HERCULES Lockheed Martin Aeronautics Company 

Marietta, Georgia 30063 

SERVICE BULLETIN 

* REVISION NOTICE * 

FUEL- SFAR 88- DRY BAY ZONAL INSPECTION, INSPECTION/REPAIR OF STATIC 

GROUND TERMINALS OF FUEL SYSTEM PLUMBING, AND MARKING OF FUEL 

QUANTITY INDICATING SYSTEM WIRING 

Attached is Revision 4, dated September 18, 2008, to Service Bulletin 82-770/382-28-19. Information added or 

changed in this issue is indicated by a vertical revision bar in the margin of affected pages, or pointing hand for 

illustrations. 

This revision updates contact information, clarifies accomplishment instructions, and changes Section 2, 

Paragraph C.(8)(a)2a to agree with text of Figure 29. 

This revision is a complete reissue and replaces Revision 3 of this Service Bulletin dated November 30, 2006. 

Retain this notice with your copy of this Service Bulletin. 

Aircraft previously modified by this Service Bulletin should be re-inspected to ensure compliance. 

Basic 

Revision 1 (Reissue) 

Revision 2 (Reissue) 

Revision 3 (Reissue) 

_________ # ______ __ 

File: CSB 907 I M41 057 /1-3042 

EXPORT CONTROLLED INFORMATION 

October 17, 2003 

November 5, 2003 

January 28, 2004 

November 30, 2006 

WARNING • This document contains data whose export Is restricted by the Arms Export Control Act (Title 22, U.S.C., Sec 2751, et 

seq.) as amended, or the Export Administration Act (Title 50, U.S.C., App 2401 et seq.) as amended. Violations of these export laws 

are subject to severe criminal and civil penalties. 

C200& l0C(I'I£f. O .\AA.."C TIN COIV'O'I:I\TON l OCI('itiED MAll: fiN PROP!t'(.IAAY INFOIC,Al iON 

Revision 4, September 18, 2008 

382-28-19 

82-770 

HERCULES Lockheed Martin Aeronautics Company 

Marietta, Georgia 30063 

SERVICE BULLETIN 

FUEL- SFAR 88- DRY BAY ZONAL INSPECTION, INSPECTION/REPAIR OF STATIC 

GROUND TERMINALS OF FUEL SYSTEM PLUMBING, AND MARKING OF FUEL 

QUANTITY INDICATING SYSTEM WIRING 

1. PLANNING INFORMATION 

A. EFFECTIVITY 

(1) 382-28-19, FAA Certificated Aircraft: This Service Bulletin is applicable to all model 382, 382B, 

382E, 382F, and 382G series FAA Certificated Hercules aircraft (excluding 382J series aircraft). 

(2) 82-770, Foreign Direct Sales Aircraft: This Service Bulletin is applicable to all model 282, 382, 

382C, and 382T series Hercules aircraft (excluding 382U and 382V series aircraft). 

(3) 82-770, MAP/FMS/SAP Aircraft: This Service Bulletin is applicable to all model C-130 series 

Hercules aircraft (excluding C-130J Hercules aircraft). 

B. REASON 

(1) As part of compliance with Special Federal Aviation Regulation (SFAR) 88, the following four 

requirements were identified, which are addressed in this Service Bulletin. 

Develop maintenance documents to implement repetitive detailed inspections for the Fuel Level 

Control Valve (FLCV) wires and conduits to verify there is no damage. 

Develop maintenance documents to implement repetitive detailed inspections of the power 

wiring on the leading and trailing edges of the wing to verify that the separation of these wires 

to the tank wall has not been compromised. This action is to preclude any arcing to the fuel 

tank . This is the Zonal Inspection. This ensures that the original design remains intact and is 

not defeated by subsequent installations and inspections. 

NOTE: Lockheed Martin used the Honeywell FG220A and FG430A class fuel quantity probes, not 

the Honeywell FG420A, Series 1, 2, and 3 that were brought into question by NTSB 

Recommendations A98-34 and A98-35. 

Develop service information to implement a program where any Honeywell Series 1-3 Fuel 

Quantity tank probe connectors are replaced with Series 4 type connectors. 

• Develop service information to implement repetitive inspections of the fuel system electrical 

bonding system. These inspections should have measurements for critical bonds (i.e. electrical 

conduit, electrical components) and visual inspection for less critical bonds (i.e. fuel tube static 

bonds). 

• Add identity marker for fuel quantity indicating system wire. 

EXPORT CONTROLLED INFORMATION 

WARNING. This document contains data whose export is restricted by the Arms Export Control Act (Title 22, U.S. C., Sec 2751, et 

seq.) as amended, or the Export Administration Act (Title 50, U.S. C., App 2401 et seq.) as amended. VIolations of these export laws 

are subject to severe criminal and civil penalties. 

