SERVICE BULLETIN FUEL- SFAR 88- DRY BAY ZONAL INSPECTION

structure and components. Guidance for demonstrating compliance with this regulation is provided in AC 20-53A, "Protecti on of Aircraft Fuel Systems Against Fuel Vapor Ignition Due to Lightning". (c) AC 25.981-1C Draft paragraph 7.C, requires several inspections to veri fy that the components are in acceptable worki ng order and will not result in a catastrophic event in case of failure. (3) An operator reported a fire in the No. 2 main tank . Accordi ng to the operator, two of three breakers associated with the No. 2 fuel dump boost pump opened during a fuel tank purging operation. When the tank was entered to troubleshoot the failed boost pump, evidence of a fire was found. A "teardown" of the pump in the lab found a conductor had an internal path to the pump housing (short). The lab also found that a non-conductive coating on the mounting base of the subject pump most likely prevented the pump from being electrically bonded to the aircraft structure. These two findings support the theory that an arc occurred between the pump housing and a surrounding entity (possibly either a conduit or fuel line) and resulted in ignition of fuel vapors in the ullage areas of the fuel tank. The mishap pump, P/N 60-371 D, SIN 9249, is not the correct part number for this application. The correct part number is 60-371B. The electrical conduit connection for this pump was altered for installation. This may have been a contributing factor to the pump internal failure. (4) Lockheed Martin Aeronautics Company recommends that those operators who have not accomplished the previous revision to this Service Bulletin comply with this revision on each affected aircraft at the next heavy maintenance but no later than 1 year after receipt of this Service Bulletin. Lockheed Martin Aeronauti cs Company further recommends that the Fuel Quantity Indicating System Wire Marker modification specified in Section 2, Paragraph C(8)(b) herein be accomplished during this inspection or at the next heavy maintenance period after January 1, 2008. (5) Aircraft previously modified by this Service Bulletin are affected by this revision by addi ng identity marker for fuel quantity indicating system wire. 382-28-19 82-770 October 17, 2003 Page 2 Revision 4, September 18, 2008 (Reissue) HERCULES Lockheed Martin Aeronautics Company Marietta, Georgia 30063 SERVICE BULLETIN C. DESCRIPTION This Service Bulletin consists of visual/electrical inspections of fuel system plumbing grounding/bonding connections for corrosion and/or incorrect resistance, misplaced or inappropriately installed grounding/bonding jumpe rs , installation of new grounding/bonding jumpers , visual inspection of fuel system electrical wires. and visual inspection of fuel tanks for contamination. This Zonal Inspection further expands into any system capable of developing enough energy to cause an ignition of the fuel system or is a source of fuel for a primary/root cause fire. This Service Bulletin also modifies fuel quantity indicating system (FQIS) wiring by installation of color coded identification cable marke rs or heat shrink sleeving to the existing FQIS wires from plugs that exit the fuel tanks or bladders, through outer wing breaks and wheel well pressure breaks to the individual fuel tank indicator plugs on the Fuel System Control Panel. D. APPROVAL (1) The aircraft owner/operator shall make an appropriate entry in the aircraft log records upon compliance with this Service Bulletin. (2) Please complete and mail a Notice of Service Bulletin Compliance after the work has been completed on each affected aircraft. (3) 382-28-19, FAA Certificated Aircraft: The rework instructions described in this Service Bulletin have been approved by the FAA as complying with applicable Federal Aviation Regulations. E. MANPOWER NOTE: This Service Bulletin is based upon the configuration of the aircraft as it was delivered from Lockheed Martin. Previous service bulletins issued by Lockheed Martin have been considered in the preparation of this Service Bulletin, but no consideration has been given to peculiar changes made to the aircraft by the owner/operator since its delivery. The work prescribed in this Service Bulletin has not been performed at the Lockheed Martin facility exactly as described herein . Therefore, the manpower estimates provided have not been validated, and should not be construed as being acceptable for use in making fixed price quotes for accomplishment of the work. These estimates are provided only as a convenience fo r customer planning purposes . It is estimated that approximately 952 man-hours (a crew of 4) will be required to accomplish the work described herein on each affected aircraft. This inspection will take approximately 238 hours elapsed time while the aircraft is out of service. F. MATER IAL Parts li sted in paragraph 3 may also be purchased from Lockheed Martin, as noted , if desired . Direct inquiries concerning prices and availability to the following: October 17, 2003 Phone: (877)456-7278 E-Mail : 4.1mparts@lmco.com Mail: Lockheed Martin Global Supply Chain Services 210 Industrial Park Road Johnstown , PA 15904, USA Revision 4, September 18, 2008 382-28-19 82-770 Page 3 HERCULES Lockheed Martin Aeronautics Company Marietta, Georgia 30063 SERVICE BULLETIN G. TOOLING AVTRON model T477W, P/N C15292 Bonding Meter with PIN C22161 Pistol Grip Probe or equivalent Stainless Steel Rotary Brush Manual or Power Drill Abrasive Paper or Cloth Sheet (150 to 400 grit aluminum oxide) H. WEIGHT AND BALANCE Not Applicable I. REFERENCES Special Federal Aviation Regulation 88 Federal Aviation Regulation Section 25.901 Federal Aviation Regulation Section 25.954 Advisory Circular 25-8 Advisory Circular 20-53A Hercules Wiring Diagram Manual Advisory Circular 25 .981-1 C Draft SAE-AS81531 , Marking of Electrical Insulating Materials Hercules Corrosion Prevention and Control Manual (1) 382-28-19, FAA Certificated Aircraft: Hercules Maintenance Manual Hercules Airfreighter Progressive Inspection Procedures (2) 82-770, Foreign Military Aircraft : Hercules Maintenance Instructions Manual Hercules Airfreighter Series Progressive Inspection Procedures J. OTHER PUBLICATIONS AFFECTED (1) 382-28-19, FAA Certificated Aircraft : Hercules Airfreighter Progressive Inspection Procedures (2) 82-770, Foreign Military Aircraft: Hercules Airfreighter Series Progressive Inspection Procedures 382-28-19 82-770 USE, CO~YINO;, Ml).Qlt OlSCI.OSUR! i$ OOVER'I IEO 8Y lH E S llol EM! 