSE INSTALLATION [Group 3] ......... 9 3 FIGURE 4: FUEL LEVEL FLOAT SWITCH IN-LINE FUSE INSTALLATION [Group 4] ......... 9 6 FIGURE 5: FUEL LEVEL FLOAT AND PRESSURE SWITCH IN-LINE FUSE INSTALLATION [Group 5] .................................................. 9 9 FIGURE 6: FUEL LEVEL FLOAT AND PRESSURE SWITCH IN-LINE FUSE INSTALLATION [Group 6] ................................................. 1 0 2 FIGURE 7: FUEL LEVEL FLOAT AND PRESSURE SWITCH IN-LINE FUSE INSTALLATION [Group 7] ................................................. 1 0 5
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Original Issue: December 01, 2009 DC9-28-217Revision 1: August 12, 2010 3 of 166 BOEING SERVICE BULLETIN DC9-28-217
FIGURE 8: FUEL LEVEL FLOAT AND PRESSURE SWITCH IN-LINE FUSE INSTALLATION [Group 8] ................................................. 1 0 8 FIGURE 9: FUEL LEVEL FLOAT AND PRESSURE SWITCH IN-LINE FUSE INSTALLATION [Group 9] ................................................. 1 1 1 FIGURE 10: FUEL LEVEL FLOAT AND PRESSURE SWITCH IN-LINE FUSE INSTALLATION [Group 10] ................................................. 1 1 4 FIGURE 11: FUEL LEVEL FLOAT AND PRESSURE SWITCH IN-LINE FUSE INSTALLATION [Group 11] ................................................. 1 1 8 FIGURE 12: FUEL LEVEL FLOAT AND PRESSURE SWITCH IN-LINE FUSE INSTALLATION [Group 12] ................................................. 1 2 1 FIGURE 13: FUEL LEVEL FLOAT AND PRESSURE SWITCH IN-LINE FUSE INSTALLATION [Group 13] ................................................. 1 2 4 FIGURE 14: FUEL LEVEL FLOAT AND PRESSURE SWITCH IN-LINE FUSE INSTALLATION [Group 14] ................................................. 1 2 7 FIGURE 15: FUEL LEVEL FLOAT AND PRESSURE SWITCH IN-LINE FUSE INSTALLATION [Group 15] ................................................. 1 3 1 FIGURE 16: FUEL LEVEL FLOAT AND PRESSURE SWITCH IN-LINE FUSE INSTALLATION [Group 16] ................................................. 1 3 4 FIGURE 17: FUEL LEVEL FLOAT AND PRESSURE SWITCH IN-LINE FUSE INSTALLATION [Group 17] ................................................. 1 3 7 FIGURE 18: FUEL LEVEL FLOAT AND PRESSURE SWITCH IN-LINE FUSE INSTALLATION [Group 18] ................................................. 1 4 1 FIGURE 19: FUEL LEVEL FLOAT SWITCH IN-LINE FUSE INSTALLATION [Group 19] ........ 1 4 5 APPENDIX A: CONTINUITY CHECK [Group 1] ............................... 1 4 8 APPENDIX B: CONTINUITY CHECK [Group 2] ............................... 1 4 9 APPENDIX C: CONTINUITY CHECK [Group 3] ............................... 1 5 0 APPENDIX D: CONTINUITY CHECK [Group 4] ............................... 1 5 1 APPENDIX E: CONTINUITY CHECK [Group 5] ............................... 1 5 2 APPENDIX F: CONTINUITY CHECK [Group 6] ............................... 1 5 3 APPENDIX G: CONTINUITY CHECK [Group 7] ............................... 1 5 4 APPENDIX H: CONTINUITY CHECK [Group 8] ............................... 1 5 5 APPENDIX I: CONTINUITY CHECK [Group 9] ............................... 1 5 6 APPENDIX J: CONTINUITY CHECK [Group 10] .............................. 1 5 7 APPENDIX K: CONTINUITY CHECK [Group 11] .............................. 1 5 8 APPENDIX L: CONTINUITY CHECK [Group 12] .............................. 1 5 9 APPENDIX M: CONTINUITY CHECK [Group 13] .............................. 1 6 0 APPENDIX N: CONTINUITY CHECK [Group 14] .............................. 1 6 1 APPENDIX O: CONTINUITY CHECK [Group 15] .............................. 1 6 2 APPENDIX P: CONTINUITY CHECK [Group 16] .............................. 1 6 3 APPENDIX Q: CONTINUITY CHECK [Group 17] .............................. 1 6 4 APPENDIX R: CONTINUITY CHECK [Group 18] .............................. 1 6 5 APPENDIX S: CONTINUITY CHECK [Group 19] .............................. 1 6 6
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Original Issue: December 01, 2009 DC9-28-217Revision 1: August 12, 2010 4 of 166 BOEING SERVICE BULLETIN DC9-28-217
Commercial Airplanes DC9 Service Bulletin Revision Transmittal SheetNumber: DC9-28-217Original Issue: December 01, 2009 Revision 1: August 12, 2010 ATA System: 2821 2822 SUBJECT: FUEL - Switch Fuel Level Float - Fuel Level Float and Pressure Switch In-Line Fuse Installation This revision includes all pages of the service bulletin.