October 17, 2003 

Revision 4, September 18, 2008 

382-28-19 

82-770 

Page 1 of 50 I 
HERCULES Lockheed Martin Aeronautics Company 

Marietta, Georgia 30063 

SERVICE BULLETIN 

(2) The following background information resulted in a requirement to generate this Service Bulletin. 

(a) Federal Aviation Regulation (FAR) Section 25.901 (b)(4) requires electrically bonding the major 

components of the propulsion system to other parts of the aircraft. The affected major 

components of the propulsion system include the fuel tank system. Compliance with this 

requirement for fuel tank systems must be demonstrated by showing that all major components of 

the fuel tank are electrically bonded to the airplane structure. This precludes accumulation of 

electrical charges on the components and the possible arcing in the fuel tank that could otherwise 

occur. In most cases, electrical bonding is accomplished by installing jumper wires from each 

major fuel tank system component to the airplane structure. Advisory Circular (AC) 25-8, 

"Auxiliary Fuel Tank Installations," also provides guidance for bonding of fuel tank system 

components and means of precluding ignition sources within transport airplane fuel tanks. 

(b) FAR Section 25.954 requires that the fuel tank system be designed and arranged to prevent the 

ignition of fuel vapor within the system due to the effects of lightning strikes. Compliance with 

regulation is shown by incorporation of design features such as minimum fuel tank skin thickness, 

location of vent outlets out of likely lightning strike areas, and bonding of fuel tank system 

structure and components. Guidance for demonstrating compliance with this regulation is 

provided in AC 20-53A, "Protection of Aircraft Fuel Systems Against Fuel Vapor Ignition Due to 

Lightning". 

(c) AC 25.981-1C Draft paragraph 7.C, requires several inspections to verify that the components 

are in acceptable working 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 . According 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 60-371 B. 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 Aeronautics 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 adding 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 jumpers, 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 markers 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 for 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. MATERIAL 

Parts listed 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'IIEO 8Y lHE S llolEM! 'II 0 ";" lHf. flrt.lt PAG! 0 ' 111:$ OOC:UU!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 THIS 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 

IMPAIR 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 EQUIPMENT, 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 

WITH 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 wing 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;[ SfAJft.I[ Nl ON hiE TITlE PAOt O F THIS OOCUirotE'il 

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 Maintenance Manual or Hercules Maintenance 

Instructions Manual. After fumes have dissipated, maintain a continuous supply of fresh air for 

personnel working in the tank(s). 

CAUTION: WORK DIRECTLY ASSOCIATED WITH THIS 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 OPENING. 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 described in the following paragraphs. Using a high powered explosion-proof 

light, inspect all ground/bonding jumpers attached to fuel components (tubes, plumbing adapters, 

tube connections) for evidence of corrosion and security. Visible corrosion is defined as 

discoloration, jumper strand separation, or jumper strand breakage and all 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 points for good contact and tightness. 

~ Inspect for jumpers that are worn or frayed. 

~ Inspect all tubing 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 Control Manual 

382-28-19 

82-770 Ull C:C>Pl'!NO A.~O~~ D SC1.0SUU fSGOV'EIIIN£01V f'"[SI AT l 0'11 fHt 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! , COPYcHG A. O~ OISCLC»U'!:£ SGOVU t: ::I Y fHt SlAlEioi! !H O !II I ME HllE PAU O~ 114tS OOCUM! 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 install 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 

fail 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 jumpers are authorized for use in fuel cells. Refer to the 

following chart for bonding jumpers inside of fuel tanks only: 

REPLACEMENT JUMPER 

M83413/8-C00488 

M83413/8-C00488 

M83413/8-C00688 

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 EXPLOSIVE 

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 with 

paragraph (14). 

382-28-19 

82-770 t.. oPVIH3 () 'II clo su ~~: Go 'l r:o ev tt srAJ ,.. lo-. '"E l lh.EP.tOEo" 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! , COPYINO, A.-.0,0,11 SCl II: SGOV!: ItN!O!I Y StAr ,., fO~ U1t Wl! ....... :a:o, hH$ oocuuENf 

Revision 4, September 18, 2008 (Reissue) 

382-28-19 

82-770 

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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 terminal. 

1 Install a dummy (uninsulated) terminal and take the measurement from that terminal. 

~ 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 CERTIFIED FOR USE IN FUEL OR OXYGEN-RICH EXPLOSIVE 

ENVIRONMENTS. FAILURE TO COMPLY MAY RESULT IN SEVERE INJURY 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 INTERFACE ----..! 