'I I 0 ";" lHf. flrt.lt PAG! 0 ' 111 :$ OOC:U U !MI October 17 , 2003 Page 4 Revision 4, September 18, 2008 (Reissue) HERCULES Lockheed Martin Aeronautics Company Marietta, Georgia 30063 SERVICE BULLETIN 2. ACCOMPLISHMENT INSTRUCTIONS WARNING: ENSURE THAT APPLICABLE SAFETY PRECAUTIONS PERTAINING TO WORK IN FUEL/FUME AREAS ARE STRICTLY OBSERVED. PERSONNEL SHALL WEAR NONSPARKING PROTECTIVE CLOTHING. ENTRY INTO TANKS AND DRY BAY MUST NOT BE MADE UNTIL AREAS HAVE BEEN PURGED TO A FIRE-SAFE 20 PERCENT LOWER EXPLOSION LIMIT (LEL) , AS DETERMINED USING FUEL VAPOR DETECTION AND MEASURING EQUIPMENT. FULL-FACE RESPIRATORS MUST BE WORN UNTIL AREA HAS BEEN PURGED TO THE HEALTH-SAFE 0.0- TO 1.5-PERCENT LELAND 19.5 PERCENT OXYGEN CONTENT. FAILURE TO COMPLY MAY RESULT IN SERIOUS INJURY OR DEATH. WARNING: FUEL TANK DEFUELING, DRAINING, PURGING AND MAINTENANCE REQUIRING ENTRY INTO THE TANK(S) SHALL BE PERFORMED ONLY IN DESIGNATED AREAS HAVING CLEAR ACCESS PATHS FOR FIRE FIGHTING AND EMERGENCY EQUIPMENT. THESE AREA(S) SHALL BE PROMINENTLY IDENTIFIED AS FUEL SYSTEM WORK AREA(S) AND POSTED WITH NO SMOKING AND AUTHORIZED PERSONNEL ONLY SIGNS . WARNING: PORTABLE FIRE EXTINGUISHERS MUST BE POSITIONED IN CONVENIENT LOCATIONS. FIRE FIGHTING PERSONNEL AND EQUIPMENT SHALL BE STATIONED NEARBY DURING DEFUELING, DRAINING, AND PURGING OPERATIONS. CAUTION: MAINTENANCE AND INSTALLATION PERSONNEL MUST EXERCISE CAUTION WHILE INCORPORATING TH IS SERVICE BULLETIN TO ENSURE THAT WIRING SYSTEMS ARE PROTECTED AND KEPT CLEAN AT ALL TIMES. NOTE THAT METAL SHAVINGS CAUSED BY DRILLING AND OTHER FORMS OF DEBRIS THAT CONTACT WIRE BUNDLES MAY IM PAIR WIRE SYSTEM INTEGRITY AND SHORTEN SYSTEM AND COMPONENT SERVIES LIFE. CAUTION: DO NOT ATTEMPT TO AIR-PURGE TANKS IF AN ELECTRICAL STORM OR WIND IN EXCESS OF 15 KNOTS IS FORECAST. DUST OR OTHER FOREIGN MATTER MAY ENTER THE TANK OPENINGS. A PREPARE AIRCRAFT FOR INSPECTION AND/OR MODIFICATION WARNING: ALL EQU IPMENT, INCLUDING WORK STANDS, SHALL BE ELECTRICALLY GROUNDED TO THE AIRPLANE AND TO AN APPROVED GROUNDING POST. GROUND WIRES SHALL BE SECURELY ATTACHED TO CONNECTING POINTS TO MINIMIZE ACCIDENTAL DISCONNECTION . WORK STANDS SHALL BE EQUIPPED W ITH COPPER. ZINC, OR ZINC-COATED GROUNDING PLATES THAT CAN BE CONVENIENTLY CONTACTED BY PERSONNEL ENTERING THE WORK AREA. (1) Static ground aircraft in accordance with appropriate Hercules Maintenance Manual or Hercules Maintenance Instructions Manual. (2) Lower flaps to full down position to allow access to wi ng trailing edge. (3) Remove electrical power from aircraft (including external ground power). Disconnect aircraft battery and tag battery cable. October 17, 2003 USE, COPYING, A'ii).()FI 0 !$Cl0S VRE IS GOVE~SfO 81 Tt;[ SfAJf t.I [ Nl ON hiE TITlE P AO t O F THIS OOCU irot E'i l Revision 4, September 18, 2008 (Reissue) 382-28-19 82-770 Page 5 HERCULES Lockheed Martin Aeronautics Company Marietta, Georgia 30063 SERVICE BULLETIN (4) Rope off an area for a 50-foot radius from all open tanks and vents. Post fuel hazard banners or signs in the area. (5) Remove access panels to fuel tanks, dry bays, wing trailing edges, pylon tank(s) and cross beam sections as needed. (6) Air-purge tank(s) as described in appropriate Hercules Ma intenance Manual or Hercules Ma intenance Instructions Manua l. After fumes have dissipated, ma intain a continuous supply of fresh air for personnel worki ng in the tank(s). CAUTION: WORK DIRECTLY ASSOCIATED WITH TH IS SERVICE BULLETIN SHALL BE ALLOWED ONLY DURING FUEL TANK MAINTENANCE. CAUTION: AT ALL TIMES, CARE MUST BE TAKEN TO PREVENT ENTRY OF CONTAMINANTS INTO THE FUEL TANK(S) THROUGH THE OPEN ING . OPENING SHALL BE COVERED WITH LINT-FREE CHEESECLOTH WHENEVER THE TANK COVERS ARE REMOVED AND WORK IS NOT IN PROGRESS. CAUTION: USE RUBBER MATS TO PROTECT THE BOTTOM OF TANK(S) . NOTE: Should any inspection fail , rework the failed article in accordance with Hercules Corrosion Prevention and Control Manual. B. INSIDE FUEL TANKS (1) Visual Inspection Perform all inspections descri bed in the following paragraphs. Using a high powe red explosion-proof light, inspect a ll ground/bonding jumpers attach ed to fuel components (tubes, plumb in g adapters, tube connections) for e vi dence of corrosion and security. Visible corrosion is de fi ned as discoloration, jumper strand separation , or jumper strand breakage and a ll are cause for rejection and repair or replacement. (a) Bonding Jumpers : 1 Inspect for corrosion of bonding jumper wires. Corrosion can result in failure of the jumper. g Inspect ground attachment po ints for good contact and tightness. ~ Inspect for jumpers that are worn or frayed . ~ Inspect all tubi ng and plumbing fittings greater than 3 inches in length for presence of bonding jumpers or other means of bonding. ~ Any bonding jumper or attach points that fail the visual inspection should be reworked in accordance with Hercules Corrosion Prevention and Co ntrol Manual 382-28-19 82-770 Ull C:C>Pl'!NO A.~O~~ D SC1.0SUU fSGOV'EIIIN£01V f'"[SI AT lV l ~ l 0'11 fH t fnlt P..U!O" f H!SOOCVM.f.IH October 17, 2003 Page 6 Revision 4, September 18, 2008 (Reissue) HERCULES Lockheed Martin Aeronautics Company Marietta, Georgia 30063 SERVICE BULLETIN (b) Electrical Wiring Conduits in Tank Ensure that. where electric wires are routed through conduits installed in a fuel tank; these conduits show no evidence of high surface temperatures or arcing through the conduit wall. All wiring conducting power (e.g. , fuel pump(s) , power supplies, fuel level sensor(s), Fuel Level Control Valves (FLCV), etc.) into or through a fuel tank should be evaluated assuming arcing to surfaces such as metallic conduits or wing surfaces, unless fail-safe protective features are provided. If evidence of arcing is present rework or replace the conduit. (c) Fuel Quantity Indicating System (FQIS) Wiring ! Ensure that wires are not spot tied inside fuel tanks. NOTE: Steps f. and~ are not applicable to Lockheed Martin serial numbers 4144 through 4715 and aircraft with bayonet type connectors. f. Ensure that shields are terminated within 0.5-inch of the HI-Z terminal lug using solder sleeves and 20 AWG jumper wire (if required). ~ Ensure that terminal lug size on FQIS wires are: • Hl-Z- size 6. • LO-Z- size 10. • Ground - size 8. 