COMPLIANCE INFORMATION RELATED TO THIS REVISION 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.
No more work is necessary on airplanes changed in accordance with the original issue of this service bulletin.
REASON FOR REVISION This revision is sent to incorporate engineering released subsequent to the Original Issue of this service bulletin, which adds a new configuration. The new configuration consists of airplanes that were previously in Group 3 but also had forward and rear auxiliary fuel tanks. This revision adds Group 19 consisting of the airplanes with forward and rear auxiliary fuel tanks that were previously included in Group 3.
These sections were changed:
1. In Paragraph 1.A., Effectivity, added Group 19, which consists of airplanes previously in Group 3.
2. In Paragraph 1.D., Description, changed description and maintenance zone tables to account for Group
19.
3. In Paragraph 1.G., Manpower, changed tables to account for Group 19 and to include data for applicable figures.
4. In Paragraph 1.H., Weight and Balance Changes, changed tables to account for Group 19.
5. In Paragraph 1.J.2.a., Drawings, changed drawing revision letter.
6. In Paragraph 1.J.4., Process Data, added process specification statement.
7. In Paragraph 2.A., Material - Price and Availability, added SB09280217-39 Service Kit, updated pricing and Reorder Lead Time (ROLT).
8. In Paragraph 2.C.1., Kits/Parts, added SB09280217-39 Service Kit table and SB09280217-37 Wire Package data.
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Original Issue: December 01, 2009 DC9-28-217Revision 1: August 12, 2010 5 of 166
9. In Paragraph 2.C.2., Parts and Materials Supplied by the Operator, added Group 19 to applicable parts table.
10. In Paragraph 3.A., General Information, changed Note 7 and added Notes 10, 11, 12 and 13.
11. In Paragraph 3.B., Work Instructions, added work instructions for Group 19.
12. Added Figure 19 and Appendix S, which are applicable to Group 19.
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 01, 2009Original Issue:
August 12, 2010Revision 1:
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Original Issue: December 01, 2009 DC9-28-217Revision 1: August 12, 2010 6 of 166 BOEING SERVICE BULLETIN DC9-28-217
Commercial Airplanes DC9 Service Bulletin SummaryNumber: DC9-28-217Original Issue: December 01, 2009 Revision 1: August 12, 2010 ATA System: 2821 2822 SUBJECT: FUEL - Switch Fuel Level Float - Fuel Level Float and Pressure Switch In-Line Fuse Installation
CONCURRENT REQUIREMENTS None.
BACKGROUND An investigation by Boeing has determined that fuel level float switch wires located on the left and right wing forward spars, the center tank forward spar, and the forward and aft auxiliary fuel tanks and pressure switch wires located on the forward and aft auxiliary fuel tanks are routed in the same bundles as power wires. If a short circuit between a fuel level float or pressure switch wire and a power wire occurs, an over current can cause excessive temperature in the fuel level float or pressure switch wire, resulting in damage and become a potential ignition source. Adding an in-line fuse as a self-contained component in each fuel level float and pressure switch circuit will minimize the possibility of excessive temperatures in the fuel level float or pressure switch wires. If not corrected, and there is a short circuit of a fuel level float or pressure switch wire to a power wire, possible damage to the fuel level float or pressure switch wire could occur, and become a potential ignition source for the fuel tank.
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.
ACTION Group 1, 3-4:
This service bulletin installs fuel level float switch in-line fuses on the left and right wing forward spars and the center wing forward spar.
Group 2:
This service bulletin installs fuel level float switch in-line fuses on the left and right wing forward spars.
Group 5:
This service bulletin installs fuel level float and pressure switch in-line fuses on the left and right wing forward spars, the center wing forward spar and the aft auxiliary fuel tank.
Group 6-9, 11-13, 15-16:
This service bulletin installs fuel level float and pressure switch in-line fuses on the left and right wing forward spars, the center wing forward spar, and the forward auxiliary fuel tank.
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Original Issue: December 01, 2009 DC9-28-217Revision 1: August 12, 2010 7 of 166
Group 10, 14, 17-18:
This service bulletin installs fuel level float and pressure switch in-line fuses on the left and right wing forward spars, the center wing forward spar, and the forward and aft auxiliary fuel tanks.
Group 19:
This service bulletin installs fuel level float switch in-line fuses on the left and right wing forward spars, the center wing forward spar, and the forward and aft auxiliary fuel tanks.
EFFECTIVITY DC-9-14, DC-9-15, DC-9-15F, DC-9-21, DC-9-31, DC-9-32, DC-9-32(VC-9C), DC-9-32F, DC-9-32F(C-9A), DC-9-32F(C9-B), DC-9-33F, DC-9-34, DC-9-34F, DC9-41 and DC-9-51 Airplanes. 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.
INDUSTRY SUPPORT INFORMATION Boeing warranty remedies are not available for the configuration changes given in this service bulletin.