PRE-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$C~O$ RE iS GOVERNED I V THE STATEiot( 'IJ 0'1 fHE l !TU: PAQ( OF THIS OOCVU (Nt 

Revision 4, September 18, 2008 (Reissue) 

SFAR-88-SB-2-001 

382-28-19 

82-770 

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HERCULES Lockheed Martin Aeronautics Company 

Marietta, Georgia 30063 

SERVICE BULLETIN 

PRIMARY STRUCTURE 

BONDING METER 

SECONDARY STRUCTURE 

(BRACKET) 

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(, COPY NG A.'IIOtOII OISCLOSUU!SGOVflt'o f.0 1'1'1 otf.STAil , ( HI O N 1,.( TIT ~l ftAQl 0' 3 OOCU\Il " 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) for meter connection 

procedures and figure 4. 

382-28-19 

82-770 

Page 14 

BONDI NG METER 

FAYING SURFACE BOND 

SF AR-88-SB- I -003A 

Figure 4 

Resistance Measurement of Faying Surface Bonds 

USE, COPYiNG, A."ii).QR O.SCI..OSI.IRE IS CO\It1tNfO !lY fHf S I AI!MfNl 0 ,'1 H~f flllf P~E OF Tt1 iS OOCUiotEHf 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(.UfNt ON THE flll,.t, PAGtOF HUSOOCUU!.N f 

Revision 4, September 18, 2008 (Reissue) 

SFAR-88-SB-1-004A 

382-28-19 

82-770 

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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 

SFAR-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~~'V HG, A~O.O~ OISClOSU,_E 1$ GOIIERNEO BY THE StATE\IIENf ~ li'tE 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, Georgia 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!: IH AN OQ'l0 0SU.II:f OVf.II: f0 (U'T-tES A.r W:[Nf N hi[ rlfl.l: P~fOF n mo OOCUMf.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 must be prepared by hand, using an abrasive sheet of paper or cloth (240 to 

400 grit), 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 .:•~ I)(),. 0 SC OSUit IS G0Vf..ll.;f: 8'fl 1'1li 1~1( l ON 11'1(. I II LE I'AOl O!' fM tSOOCU-..! "11 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 material, 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 being removed. 

!:!. Only a minimum of the metal will be removed. 

(c) Solvent Cleaning -Cleaning Method 3 

This method will be used for the cleaning of terminals, 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-metallic bristle 

brush. 

~ Apply light pressure between the brush or wiper and the surface. 

§. Avoid the use of excessive amounts of solvent. 

§. Make applications of cleaning solvent and wiping (or brushing), using clean materials, until no 

residue is visible on the bonding 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 

paragraph (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. Cleaning 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 ~l S:.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 CLEANING 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 (MILD TO 

HIGH STRENGTH M Para. (12)(a) cloth, pads, and 

Topcoat glass beads. CRES) 51,46 Brushes or discs TERMINALS 

Chromate 2 Fine to ultra-fine --- Conversion Para. (12)(b) abrasive paper. 

Coated cloth pads. discs, 

Cadmium 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: COPYI-.o • .-..-.o.Oit OISCLOSU"f ISGOVt.NN! OitY 111! SfMOol.f NT 0~ IM( fl1lf 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 Resealing 

(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 

installation is less than 1/8-inch. 

(c) Do not paint machine-finished flanges of fuel or hydraulic pumps, valves, and similar 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 provided 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 lines- 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 'It~O A.'IO.OIII 0-SClOS,n t£ !$ GOvtJIINIO (1;'1' 1 " ' 1 1 At lVl 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 TITANIUM STRUCTURE 

Figure 8 

Jumper to Plated Steel, CRES, or Titanium Bolted Connection 

October 17, 2003 US£. COPYING. ANO.O,. OISCLOSIJ:'IE IS GOVtltNED I Y fM! S t A1L\II[Nf 0 "1 tl'l!. llll! P~! OF THI$ 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 AFTER INSTALLATION 

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 WlTH PARAGRAPH (12). 

2. REFINISH TO WlTHIN 1/32 INCH MINIMUM OF WASHER. 

3. SEAL IN ACCORDANCE WlTH PARAGRAPH (15) WHEN SEALING IS REQUIRED. 

Figure 10 

Jumper to Aluminum Bolted Connection 

October 17, 2003 USIE COPYI,.::O. A)IIO.OJIII O!SCtOS U't( IS GOVU 'IIlO BY lti( SJAlht [ N l ON TH( l +Hl lltNl( 01' f,..I:S OOCUVtHl 

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 analysis, 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 Wire 

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! SC OSU~t ISGOvti'CN!O SY 1M! SlAThtE.•H ON Tt1f. fiTlE P.-.GEOf h~ 00C MfN 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 inter-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 terminals (except pre-insulated types) to provide 

electrical protection and mechanical support and is secured to prevent slippage of the tubing from 

the terminal. 