1 Should FQIS wiring not be in accordance with steps 1, 2, or 3 above ensure it is brought within specification immediately. October 17. 2003 US! , COP YcHG A.l'i O·O~ OISCLC»U'!:£ tSGO VU ~ t: ::I SY fHt Sl AlEioi ! !H O !II I ME Hll E PAU ! O~ 114tS OOCU M ! Nl Revision 4 , September 18, 2008 (Reissue) 382-28-19 82-770 Page 7 HERCULES Lockheed Martin Aeronautics Company Marietta, Georgia 30063 SERVICE BULLETIN (d) Other Items: 1 Inspect for corrosion that could diminish the effectiveness of the bonding surfaces for all fuel tank access panels. ~ Inspect for loose or corroded rivets that are along the bond-path for any component that is to be bonded. For example, inspect the rivets used to in stall any bracket that a pump or valve is bonded to, or a bracket that a bonding jumper is terminated to it. NOTE: If inspection reveals a missing or deteriorated bonding jumper, or if bonding jumpers fa il inspection, the bonding jumper is to be removed and replaced. Jumpers meeting the requirements of MIL-C-83413/8 type C (part number M83413/8-C(Iength)(lug)(lug)) are the preferred replacement bonding jumper inside the fuel tank, but if not available in stock, MS25083-2 bonding jumpe rs are authorized for use in fuel ce ll s. Refer to the following chart for bonding jumpers inside of fuel tanks only: REPLACEMENT JUMPER M83413/8-C00488 M83413/8-C00488 M83413/8 -C 00688 M83413/8-C00488 M83413/8-C00788 M83413/8-C00488 (2) Fuel Pump Inspection EXISTING JUMPER MS25083-1 883 MS25083-1 884 MS25083-1 886 MS25083-2884 MS25083-2887 MS25083- 3884 WARNING: ENSURE METER IS CERTIFIED FOR USE IN FUEL OR OXYGEN-RICH EXPLOS IVE ENVIRONMENTS. FAILURE TO COMPLY MAY RESULT IN SEVERE INJURY OR DEATH. Inspect all fuel pumps to ensure proper grounding . NOTE: Maximum resistance between aircraft structure and fuel pump should be 0.37 milliohms. (a) Remove every fuel pump in accordance with appropriate Hercules Maintenance Manual or Hercules Maintenance Instructions Manual. (b) Clean the faying surface of each pump to remove all anodized coating in accordance with paragraph (14). (c) Clean the aircraft mounting surface for each pump to remove all primer in accordance wi th paragraph (14). 382-28-19 82-770 us t.. coPVIH3. AH 0() 'II O !sclo su ~~: r • s Govu 'l r:o ev l tt E srAJE,.. EN lo-. '" E l l h.EP.tO Eo" rn;$ oocu "' ' "'' October 17 , 2003 Page 8 Revision 4, September 18, 2008 (Reissue) HERCULES Lockheed Martin Aeronautics Company Marietta, Georgia 30063 SERVICE BULLETIN (d) Reinstall fuel pumps in accordance with appropriate Hercules Maintenance Manual or Hercules Maintenance Instructions Manual. (e) Perform resistance measurement in accordance with paragraph (4) . (f) If the resistance check fails repeat steps (a) through (e) above. (3) Fuel Level Control Valve (FLCV) Check conduit for evidence of arcing or discoloration. NOTE: Should the conduit show evidence of arcing or discoloration replace it. (4) Grounding/Bonding Measurements WARNING: ENSURE METER IS CERTIFIED FOR USE IN FUEL OR OXYGEN-RICH EXPLOSIVE ENVIRONMENTS. FAILURE TO COMPLY MAY RESULT IN SEVERE INJURY OR DEATH. The maximum resistance between aircraft structure and the following should be: • Fuel pump and associated conduit- 0.37 milliohms. • FLCV and associated conduit- 1.86 milliohms. • Fuel tank access panels - 0.37 milliohms. • Fuel lines - 1.00 ohm . Perform resistance measurements on all fuel pumps and Fuel Level Control Valves (FLCV) in accordance with paragraphs (5) through (17). NOTE: If the measurement fails the test, the bonding/grounding termination shall be reworked and retested until the resistance is less than maximum listed above. (5) Bonding Verification Bonding verification should be performed and identified at a logical point so that any rework can be accomplished in a timely manner. (a) Measure bond resistance with connector plugs removed from equipment mounted on plastic tanks, pipes, etc. (b) In all cases, the resistance values refer to the overall resistance measured across the bond interface from the object to structure into which the bond is installed, unless otherwise indicated. (c) Measurement instrument probes will be applied as near as possible to the bond. October 17' 2003 US! , COP YINO, A.-. 0 ,0,11 O! SClO S U II:t ~SGOV!: ItN!O!I Y ht ! StAr !,., ! N fO ~ U1 t Wl! ..... ..:a:o, hH$ oocuu ENf Revision 4, September 18, 2008 (Reissue) 382-28-19 82-770 Page 9 HERCULES Lockheed Martin Aeronautics Company Marietta, Georgia 30063 SERVICE BULLETIN (d) For bonds using a jumper or ground lead, the point for measuring the resistance will be any cleaned area on the same piece of metal, within 4-inches of the jumper or ground lead terminal being checked. (e) Do not use test currents in excess of 50 amps when measuring the bond resistance of current ground paths. NOTE: Notify the local Fire and Safety Authority, or equivalent, and obtain permission before measuring bond resistance in any area where pure oxygen may combine with any fossil fuel or combustible liquid. (f) All meters used for measuring bonding resistance will have the appropriate certified measuring range . (g) Do not measure bonding resistance from an insulated termina l. 1 Install a dummy (uninsulated) terminal and take the measurement from that termina l. ~ Do not pierce the insulation of terminals. (h) Impressions on electrical wire terminals caused by resistance measuring equipment that do not expose the base metal are acceptable. (i) Any part from which the original finish has been removed to perform bonding resistance measurements will be refinished in accordance with paragraph (15). (j) Perform a bonding meter check, when a unit requiring electrical bonding is removed and replaced, before the installation /reinstallation is accepted by Quality Assurance. (k) Should any inspection point fail the visual (corrosion) or resistance inspection, that item shall be reworked in accordance with Hercules Corrosion Prevention and Control Manual. 