MANPOWER Elapsed HoursTotal Task HoursGroup(s)
5.210.41, 3
3.87.62
6.412.84, 6, 8, 11-12, 15-16
7.615.25, 7, 9, 13
8.416.810, 14, 17-18
7.014.019
MATERIAL INFORMATION Boeing Supplied Kits/Parts.
Refer to Paragraph 2.A., Material - Price and Availability.
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Original Issue: December 01, 2009 DC9-28-217Revision 1: August 12, 2010 8 of 166 BOEING SERVICE BULLETIN DC9-28-217
BOEING SERVICE BULLETIN DC9-28-217
FUEL LEVEL FLOAT AND
PRESSURE SWITCH IN-LINE
FUSE INSTALLATION 1824389 Original Issue: December 01, 2009 Revision 1: August 12, 2010 BOEING PROPRIETARY - DC9-28-217 Copyright © Unpublished Work - See page 1 for details. 9 of 166
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BLANK PAGE
Commercial Airplanes DC9 Service Bulletin Number: DC9-28-217 Original Issue: December 01, 2009 Revision 1: August 12, 2010 ATA System: 2821 2822 SUBJECT: FUEL - Switch Fuel Level Float - Fuel Level Float and Pressure Switch In-Line Fuse Installation
1. PLANNING INFORMATION A. Effectivity
1. Airplanes NOTE: The intent of this installation was done on fuselage number 834 prior to the original issue of this service bulletin in accordance with Service Rework Drawing SR09280100 Revision B.
DESCRIPTIONCONFIGURATIONGROUP DC-9-14, DC-9-15 and DC-9-15F airplanes with left wing, right wing and center wing fuel tanks affected by SR09280100-7001 and -7021 drawing configurations.
-1 DC-9-14 airplanes with left wing and right wing fuel tanks affected by SR09280100-7011 and -7023 drawing configurations.
-2 DC-9-21, DC-9-31, DC-9-32, DC-9-32F, DC-9-33F, and DC-9-51 airplanes with left wing, right wing and center wing fuel tanks affected by SR09280100-7001 and -7025 drawing configurations.
-3 DC-9-32 and DC-9-32F airplanes with left wing, right wing and center wing fuel tanks affected by SR09280100-7013 and -7027 drawing configurations.
-4 DC-9-34F airplanes with left wing, right wing, center wing and aft auxiliary fuel tanks affected by SR09280100-7003 and -7029 drawing configurations.
-5 DC-9-32 and DC-9-33F airplanes with left wing, right wing, center wing and forward auxiliary fuel tanks affected by SR09280100-7005 and -7031 drawing configurations.
-6
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DESCRIPTIONCONFIGURATIONGROUP DC-9-31, DC-9-32, DC-9-32F and DC-9-33F airplanes with left wing, right wing, center wing and forward auxiliary fuel tanks affected by SR09280100-7007 and -7033 drawing configurations.
-7 DC-9-32 and DC-9-33F airplanes with left wing, right wing, center wing and forward auxiliary fuel tanks affected by SR09280100-7005 and -7035 drawing configurations.
-8 DC-9-32 airplanes with left wing, right wing, center wing and forward auxiliary fuel tanks affected by SR09280100-7007 and -7037 drawing configurations.
-9 DC-9-34 and DC-9-34F airplanes with left wing, right wing, center wing, forward auxiliary and aft auxiliary fuel tanks affected by SR09280100-7009 and -7039 drawing configurations.
-10 DC-9-41 airplanes with left wing, right wing, center wing and forward auxiliary fuel tanks affected by SR09280100-7005 and -7041 drawing configurations.
-11 DC-9-41 airplanes with left wing, right wing, center wing and forward auxiliary fuel tanks affected by SR09280100-7005 and -7043 drawing configurations.
-12 DC-9-41 airplanes with left wing, right wing, center wing and forward auxiliary fuel tanks affected by SR09280100-7007 and -7045 drawing configurations.
-13 DC-9-41 airplanes with left wing, right wing, center wing, forward auxiliary and aft auxiliary fuel tanks affected by SR09280100-7009 and -7047 drawing configurations.
-14 DC-9-51 airplanes with left wing, right wing, the center wing, and the forward auxiliary fuel tanks affected by SR09280100-7005 and -7049 drawing configurations.
-15 DC-9-51 airplanes with left wing, right wing, center wing and forward auxiliary fuel tanks affected by SR09280100-7005 and -7051 drawing configurations.
-16 DC-9-51 airplanes with left wing, right wing, center wing, forward auxiliary and aft auxiliary fuel tanks affected by SR09280100-7009 and -7053 drawing configurations.
-17 DC-9-51 airplanes with left wing, right wing, center wing, forward auxiliary and aft auxiliary fuel tanks affected by SR09280100-7009 and -7055 drawing configurations.
-18
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Original Issue: December 01, 2009 DC9-28-217Revision 1: August 12, 2010 12 of 166 BOEING SERVICE BULLETIN DC9-28-217