October 17, 2003 vsE coPY!'iO, AN:l.OitO!SC!.OSUIU: •soovtiiiNt'.OII'f'f"e""'l ..,! HI 01'1 '"' tiHI! "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 wires 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 Wires 

382-28-19 

82-770 $E C0"'tl'fG AN0.0~ 0.$Ct0$U~E t: QO\I'EitNIE D8V THE StAtEI.tt:Ht ON THE f iH-f, PAG! Cf THIS OOC-0\fENT 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 wire 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 fluid 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)(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 will 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 

tubing, 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. 

& MINIMUM BEND RADIUS - 3 TIMES THE 

DIAMETER OF THE WIRE OR CABLE. 

Figure 15 

Minimum Bend Radii 

USE, COP't\NG. A,"il),QR 0-$Ct.OSIJRE. ISOOV't-1tNE08Yl 11E S TA.f£Mf,IU Olf T11E frll!! l>.r.G! Of T,.:$ OOCUV!NT 

Revision 4, September 18, 2008 (Reissue) 

SUPPORT AT BOTH 

ENDS Of WIRE BEND 

SF AR-88-sa-o-ol ~ 

382-28-19 

82-770 

Page 31 
HERCULES Lockheed Martin Aeronautics Company 

Marietta, 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 will clamp properly. (See figure 18.) 

WEDGE POSITION ON SIZE 2 AND 3 CLAMPS 

PREFERRED 

WEDGE POSITION ON SIZE 4 AND UP CLAMPS 

Figure 16 

Proper Installation of Cable Clamps 

382-28-19 

82-770 USE. COPVINO. ANJIO'\ OlSt:lOSURE IS COVER :> 8 YIHE S fAIUt!Nl 0~ II'(( tilL! ~A0 £0. THIS OOCU!J! Nl October 17, 2003 

Page 32 Revision 4, September 18, 2008 (Reissue) 
HERCULES Lockheed Martin Aeronautics Company 

Marietta, Georgia 30063 

SERVICE BULLETIN 

1/16 TO 

1/4 INCH 

MINIMUM 

t 

t 

NAS623 

SCREW 

MS21042-3 

LOCKNUT 

TO STRUCTURE 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, floors, or structural members where it is impossible to install off-angle clamps to 

maintain wiring separation. In such cases, additional protection in the form of plastic or 

insulating tape may be used. (See figures 19 and 20.) 

RUBBER GROMMET 

ANGLE BRACKET WITH --!1-4M 

TWO-POINT 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 OlSClOSVItf 1$(i.:;)V£.ANE0 &Y h~f SfAlhtfNT 0/'1: H~f flh.E P.IOE OF tr;..S OCX::UUt '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 

DRAIN 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 

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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 wire 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 engineering 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 wells, 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 $ClOSV~l £$ GOVI11Nf0 IV fHt I T Atl"lN I ON tHt T!TI.t IIN)l 0' 1" .-S OOC:U fiH 

382-28-19 

82-770 

Revision 4, September 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) 
HERCULES Lockheed Martin Aeronautics Company 

Marietta, Georgia 30063 

SERVICE BULLETIN 

SFAR-88-SB-Q-012 

Figure 27 

Cable Ties for "Y" Breakout 

U) Terminal Modules 

1 Ensure that terminal connections on terminal block studs and nuts on unused studs are tight. 

g_ Ensure that terminal modules are securely mounted and provided with adequate electrical 

clearances or insulation strips between mounting hardware and conductive parts, except those 

used for grounding purposes. (See table 2 and figure 28.) 

Stud Size 

No.6 

No. 10 

1/4 inch 

5/16 inch 

3/8 inch 

1/2 inch 

October 17, 2003 

Revision 4, September 18, 2008 (Reissue) 

Table 2. Torque Value for Terminal Lugs 

Torque Value in Inch-Pounds 

Copper Terminals 

Plain Nuts Self-Locking Nuts 

12 to 17 16 to 20 

15 to 20 25 to 30 

45 to 60 45 to 60 

70 to 80 120 to 130 

110to120 180 to 190 

135 to 150 245 to 260 

Aluminum Terminals 

Plain or Self-Locking Nuts 

45 to 60 

135 to 165 

220 to 250 

440 to 470 

382-28-19 

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Page 39 
HERCULES Lockheed Martin Aeronautics Company 

Marietta, Georgia 30063 

SERVICE BULLETIN 

LUG& 

OR NAS 1149-0 

STRUCTURE 

liE 

& THESE LUGS CAN BE INVERTED. 