382-28-19 82-770 October 17, 2003 Page 10 Revision 4, September 18, 2008 (Reissue) HERCULES Lockheed Martin Aeronautics Company Marietta, Georgia 30063 SERVICE BULLETIN (6) Resistance Measurement of Grounds WARNING: ENSURE METER IS CER TI FIED FOR USE IN FUEL OR OXYGEN-RICH EXPLOSIVE ENVIRONMENTS. FA ILURE TO COMPLY MAY RESULT IN SEVERE IN JURY OR DEATH. For direct measurement with a bonding meter, use secondary structure-to-primary structure bonds for resistance measurement. (See figures 1, 2, and 3.) /PRIMARY STRUCTURE BONDING METER PRIMARY STRUCTURE =---- STRUCTURE IN TERFACE ----..! PR E- INSTALLED BUILDUP DIRECT BUILDUP RESISTANCE MEASUREMENT MUST BE AS CLOSE AS POSSIBLE TO BOND UNLESS OTHERWISE DICTATED. Figure 1 Direct Resistance Measurement of Current Return Grounds October 17, 2003 USE COPV:.~Q . 11.'10.0~ 01$C~O$URE i S GOVERNED I V T HE STATEiot ( 'I J 0'1 fHE l ! TU: PAQ( OF TH IS OOCV U (N t Revision 4, September 18, 2008 (Reissue) SFAR- 88 - SB-2- 00 1 382-28-19 82-770 Page 11 HERCULES Lockheed Martin Aeronautics Company Marietta, Georgia 30063 SERVICE BULLETIN PR IMARY STRUCTU RE BOND ING METER SECONDARY STRUC TURE (BRACKE T) Figure 2 BONDING JUMPER SFAR-88- SB- l - 002A Direct Resistance Measurement of a Bonding Jumper 382-28-19 82-770 Page 12 October 17, 2003 Revision 4, September 18, 2008 (Reissue) HERCULES Lockheed Martin Aeronautics Company Marietta, Georgia 30063 SERVICE BULLETIN PRIMARY STRUCTURE BONDING METER SECONDARY STRUCTURE (BRACKET) Figure 3 Direct Resistance Measurement of a Stud Installation October 17, 2003 US( , COP Y NG A.'II OtOII OISCLOSU U!SGOVflt 'o f.0 1'1'1 otf.STAi l , ( HI O N 1,. ( TIT ~l ftAQl 0' 1 ~ 13 OOCU\I l " l Revision 4, September 18, 2008 (Reissue) SFAR-88- SB - 1- 0026 382-28-19 82-770 Page 13 HERCULES Lockheed Martin Aeronautics Company Marietta, Georgia 30063 SERVICE BULLETIN (7) Resistance Measurement of Faying Surfaces For resistance measurement of faying surfaces, reference paragraph (6) fo r meter connection procedures and figure 4. 382-28-19 82-770 Page 14 BONDI NG METER FAYING SURFAC E BOND SF AR-88- SB - I - 003A Figure 4 Resistance Measurement of Faying Surface Bonds USE, COPYiNG, A."ii).QR O.SC I..OS I.IRE IS CO\It1t NfO !lY fHf S I AI !MfNl 0 ,'1 H~f f lllf P~ E OF Tt1 iS OOCU iot EH f October 17. 2003 Revision 4, September 18, 2008 (Reissue) HERCULES Lockheed Martin Aeronautics Company Marietta, Georgia 30063 SERVICE BULLETIN (8) Resistance Measurement Across Hydraulic Fittings and Tubing Installations For resistance measurement across hydraulic fittings and tubing installations, reference paragraph (6) for meter connection procedures and figure 5. / BONDING METER BONDING METER Figure 5 Resistance Measurement of Hydraulic Fittings and Tubing Installations October 17, 2003 US! COI'Y!HG A"ii),()lt DdClOSU't!: 1$GOVfJtNf08Yl"E SfA.f(.UfN t ON THE fll l,. t, PAG tOF HUSOOCUU!.N f Revision 4 , September 18, 2008 (Reissue) SFA R-88-SB-1-004A 382-28-19 82-770 Page 15 HERCULES Lockheed Martin Aeronautics Company Marietta, Georgia 30063 SERVICE BULLETIN (9) Resistance Measurement of Tube-To-Bulkhead Fittings For resistance measurement of tube-to-bulkhead fittings, reference paragraph (6) for meter connection procedures and figure 6. _... BONDING METER END OF FITTING SFA R- 88 - SB - 1- 0048 Figure 6 Resistance Measurement of Tube-To-Bulkhead Fittings (1 0) Resistance Measurement of Bulkhead Fittings to Primary Structure For resistance measurement of bulkhead fittings to primary structure, reference paragraph (6) for meter connection procedures and figure 7. 382-28-19 82-770 Page 16 ---BONDING METER END OF FITTING SF AR -88-SB-1-005 Figure 7 Resistance Measurement of Bulkhead Fittings to Primary Structure VS! CO~~'VIHG, A~ O.O~ OIS ClO SU,_E 1$ GO IIERNE O BY THE StATE\II ENf 0~ li't E lfl LE P-'QE Of llh $ CXX:U"'-f Nl October 17, 2003 Revision 4, September 18, 2008 (Reissue) HERCULES Lockheed Martin Aeronautics Company Marietta, Georg ia 30063 SERVICE BULLETIN ( 11) Repairs When repairs are necessary, appropriate cleaning and surface preparation is required. Refer to paragraph (12} for cleaning methods and procedures. (12) Cleaning Methods and Procedures The following paragraphs provide approved cleaning methods and procedures. (a) Abrasive Cleaning -Cleaning Method 1 1 Anodic films vary in thickness and may be very difficult to remove with a wire brush. f. If wire brushing fails to remove anodic film, use an abrasive disc. Ensure the area is cleaned properly if a disc is used. ~ Any one, or combination, of the following procedures will be used followed by a solvent wipe with a clean dry cloth. NOTE: Complete the electrical bond within 4 hours after completing the following procedures. ~ Method 1 - Abrasive Sheet ~ Abrasive sheets will be reused only on the same type of material on which they were used originally. Q The surface will be prepared by hand, using Cleaning Method 3- paragraph (12)(c). f A circular motion will be maintained with the abrasive sheet. Q. The operation will be continued until the coating is removed, and a clean, bare metal surface is visible throughout the required bond area. §. Method 1 - Stainless Steel Rotary Brush October 17, 2003 ~ The surface will be prepared using a rotary, stainless steel brush, mounted in a manual or power drill. Q The wire brush is to be used with light, intermittent pressure, keeping the cutting face parallel with the surface being prepared . £ The results must be inspected after each intermittent application. Q. A minimum of the metal structure, carbon-composite structure, or conductive finish will be removed to expose a clean, bare metal surface throughout the required bond area. US!: C~YIH G. AN OQ'l0t5C l0SU.II:f t$ GOVf.II:N f0 (U'T-tES TA.r [ W:[ Nf 0 N hi [ rlf l.l: P~ fOF n mo OOCUM f. HI 382-28-19 82-770 Revision 4, September 18 , 2008 (Reissue) Page 17 HERCULES Lockheed Martin Aeronautics Company Marietta, Georgia 30063 SERVICE BULLETIN §. Method 1 - Abrasive Disc ~ The surface will be prepared using a 150 to 400 grit abrasive paper or cloth disc. Q. The abrasive disc must be fixed to a rotary mandrel mounted on a manual or power drill and the appropriate sized mandrel selected. £ As an alternate material, a fine or very fine Scotch-Brite or Bear-Tex pad disc wetted with water may be used. 9. The abrasive disc will be re-used only on the same type material on which it was originally used. ~ The abrasive disc will be used with light, intermittent pressure, keeping the cutting face parallel with the surface being prepared. f The operation will be continued until the coating is removed and a clean, bare metal surface is visible throughout the required bond area. 9. The disc must be replaced when it becomes plugged with the material being removed. b. Only a minimum of the metal will be removed. (b) Light Abrasive Cleaning - Cleaning Method 2 1 Any one, or combination , of the following procedures will be used followed by a solvent wipe with a clean dry cloth. ~ Complete electrical bond within 4 hours after these procedures. ;! See paragraph (13) for treatment of surfaces cleaned with this method. 1 Method 2 - Abrasive Sheet ~ Abrasive sheets will be re-used only on the same type of material on which they were used originally. Q. The surface mu st be prepared by hand, using an abrasive sheet of paper or cloth (240 to 400 g ri t ), or very fine to ultra fine Scotch-Brite/Bear-Tex pads. £ A circular motion will be maintained with the abrasive sheet. 9. The operation will be continued until the coating is removed and a clean, bare metal surface is visible throughout the required bond area. 382-28-19 82-770 Ioiii CQltVI -.0 A.:•~ I)(),. 0 SC LOS Uit ! IS G0Vf..ll.;f: 0 8'fl 1'1li 1~1( Yl H l ON 11'1 (. I II LE I'AO l O!' fM tSOOCU-..! "1 1 October 17. 2003 Page 18 Revision 4, September 18, 2008 (Reissue) HERCULES Lockheed Martin Aeronautics Company Marietta, Georgia 30063 SERVICE BULLETIN §. Method 2 - Abrasive Disc ;a. The surface will be prepared using a 240 to 400 grit abrasive paper or cloth disc. Q The abrasive disc will be fixed to a rotary mandrel mounted on a manual or power drill and the appropriate sized mandrel selected . £ As an alternate materia l, a fine or very fine Scotch-Brite or Bear-Tex pad disc wetted with water may be used. Q. The abrasive disc must be re-used only on the same type material on which it was originally used. ~ The abrasive disc will be used with light, intermittent pressure, keeping the cutting face parallel with the surface being prepared . The operation will be continued until the coating is removed and a clean, bare metal surface is visible throughout the required bond area. 9. The disc must be replaced when it becomes plugged with the material be ing removed . !:!. Only a minimum of the metal will be removed. (c) Solvent Cleaning -Clean ing Method 3 This method will be used for the cleaning of terminal s, plated and Class II conversion coated metals, and passivated CRES . NOTE : When using this method , complete electrical bond within 24 hours. 1 Remove excess debris (chips, shavings, loose soil, etc.) and excess grease, oil, or other loose contamination from the bond area by vacuuming, wiping, scrubbing, or other physical means. ~ Using a non-metallic brush or wiper, clean a width approximately two times wider than the width of the bond surface. ~ Wipe off all solvent while the surface is wet, using clean wiping material or non-metall ic bristle brush. ~ Apply light pressure between the brush or wiper and the surface . §. Avoid the use of excessive amounts of solvent. §. Make applications of clean ing solvent and wiping (or brushing) , using clean materials , until no residue is visible on the bondi ng surface area. October 17, 2003 Revision 4, September 18, 2008 (Reissue) 382-28-19 82-770 Page 19 HERCULES Lockheed Martin Aeronautics Company Marietta, Georgia 30063 SERVICE BULLETIN (d) Light Abrasive Polish Cleaning -Cleaning Method 4 This method will be used for cleaning on scale free, lightly oxidized, bare titanium alloys and nickel base alloy surfaces. NOTE: When using this method, complete electrical bond within 24 hours after cleaning . 1 Wash/solvent wipe bond area. f. Abrade the faying surfaces with 400 grit aluminum oxide abrasive paper or cloth, ultra fine pads, or fine grit metal polish. ~ Wipe off polishing residue with a dry, clean, soft, cotton cloth. (13) Treatment of Abrasively Cleaned Aluminum This procedure applies to aluminum that has been abrasively cleaned in accordance with pa ragraph (12)(a) and (12)(b). (a) Initiate this treatment step within 2 hours after the abrasive cleaning. (b) Re-clean the surfaces in accordance with paragraph (12)(c) if the 4-hour period is exceeded . (c) Using a brush apply the conversion coating evenly and liberally to the surface. (14) Removal of Polysulfide Sealing Compounds from Faying Surfaces If the surface is to be electrically bonded, the polysulfide sealing compounds must be removed from the mating (faying) surfaces using non-metallic trimmers (scrapers). On the following surfaces, (See table 1) use the cleaning method specified: NOTE: The bond surfaces must be solvent cleaned using clean wipers soaked with solvent. (a) Group 1. Cleaning Method 2- paragraph (12)(b). (b) Group 2. Passivated, plated and conversion coated . Cleani ng Method 3- paragraph (12)(c). (c) Group 2. Primed, top coated and anodized. Cleaning Method 1 -paragraph (12)(a) . 382-28-19 82-770 USE, COPY',NG. A."iO.QR O!~l OS:.tRE ISCOV!.ItN !D ISV 1.-tt S1Af[ ~ [N r ON HIE TillE P,tr,Q;f OF TtH$ 00C1./'wt[NT October 17, 2003 Page 20 Revision 4, September 18, 2008 (Reissue) HERCULES Lockheed Martin Aeronautics Company Marietta, Georgia 30063 SERVICE BULLETIN Table 1. Surface Cleaning Methods SURFACE CLEANING METHODS MATERIAL SURFACE FINISH CLEAN ING CLEANING FINISH CODES METHOD AGENTS Primed Topcoat 1, F, S, A Abrasive paper, cloth, pads, and MIL-A-8625, 51 , 46 1 glass beads. Type Ill Anodized AAA Para. (12)(a) Brushes or discs Bare N/A Fine to ultra-fine GROUP 1: MIL-C-5541, F 2 abrasive paper ALUMINUM Class 1A Para. (12)(b) Cloth pads, discs, MIL-A-8625, A metal polish Types I and II Anodized MIL-C-5541, s 3 Solvent Clean Class 3 Para. (12)(c) Passivated M 3 Solvent Clean (CRES) Para. (12)(c) Plated metals C, CC 3 Solvent Clean Conversion G Para. (12)(c) Coatings Phosphate ---- 3 Solvent Clean Fluoride on Para. ( 12)(c) GROUP 2: Titanium TITANIUM , Primed 1, c. cc . 1 Abrasive paper, STEEL (M ILD TO HIGH STRENGTH M Para. (12)(a) cloth, pads, and Topcoat glass beads. CRES) 51,46 Brushes or discs TERM INALS Chromate 2 Fine to ultra-fine ---Conversion Para. (12)(b) abrasive paper. Coated cloth pads. discs, Cadm ium Plated metal polish Bare --- 4 Ultra-fine abrasive Para. (12)(d) paper. cloth, paper, metal polish See paragraphs ( 12) and ( 13) for time limits. October 17, 2003 U$f: COP YI-.o• .-..