TERMINAL BLOCK 

LS35076-0-0 

& USE MS21042 LOCKNUTS WITH NAS1149 WASHERS 

AND MS21043 LOCKNUTS WITH NAS1149C WASHERS. 

ffiMS14151-1, -21 -3, -4 AND -5 FLAT WASHER REQUIRED 

ON TERMINAL STUDS SIZE 6, 10, 1/4-, 5/16- AND 3/8-INCH 

TO RETAIN MS3373-0 STRIPS UNLESS BUS BAR IS INSTALLED. 

Figure 28 

Installation of Terminal Block Assembly, Including MS 14151 Washers 

(k) Connectors 

SFAR-88-SB-0-010 

1 Perform an inspection to identify evidence of overheating (cause of over-heating shall be 

corrected), and the exteriors for corrosion and cracks. Also. wires leading to connectors must 

be inspected for deterioration due to overheating. Replace all corroded connections and 

overheated connectors. 

f. Ensure the installation of a cable clamp (MIL-C-85049) on all connectors, except those that 

are moisture-proof. 

;! Ensure that silicone tape is wrapped around wire that is secured with MS3057 cable clamps . 

~ Ensure that connectors are fully mated by checking position and tightness of coupling ring or 

its alignment with fully mated indicator line on receptacle, if applicable. 

§. Ensure that the coupling nut is safetied, by wire or other mechanical locking means. 

382-28-19 

82-770 VSE, CO ... VI'oiQ. ""O.OR.QtSCI.OSUIIE ISCOvt.!INf,OSV hi£ STAT(.U:£NT O'ol JH£ Tnt.! PHl!.O, hHSOOCUU[ 'tf October 17. 2003 

Page 40 Revision 4, September 18, 2008 (Reissue) 
HERCULES Lockheed Martin Aeronautics Company 

Marietta, Georgia 30063 

SERVICE BULLETIN 

(2) Unit Essential to Safe Operation 

Perform all units essential to safe operation inspection described in the following paragraphs. 

(a) Main Power Cables 

1 Ensure that main power cables (including generator cables) in the wing are installed to allow 

for a reasonable degree of deformation and stretching without failure and that they: 

9. Are isolated from flammable fluid lines. 

Q. Run along the front wing spar, if they are generator cables, to provide isolation from the 

fuel tanks. 

~ Heavy-Current Carrying Cables (Leading Edge) 

CAUTION: CHANGES TO GENERATOR CABLES STANDOFF BRACKETS ARE NOT 

PERMITTED. 

Ensure no modification has been made to compromise generator wires standoffs. 

(b) High Energy Wiring 

Ensure that high energy wiring is not routed through conduit or adjacent to fuel tank surfaces 

such that damage, inappropriate maintenance, or other failure/wear conditions could result in 

arcing to the conduit or metallic tank surface and development of an ignition source in the fuel 

tank. The exception to this is the fuel pump conduit and fuel level control valves. 

(3) Lightning Protection 

Ensure that individual bonding jumpers for lightning protection are not less the No.12 AWG for tinned 

stranded copper or No. 10 AWG for tinned stranded aluminum wire. 

(4) Pneumatic System Failures 

Ensure that there is no leakage of air from dueling located near fuel tanks due to duct failure resulting 

in undetected heating of tank surfaces above the auto-ignition temperature. 

October 17, 2003 USf, COP'hNG MO.Oilt D.S:::LOSU!U !SCOVUNEOIY T/'1[ SfAUt.I[H T 0~ l"l TIHI ,AOtO' l i"I:S 00CUM(N1 

Revision 4, September 18, 2008 (Reissue) 

382-28-19 

82-770 

Page 41 
HERCULES Lockheed Martin Aeronautics Company 

Marietta, Georgia 30063 

SERVICE BULLETIN 

(5) Structural and Non-Electrical Equipment Bonding 

WARNING: ENSURE METER IS CERTIFIED FOR USE IN FUEL OR OXYGEN-RICH EXPLOSIVE 

ENVIRONMENTS. FAILURE TO COMPLY MAY RESULT IN SEVERE INJURY OR 

DEATH. 

Perform all structural and non-electrical equipment bonding requiretnehts described In the follo'Ning 

paragraphs. 

NOTE: If conductive couplings or fittings are used, bonding may be achieved through the 

equipment: if not, bonding jumpers shall be used on each isolated section. 

(a) Ensure that any lines carrying fluids or gases in motion are bonded to the structure. 

NOTE: Resistance shall not exceed 1 ohm for each metal-to-metal joint when dry. 