-.o.Oit OISCLOSU "f ISGOVt.NN! OitY 111! SfMOol.f NT 0~ IM( fl1l f PAC;£ Or ht1$00CU MfNT Revision 4, September 18, 2008 (Reissue) ADDITIONAL INFO. Conversion coating Class 2. Post treatment required on bare aluminum surface Conversion coating Class 2. Post treatment required on bare aluminum surface Includes previous masked areas Includes previous masked areas Includes previous masked areas Includes previous masked areas --- - -- Includes masked areas 382-28-19 82-770 Page 21 HERCULES Lockheed Martin Aeronautics Company Marietta, Georgia 30063 SERVICE BULLETIN (15) Refinishing and/or Reseal in g (a) After assembly and bond resistance tests on the fasteners to structure, fray surface bonds, etc., when required; reapply all primers and sealants to within 1/32-inch minimum of bond joint or test probe area. (b) Masked areas for electrical disconnect panels require no touch-up if the masked area after in stallation is less than 1/8-inch. (c) Do not paint machine-finished flanges of fuel or hydraulic pumps, valves, and simi la r equipment that must maintain a liquid-tight seal at the mounting surface. {d) Any exposed surfaces, from which paint or other non-conductive coatings have been removed, must be reapplied . (e) Any surfaces which have had the anodic finishes removed will be refinished with varnish. (f) Refinishing of the bonded areas of magnesium alloy parts must be completed within 24 hours of the removal of the protective finish . (g) After assembly, clamped, riveted, or bolted joints will be refinished with one coat of epoxy primer and a top coat to match the adjacent parts. (16) Installation of Faying Surface Bonds (a) Prepare the faying surfaces using the appropriate cleaning method prov ided in paragraph (12). WARNING: ENSURE METER IS CERTIFIED FOR USE IN FUEL OR OXYGEN-RICH EXPLOSIVE ENVIRONMENTS. FAILURE TO COMPLY MAY RESULT IN SEVERE INJURY OR DEATH. (b) Measure the resistance of the bond. • Fuel pump and associated conduit - 0.37 milliohms. • FLCV and associated conduit- 1.86 milliohms. • Fuel tank access panels- 0.37 milliohms. • Fuel li nes- 1.00 ohm. (c) Resistance testing made on all items must meet the bonding requirements specified in this Service Bulletin . 382-28-19 82-770 Vst CO~ 'It~O A.'IO.O III 0 -SClOS,n t£ !$ GOvtJIINIO (1;'1' 1 " ' 1 1At lV l N I 0 "" l "l flllf ~'IJ{Jf OF ' " -' OOC .J \II( "'t October 17 , 2003 Page 22 Revision 4, September 18, 2008 (Reissue) HERCULES Lockheed Martin Aeronautics Company Marietta, Georgia 30063 SERVICE BULLETIN (17) Assembly of Bond Jumpers and Ground Leads (a) Assemble jumper to plated steel, CRES, or titanium bolted connection as shown in figure 8. SCREW (LK106V() ()) LOCKWASHER (MS35228( )) LOCKWASHER (MS35338 ( )) _ .--- TERMINAL WASHER (NAS11490()) SCREW (LK106V() ()) TERMINAL ~~--------~~------~~ REFINISH AFTER INSTALLATION TO WITHIN 1/32 INCH OF WASHER STRUCTURE CLEAN BASE METAL AN AREA 1-1 /4 TIMES THE DIAMETER OF THE TERMINAL SF AR-88-SB-0-006 CLEAN AND REFINISH IN ACCORDANCE WITH PARAGRAPHS (12) AND (15) USE ONLY TITANIUM OR CRES FASTENER COMPONENTS IN TITAN IUM STRUCTURE Figure 8 Jumper to Plated Steel, CRES, or Titanium Bolted Connection October 17, 2003 US£. COPYING. ANO.O ,. OISCLOSIJ:'IE IS GOVtlt NE D I Y fM! S t A1L\II[ Nf 0 "1 tl'l!. llll ! P~ ! OF TH I$ OOCU~!. ~ l Revision 4, September 18, 2008 (Reissue) 382-28-19 82-770 Page 23 HERCULES Lockheed Martin Aeronautics Company Marietta, Georgia 30063 SERVICE BULLETIN (b) Assemble jumper to tube clamp connection as shown in figure 9. CLAMP (MATERIAL AS APPLICABLE TO TUBE) BONDING OR CURRENT RETURN JUMPER REFINISH AFT ER INS TALLATION TO WITHIN 1132 INCH MINIMUM OF CLAMP. NOTE 2, 3 BRUSH OR FILLET SEAL ALL EDGES OF CLAMP ram REFINISH AFTER INSTALLATION TO WITHIN 1132 INCH MINIMUM OF HARDWARE. NOTE 2, 3 SEALING COMPOUND TO COVER ALL PORTIONS OF ATTACHMENTS CLEAN TO BASE METAL AN AREA 1 -114 TIMES THE CLAMP WIDTH AND INSIDE OF CLAMP NOTE 1 CLEAN AREA OF CLAMP TAB THAT TOUCHES TERMINAL TO BASE METAL. NOTE 1 1. CONTACT AREA PREPARATION 1- 114 TIMES CONTACT AREA . 382-28-19 82-770 Page 24 2. SEAL AN AREA 1-114 TIMES THE PREPARED AREA. WHEN REQUIRED. 3. REFINISH IN ACCORDANCE WITH PARAGRAPH (15). SF AR-88-SB-0-007 Figure 9 Jumper to Tube Clamp Connection October 17. 2003 Revision 4, September 18, 2008 (Reissue) HERCULES Lockheed Martin Aeronautics Company Marietta, Georgia 30063 SERVICE BULLETIN (c) Assemble jumper to aluminum bolted connection as shown in figure 10. PANEL 11m LK200F() NUT NAS1149D( )J FLAT WASHER LK106V() BOLT 1. PREPARE SURFACE AREA IN ACCORDANCE Wl TH PARAGRAPH (12). 2. REFINISH TO Wl THIN 1/32 INCH MINIMUM OF WASHER. 3. SEAL IN ACCORDANCE WlTH PARAG RAPH (15) WHEN SEALI NG IS REQUIRED. Figure 10 Jumper to Aluminum Bo lted Connection October 17, 2003 USIE COPYI ,. ::O. A)IIO .OJIII O!SC tOS U 't ( IS GOVU 'II lO BY lti( SJAlht [ N l ON TH( l +Hl lltNl ( 01' f,.. I:S OOCUV tHl Revision 4, September 18, 2008 (Reissue) SF .AR-88 - SB -o-008 382-28-19 82-770 Page 25 I I HERCULES Lockheed Martin Aeronautics Company Marietta, Georgia 30063 SERVICE BULLETIN C. ZONAL INSPECTION OF DRY BAY AREAS AND OTHER REQUIRED AREAS The Zonal Safety Analysis (ZSA) formed a part of the safety compliance documents required to meet the requirements of Federal Aviation Administration, Special Federal Aviation Regulation SFAR 88 "Transport Airplane Fuel Tank System Design Review, Flammability Reduction, and Maintenance and Inspection Requirements." The ZSA used SAE Aerospace "Guidelines and Methods for Conducting the Safety Assessment Process on Civil Airborne Systems and Equipment" (SAE ARP4761) as a suggested format. The ZSA identified design and installation requirements and individual failure modes, which may have the potential to lead to a catastrophic or hazardous failure event. The analysis recognized the potential hazards of the physical installation of system hardware and the effect it has on the independence of associated systems. It also incorporated analysi s, of events outside the system(s) concerned, but which may influence events within the system(s). To assess these potential hazards or threats, the ZSA considered the installation aspects of new and/or modified individual system/components and the mutual influence between several systems/components installed in close proximity on the airplane. To accomplish this task the engineering drawing package and actual aircraft installations were inspected to prove compliance with Lockheed Drawi_Q_gs and §P-e..c.ificatio_ns_prrd FAA requirements. The aircraft as delivered to each customer met the design requirements that Lockheed Martin feels is the minimum