(b) Ensure that plumbing equipment and control devices 'Nith a linear dimension over three inches 

are electrically bonded directly to the airplane structure to prevent static buildup. 

(6) ATAIJASC 28 - Fuel Systems 

Perform all AT A/JASC 28 Fuel System requirements described in 'the following paragraphs. 

(a) Ensure that fuel lines have been routed such that they do not chafe against control cables, 

airframe structure, or come in contact 'Nith electrical wiring or cables. In no case should the fuel 

line support wiring. 

(b) Ensure that bends in tubing are aligned 'Nith all support clamps and end fittings and are not 

drawn, pulled, or otherwise forced into place by the clamps. 

(c) Ensure that support clamps or bracket for metallic lines are as shown below: 

Tube O.D. 

1/8 inch - 3/16 inch 

1/4 inch - 5/16 inch 

3/8 inch - 1/2 inch 

5/8 inch - 3/4 inch 

1 inch - 1-1/4 inches 

1-1/2 inches - 2 inches 

Approximate Distance Between Supports 

9inches 

12inches 

16inches 

22inches 

30inches 

40 inches 

382-28-19 

82-770 October 17, 2003 

Page 42 Revision 4, September 18, 2008 (Reissue) 
HERCULES Lockheed Martin Aeronautics Company 

Marietta, Georgia 30063 

SERVICE BULLETIN 

(7) Drains and Vents 

Perform an inspection at metal drains and vent fittings on the aircraft that shall satisfy a Class L bond 

requirement (dump mast). 

Class L- Lightning: minimizes potential caused by DC or audio frequency (f <500kHZ) currents such 

as those caused by lightning strikes. (Resistance value is 0.0025 ohm). 

(8) Fuel Quantity Indicating System (FQIS) Wiring 

Perform all FQIS wiring requirements described in the following paragraphs. 

(a) Inspection 

October 17, 2003 

1 Inspect the FQIS wiring for any visible damage, wear, chafing, or indications of electrical 

arcing. Repair FQIS wiring in accordance with appropriate Hercules Wiring Diagram 

Manual, Hercules Maintenance Manual, or Hercules Maintenance Instructions Manual and 

procedures. 

f. Ensure physical separation requirements have been maintained for FQIS wiring as follows: 

~ Ensure that FQIS wires are routed separately from all AC power wires in areas 

between FS 245.0 and FS 457.0 in the cargo compartment and in the wing root area 

outside the pressure vessel and along the wing trailing edge except where wires pass 

through cutouts in the structure. A minimum of 6 inches separation shall be maintained 

in these areas. If impractical to obtain 6 inches, a minimum of 4 inches shall be 

obtained and if impractical to obtain 4 inches, a minimum of 1 inch shall be obtained. 

NOTE: Under certain conditions, lightning discharges have sufficiently high rates of 

current rise that they produce an inductive potential that induces voltages into the 

fuel capacitance gage wiring and other wiring leading into the fuel tanks. It is, 

therefore necessary that wiring from antennas, pitot heaters, wing tip lights, etc .. 

be routed away from the electric wiring leading into fuel tanks and/or wiring 

should be shielded. 

Q. Ensure that shielded wires are in accordance with MIL-C-27500. 

£ Ensure that AC ground wires from FQIS system are NOT grounded to DC or signal 

ground stud. 

Q. Ensure wire terminations at fuel probes are undamaged. 

• Remove wires from fuel probes. 

• Inspect wires for damage. 

• If wires are damaged replace wires. 

• Connect wires to fuel probes. 

;! Notify Lockheed Martin Technical Support Center of any discrepancies found during 

inspection. 

382-28-19 

82-770 

Revision 4, September 18, 2008 Page 43 

I 

I 
HERCULES Lockheed Martin Aeronautics Company 

Marietta, Georgia 30063 

SERVICE BULLETIN 

(b) Modification 

1 FQIS wires shall be marked in accordance with SAE-AS81531 with "FQIS" every 18 inches 

beginning at the plugs that exit the fuel tanks or bladders, through outer wing breaks and 

wheel well pressure breaks to the individual fuel quantity indicator plugs on the Fuel 

System Control Panel. 

f. FQIS wires shall not be bundled with high voltage carrying wires. 

~ Fabricate pink identification cable markers (base part numbers CM-SCE-1/4-4H-2L or 

CM-SCE-1/2-4H-2L) or sleeving (base part numbers M23053/5-106-P or M23053/5-108-P). 

1 Install identification cable markers or sleeving on the wires within 8 inches of the end 

connector (near the existing wire identification) in accordance with Hercules Wiring 

Diagram Manual. 