to assure fuel tank safety. This section should be accomplished on any changes to the aircraft since delivery to the customer. Original installations by the Lockheed Martin meet these requirements. The following documents are to be used in bringing the installation/repair into compliance: • Hercules Corrosion Prevention and Control Manual • Hercules Airfreighter Progressive Inspection Procedures or Hercules Airfreighter Series Progressive Inspection Procedures • Hercules Maintenance Manual or Hercules Maintenance Instructions Manual • Hercules Wiring Diagram Manual The center wing dry bay, dry bays 1, 2, 3, and 4, the wing leading-edge, the wing trailing edge, and the fuel probes, shall be inspected in accordance with the following paragraphs: -.J ( 1) Electrical Systems Inspection Perform all inspections described in the following paragraph. (a) Aluminum W ire Ensure aluminum wire is not used in the following locations: 1 Aluminum wire smaller than No. 4 AWG shall not be used for main generator cables. f. Aluminum wire shall not be installed in areas of corrosive fumes or severe vibration. ~ Aluminum wire shall not be connected to engine mounted accessories. 1 Aluminum wire installation shall be permanent. ~ Aluminum wire runs shall be longer than three feet 382-28-19 82-770 Ust. COI"vti(O. A.NO.OitO! SCl OSU~t ISGOvti'C N!O SY 1M! SlATht E.•H ON Tt1 f. f iTlE P.-.GEOf h~ 1 $ 00CUMfN l October 17, 2003 Page 26 Revision 4, September 18, 2008 HERCULES Lockheed Martin Aeronautics Company Marietta, Georgia 30063 SERVICE BULLETIN (b) Copper Wire Ensure that no wire smaller that AWG 22 is used for in ter-connecting equipment(s). (c) Engine Mounted Accessories Ensure that for direct attachment to engine mounted accessories wire and cable smaller than No . 20 AWG high strength alloy shall not be used. (d) Spare Cable Length Ensure that harnesses are installed to permit replacement or repair of individual cables without removal of the entire harness. At least two inches of spare cable length shall be provided to allow for broken connections. (e) Insulating Tubing Ensure that insulating tubing is placed over term in a ls (except pre-insulated types) to provide electrical protection and mechanical support and is secured to prevent slippage of the tubing from the termina l. October 17 , 2003 vsE coPY!'iO, AN:l.OitO!SC!.OSUIU: •soovtiii Nt'.O II'f'f" e" "' l .., ! HI 01'1 '" ' tiH I! "A0l0f' '"' •oocv "" u" Revision 4, September 18, 2008 (Reissue) 382-28-19 82-770 Page 27 HERCULES Lockheed Martin Aeronautics Company Marietta, Georgia 30063 SERVICE BULLETIN (f) Dead-Ended Wires Perform an inspection to ensure that electrically energized conductors are not dead-ended. If wi res must be dead-ended, however, wire end caps shall be used . A minimum of 0.2-inch between the end caps and/or metallic objects shall be maintained . (See figures 11 and 12.) Figure 11 Properly Installed Wire End Caps Figure 12 Improperly Terminated Wi res 382-28-19 82-770 V$E. C0"'tl'fG, AN0.0~ 0.$Ct0$U~E t: S QO\I'EitNIE ·D8V THE StAtE I.tt:H t ON TH E f iH-f, PAG! Cf THIS OOC-0\f EN T October 17, 2003 Page 28 Revision 4, September 18, 2008 (Reissue) HERCULES Lockheed Martin Aeronautics Company Marietta, Georgia 30063 SERVICE BULLETIN (g) Wire Routing 1 Ensure that electrical wi re is not routed under fluid carrying tubes. ~ Ensure that when running wires over a fluid line that sufficient cable clamps are installed so that a broken wire cannot contact the flu id line. (See figure 13.) Figure 13 Broken Wire Over Fluid Line ~ Ensure that wire bundles within clamps are not larger than two inches in diameter. ~ Ensure that generator feeder wires are bundled separately from all other wires in the wing leading edge and fuselage areas. Ensure that all generator wire bundles, feeder and control, are separated from fuel tank boundaries (wall or bulkheads) in the wing leading edge area per original type design; i.e ., feeder wires in cable clamp and stand-off brackets in accordance with Step 2 . C . (2)(a)~ and control wires tightly tied in accordance with Step 2.C.( 1)(g)Z. using suitable material. §. Ensure the electrical power leaves the nacelle in the upper left quadrant and fuel is delivered to the engine in the lower right quadrant. October 17, 2003 Revision 4, September 18, 2008 382-28-19 82-770 Page 29 I HERCULES Lockheed Martin Aeronautics Company Marietta, Georgia 30063 SERVICE BULLETIN §. Ensure that wires are routed at least six inches away from lines or equipment containing flammables. Wires or cables closer than six inches shall be supported so that they wi ll not deflect closer than 0.5-inches from the lines or equipment, except where il")tervening structure or barriers exist between the lines or equipment and the wire or cables, which would make contact impossible. Where these requirements cannot be met, protection such as conduit or insulating material shall be used . (See figure 14.) Figure 14 Hydraulic - Electrical Lines Routed too Close 7 Ensure that wires are routed away from , or protected from, all hot equipment and lines to prevent insulation breakdown. The normal safe distance from bundles to bleed air ducts is twelve inches, and essential coaxial cables are nine inches. Ensure.all buodl ~~with 2 to 12 inches of hqtequiprnentaod lines are spot-tied using flame resistant lacing braid. Use fiberglass braid in power plant areas. §. Ensure that electrical wires are not routed through areas where they can be immersed in or saturated with fluids. When this is impossible, they should be enclosed in rigid conduit, plastic tubin g, or shrinkable tubing for a sufficient distance to prevent any fluid contact with the wires or cables. 382-28-19 82-770 October 17, 2003 Page 30 Revision 4, September 18 , 2008 HERCULES Lockheed Martin Aeronautics Company Marietta, Georgia 30063 SERVICE BULLETIN jt Ensure that provisions have been installed to prevent insulation chafing. Wires and bundles should be installed by routing and clamping to ensure sufficient spacing from structure or other parts after any single failure. Bend radii should be large enough to ensure that insulation cracking does not occur. (See figure 15.) October 17. 2003 NO SUPPORT AT END OF BEND 2 DIAMETER Of WIRE OR CABLE MINIMUM BEND RADIUS FOR WIRE INSTALLATION mm & MINIMUM BEND RADIUS - 10 TIMES THE DIAMETER OF THE WIRE OR CABLE. & MINI MUM BEND RADIUS - 3 TIMES THE DIAMETER OF THE WIRE OR CABLE. Figure 15 Minimum Bend Radii USE, COP 't\NG. A,"il),QR 0-$C t.OSIJRE. ISOOV't-1tNE08Y l 11 E S TA.f£Mf,IU O lf T11E frll !! l>.r.G ! Of T,.:$ OOCU V !NT Revision 4, September 18, 2008 (Reissue) SUPPORT AT BOTH ENDS Of WIRE BEND SFAR - 88-sa-o-o l ~ 382-28-19 82-770 Page 31 HERCULES Lockheed Martin Aeronautics Company Ma rietta, Georgia 30063 SERVICE BULLETIN (h) Wiring Supports 1 Ensure that wires and cables are adequately supported to prevent excessive movement in areas of high vibration (all wing areas). f. Ensure that no friction or plastic tape has been used on the wires and/or cables under clamps. NOTE: Plastic type tapes will dry out in service and produce a chemical reaction with the wire or cable insulation, or absorb moisture. ~ Ensure that suitable clamps, grommets, or other devices support wire and cables at intervals of not more the 24-inches. 1. Ensure that metal standoffs are used to maintain clearance between wire and structure. Employing tape or tubing is not acceptable as an alternative to standoffs for maintaining clearance. ~ Ensure that clamps and ties around bundles do not present a rough surface that may damage the wire insulation. The clamps should be tight enough to hold the wires in place, but not so tight that insulation damage would occur during installation, or later. (See figures 16 and 17.) NOTE: Filler rods may be used when a clamp does not ensure adequate clamping and there is not a smaller clamp, which wi ll clamp properly. (See figure 18 .) WEDGE POSIT ION ON SIZE 2 AND 3 CLAMPS PREFERRED WEDGE POSI TION ON SIZE 4 AND UP CLAMPS Figure 16 Proper Installation of Cable Clamps 382-28-19 82-770 USE. COPVINO. A NJ IO'\ OlS t: lOSURE IS COVER ~ ! :> 8 YIH E S fAI Ut! Nl 0~ II'(( tilL! ~A0 £0. TH IS OOCU !J ! Nl October 17, 2003 Page 32 Revisi on 4, September 18, 2008 (Reissue) HERCULES Lockheed Martin Aeronautics Company Marietta, Georgia 30063 SERVICE BULLETIN 1/16 TO 1/4 INC H MINIMU M t t NAS623 SC REW MS21042 - 3 LOCKNUT TO STRUCT URE TO BRACKETS October 17, 2003 AMS3356 SLICONE RUBBER fiLLER ROO Revision 4, September 18, 2008 (Reissue) Figure 17 Mounting Multiple Clamps Figure 18 Filler Rod Installation SFAR-88-SB-o-018 SFAJI-U-S8~1 T 382-28-19 82-770 Page 33 HERCULES Lockheed Martin Aeronautics Company Marietta, Georgia 30063 SERVICE BULLETIN §. Ensure that phenolic blocks, plastic liners, or rubber grommets are installed in holes, bulkheads, floo rs, or structural me mbers where it is impossible to install off-angle clamps to maintain wi ring separation. In such cases, additional protection in the form of plastic or insulating tape may be used. (See figures 19 and 20.) RU BBER GROMMET ANGLE BRACKET WITH --!1-4M TWO-P OINT FASTENING Figure 19 Protection for Wire or Cable when Passing through Bulkhead Figure 20 Wire Resting on Lightening Port (Not Allowed) ?._ Ensure that insulating tubing is kept at a minimum and must be used to protect wire and cable from abrasion, chafing, and exposure to fluids, and/or other conditions, which could affect the cable insulation . The use of insulating tubing for support of wires and cables in lieu of standoffs is prohibited . 382-28-19 82-770 USE . CO..Y\1'1 :). A~ O.OI'I OlSClOS VItf 1$(i.:;)V£.ANE0 &Y h~f SfAlhtf NT 0/'1: H~f f lh.E P.IOE OF t r;..S OCX::U Ut 'ft October 17 , 2003 Page 34 Revision 4, September 18, 2008 (Reissue) HERCULES Lockheed Martin Aeronautics Company Marietta, Georgia 30063 SERVICE BULLETIN §. Ensure that wire is routed in such a manner as to prevent chafing of insulation. Support wire to prevent harnesses from sagging into sharp metallic edges or rubbing the structure. October 17. 2003 (See figures 21 through 23.) Figure 21 Insufficient Space Under Cable DRA IN HOLE FOR WEATHER PROTECTION Figure 22 1/8' HOLE AT LOWEST POINT Drain Hole in Slack Wiring Bundle Revision 4, September 18, 2008 (Reissue) SPOT TIE OR CLAMP TUBE AT ENDS SF AR-88-SB - 0..015 382-28-19 82-770 Page 35 HERCULES Lockheed Martin Aeronautics Company Marietta, Georgia 30063 SERVICE BULLETIN WIRE BUNDLE ADAPTER SF AR-88-SB-0-016 Figure 23 Drip Loops in Wiring Bundle (i) Tying of Electrical Wires Ensure that tying of wires with plastic straps and tying braid provide the proper wi re bundle and breakout integrity. NOTE: The tying material has to be appropriate for the location within the aircraft. Figures 24 through 27 presents a sample of the proper use of tying material and knot configurations. 382-28-19 82-770 October 17, 2003 Page 36 Revision 4, September 18, 2008 (Reissue) HERCULES Lockheed Martin Aeronautics Company Marietta, Georgia 30063 SERVICE BULLETIN 1 Bundles shall be tied together with an approved plastic strap or braid. The number of spot ties should be kept to a minimum , but shall be used as necessary to produce a neat and orderly bundle. (See figure 24.) NOTE: Plastic straps shall meet the requirements of MIL-S-23190. Figure 24 Spot Tying Method f. Unless otherwise specified by an approved enginee ri ng drawing, straps shall not be used under the following restrictions: October 17. 2003 ~ Where the total temperature exceeds 185°F (85°C) . Q. Failure of the strap would permit movement of the wires and cables against parts which could damage the insulation, foul mechanical linkage, or permit the strap to fall into moving mechanical parts. £ Do not use in high vibration areas, in areas of severe wind and/or where moisture problems exist such as wheel well s, near wing flap etc .; do not use on wire bundles containing coaxial cables or other than those with solid dielectric. \ISl COPYiNG. A...O.QR 0 $ClOSV~l £$ GOVI 11Nf0 IV fHt I TAt l"lN I ON tH t T!TI.t IIN)l 0' 1" .-S OOC:U ~ fiH 382-28-19 82-770 Revision 4, Septe mb er 18, 2008 (Reissue) Page 37 HERCULES Lockheed Martin Aeronautics Company Marietta, Georgia 30063 SERVICE BULLETIN ~ When one or more wires break away from a bundle or harness , tie the breakout as shown in Figures 25, 26, and 27. When cable ties are used at "Y" breakouts, they must be wrapped around each section of the breakout. When cable ties are used at "T" breakouts on cable diameters over 3/4-inch, they must be wrapped around each section of the breakout. Figure 25 Tying Harness for Multiple Breakouts sF A.R-ee-se-o-ol3 Figure 26 Cable Ties for "T" Breakout 382-28-19 82-770 October 17, 2003 Page 38 Revision 4, September 18, 2008 (Reissue)