§. See figure 29 for a listing of the typical FQIS wire numbers that will require identification 

cable markers. 

NOTE: Refer to the appropriate aircraft wiring diagrams for specific aircraft FQIS wire XX 

numbers, 1 E1 08CXX, 5E1 09BXX, etc. 

382-28-19 

82-770 US! CO!)nNGMO.Oit O.$C\.OSIJRE 1$G0V[JINE0 8Y THE StATEMEN t ON l 11f tlflt PAG!Ot' TH:SOOCUU l N I October 17, 2003 

I Page 44 Revision 4, September 18, 2008 
HERCULES Lockheed Martin Aeronautics Company 

Marietta, Georgia 30063 

SERVICE BULLETIN 

~LEFT 

I 

AUX 

BLADDER 

CELL 

l _ 

1E108AXX 

1E109AXX 

1E107AXX 

2E108AXX 

2E109AXX 

2E107AXX 

===, 

I 

TANK N0.1 I 

IND I 

I 

TANK N0.2 I 

IND I 

I 

L---JI 

LEFT AUX I 

TANKIND 

I 

I 

CENTER 

PIN 

l _ 7E107AXX --+---< I 

L LEFT LEFT EXT TANK LH WHEEL WIELL 

PRESSURE BREAK EXTERNAL I 

TANK IND IIIII (CARGO WALL) FUEL SYSTEM 

(TYPICAL AIRPLANE) CONTROL PANEL & ROUTE THESE WIRES SEPARATELY FROM ALL AC POWIER WIRES IN AREAS BETWEEN FUS STA 245 AND 457 AND ALONG 

THE WING TRAILING EDGE EXCEPT WHERE INIRES PASS THROUGH CUTOUTS IN STRUCTURE. A MINIMUM OF 6 INCHES 

SEPARATION SHALL BE OBTAINED IN THESE AREAS. IF IMPRACTICAL TO OBTAIN 6 1NCHES, A MINIMUM OF 4 1NCHES 

SHALL BE OBTAINED AND IF IMPRACTICAL TO OBTAIN 4 INCHES, A MINIMUM OF 1 INCH SHALL BE OBTAINED. ANY 

SEPARATION UNDER SINCHES IN THESE AREAS MUST BE APPROVED BY ENGINEERING. 

2. INSTALL MARKER WITHIN 8 INCHES OF CONNECTIONS AND EVERY 181NCHES ALONG WIRES 

3. REFER TO THE APPROPRIATE AIRCRAFT WIRING DIAGRAMS FOR SPECIFIC AIRCRAFT FQIS INIRE XX NUMBERS, 

1E108CXX, 5E109BXX, ETC. SBB2- 77o-382- 28- 19-XOI-29-I 

October 17, 2003 

Fuel Quantity Indicating System (FQIS) Wiring Marker 

Figure 29 (Sheet 1 of 2) 

Ust COPVI'iG. A.'l0.01t O<SClOSUII[ !S GO\It"-N£0 S Y J o([ S l "-1 tut "'f ON THE llf Lf PAGf OF 1111$ OOCUUE!H 

Revision 4, September 18, 2008 (Reissue) 

382-28-19 

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HERCULES Lockheed Martin Aeronautics Company 

Marietta, Georgia 30063 

SERVICE BULLETIN 

TANK N0.4 

IND 

TANK N0.3 

IND 

RIGHTAUX 

TANKIND 

RIGHT _j ERNAL 

KIND 

FUEL SYSTEM 

CONTROL PANEL 

382-28-19 

82-770 

4E108AXX 

4E109AXX 

4E107AXX 

3E109AXX 

3E107AXX 

6E109AXX 

6E107AXX 

8E108AXX 

8E109AXX 

8E107AXX 

RH WHEEL WELL 

PRESSURE BREAK 

(FWD) 

~ 

RIGHT OUTER 

WNGBREAK 

(TYPICAL AIRPLANE) 

8E108CXX 

8E109CXX 

8E107CXX 

Fuel Quantity Indicating System (FQIS) Wiring Marker 

Figure 29 (Sheet 2) 

RIGHT 1 

AUX 

BLADDER I 

CELL 

_j 

-1 

CENTER I 

PIN 

_ j 

RIGHT EXT TANK 

SSB2·770-382· 28- 19-XC0-29-2 

October 17, 2003 

Page 46 Revision 4, September 18, 2008 (Reissue) 
HERCULES Lockheed Martin Aeronautics Company 

Marietta, Georgia 30063 

SERVICE BULLETIN 

(9) AT AIJASC 29 - Hydraulic Systems 

Perform all AT A/JASC-29 Hydraulic Systems requirements described in the following paragraphs. 

(a) Ensure hydraulic lines are located at least four inches from any heat source and never above a 

heat source. 

(b) Ensure hydraulic lines are routed below electrical bundles. 

Find hydraulic system components located on the wings and inspect for damaged tubing, worn or 

damaged hoses, wear of moving parts, and security of mounting for all units, safetying, and any other 

condition specified in Hercules Corrosion Prevention and Control Manual, Hercules Wiring Diagram 

Manual, Hercules Maintenance Manual or Hercules Maintenance Instructions Manual, and Hercules 

Airfreighter Progressive Inspection Procedures or Hercules Airfreighter Series Progressive Inspection 

Procedures 

D. Return Aircraft to Service 

( 1) Reinstall removed components and access panels. 

(2) Remove equipment and supplies from the inspection area. 

(3) Perform operational checkout as required in accordance with appropriate Hercules Maintenance 

Manual or Hercules Maintenance Instructions Manual. 

(4) Return aircraft to normal service. 

(5) The aircraft owner/operator shall make an appropriate entry in the aircraft log records upon 

compliance with this Service Bulletin and maintenance planning documents to require a repeat 

inspection of FQIS wiring, not to exceed 12 years. 

(6) After the work has been completed on each affected aircraft, please complete and mail or fax 

(770-494-5682) a Notice of Service Bulletin Compliance; or notify Lockheed Martin Aeronautics 

Company of compliance with this Service Bulletin at website address: www.lockheedmartin.com/ams 

and log into Data Library. 

NOTE: If assistance pertaining to this Service Bulletin or information regarding your Hercules aircraft is 

needed, contact your local Lockheed Martin Aeronautics Company representative or the 

Technical Support Center in Marietta, Georgia, USA. as follows: 

October 17, 2003 

Telephone: (770) 494-9131 

Fax: (770) 494-9122 

E-Mail: hercules.support@lmco.com 

Mail: Lockheed Martin Aeronautics Company 

86 South Cobb Drive 

Department 3E1 M, Zone 0591 

Marietta, GA 30063-0591, USA 

Revision 4, September 18, 2008 (Reissue) 

382-28-19 

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HERCULES Lockheed Martin Aeronautics Company 

Marietta, Georgia 30063 

SERVICE BULLETIN 

382-28-19 

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Page 48 

THIS PAGE INTENTIONALLY LEFT BLANK 

October 17, 2003 

Revision 4, September 18, 2008 (Reissue) 
HERCULES Lockheed Martin Aeronautics Company 

Marietta, Georgia 30063 

SERVICE BULLETIN 

3. MATERIAL INFORMATION 

The following parts/materials, required to modify each aircraft listed in paragraph 1.A., will be provided by the 

aircraft owner/operator. Parts may be obtained from Lockheed Martin Aeronautics Company in accordance 

with paragraph 1.F. 

NEW PART OLD PART INSTRUCTIONS/ 

NUMBER QUANTITY KEYWORD NUMBER DISPOSITION 

MIL-T-43435 AR Lacing Tape 

CM-SCE-Y..-4H-2L AR Cable Marker-Tie in Place (1 )(2) 

Y..-inch 

CM-SCE-Y2-4H-2L AR Cable Marker-Tie in Place (1 )(2) 

Y2-inch 

M23053/5-1 06-P AR Cable Marker, Wraparound, (3) 

Heat-Shrinkable Polyolefin 

Y..-inch 

M23053/5-1 08-P AR Cable Marker, Wraparound (3) 

Heat-Shrinkable Polyolefin, 

Y2-inch 

NOTE: 1. Specify pink cable marker-tie. Select appropriate size of cable marker-tie for each wire. 

2. Tyco Electronics Raychem 

DBA Raychem 

Electronics Division 

300 Constitution Dr. 

Menlo Park, CA 94025 

3. Specify pink cable marker wraparound. 

___ . # __ _

File: I-A013/I-3042 

October 17, 2003 US£ COPV 'IG ...,.0.0~ t>tSClOSU"f !SGO\It.Jt.Nf08Y lMf $1Alf\llfl'lf0M 1 <4 [ TITlE P,IQ,f_ OJ T.,.ioS OOC'UMENT 

Revision 4, September 18, 2008 (Reissue) 

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HERCULES Lockheed Martin Aeronautics Company 

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SERVICE BULLETIN 

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US! COF"Y'I"iG, ANOIO't01SCLOSUII:t SGOVEII:~E08Y fi;E$TATEUEIH 0'1 THE TIHE PAOIE Oc THIS OOCUUE"it October 17, 2003 

Revision 4, September 18, 2008 (Reissue) 

·,