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Commercial Airplanes DC10 Service Bulletin ALERT Number: DC10-57A156 Original Issue: September 16, 2009 Revision 2: August 23, 2011 ATA System: 5711 SUBJECT: WINGS - Spars - Inspect/Repair Left and Right Wing Rear Spar Lower Cap Between Stations Xors=400 and Xors=417 Export of this technology is controlled under the United States Export Administration Regulations (EAR) (15 CFR 730-774). An export license may be required before it is used for development, production or use by foreign persons from specific countries. The controller of this data has the individual responsibility to abide by all export laws.
9E991ECCN:
BOEING PROPRIETARY, CONFIDENTIAL, AND/OR TRADE SECRET Copyright © 2009 The Boeing Company Unpublished Work - All Rights Reserved Boeing claims copyright in each page of this document only to the extent that the page contains copyrightable subject matter. Boeing also claims copyright in this document as a compilation and/or collective work.
This document includes proprietary information owned by The Boeing Company and/or one or more third parties.
Treatment of the document and the information it contains is governed by contract with Boeing. For more information, contact The Boeing Company, P.O. Box 3707, Seattle, Washington 98124.
Boeing, the Boeing signature, the Boeing symbol, 707, 717, 727, 737, 747, 757, 767, 777, 787, Dreamliner, BBJ, DC-8, DC-9, DC-10, KC-10, KDC-10, MD-10, MD-11, MD-80, MD-88, MD-90, P-8A, Poseidon and the Boeing livery are all trademarks owned by The Boeing Company; and no trademark license is granted in connection with this document unless provided in writing by Boeing.
BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: September 16, 2009 DC10-57A156Revision 2: August 23, 2011 1 of 47
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BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: September 16, 2009 DC10-57A156Revision 2: August 23, 2011 2 of 47 BOEING SERVICE BULLETIN DC10-57A156
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Table of Contents
Revision Transmittal Sheet5
Summary7
1. PLANNING INFORMATION ........................................ 1 1 A. Effectivity ............................................... 1 1
1. Airplanes ............................................ 1 1
2. Spares Affected ........................................ 1 3 B. Concurrent Requirements ...................................... 1 3 C. Reason ................................................ 1 3 D. Description .............................................. 1 3 E. Compliance .............................................. 1 7 F. Approval ............................................... 2 3 G. Manpower .............................................. 2 4 H. Weight and Balance Changes .................................... 2 4 I. Electrical Load Data ......................................... 2 4 J. References .............................................. 2 4
1. Existing Data .......................................... 2 4
2. Data supplied with this Service Bulletin ............................ 2 5
3. Installation Drawings Used in the Preparation of this Service Bulletin ............ 2 5 K. Publications Affected ........................................ 2 5 L. Interchangeability and Intermixability of Parts ........................... 2 6
2. MATERIAL INFORMATION ........................................ 2 7 A. Material - Price and Availability ................................... 2 7 B. Industry Support Information .................................... 2 7 C. Parts Necessary For Each Airplane ................................. 2 7
1. Kits/Parts ............................................ 2 7
2. Parts and Materials Supplied by the Operator ........................ 3 9
3. Parts Modified and Reidentified ................................ 3 9
4. Parts Removed and Not Replaced .............................. 4 0 D. Parts Necessary to Change Spares ................................. 4 0 E. Special Tooling - Price and Availability ............................... 4 0 F. Special Tooling Necessary to do this Service Bulletin ....................... 4 0
3. ACCOMPLISHMENT INSTRUCTIONS .................................. 4 1 A. GENERAL INFORMATION ..................................... 4 1 B. WORK INSTRUCTIONS ....................................... 4 2
BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: September 16, 2009 DC10-57A156Revision 2: August 23, 2011 3 of 47 BOEING SERVICE BULLETIN DC10-57A156
ALERTALERT
BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: September 16, 2009 DC10-57A156Revision 2: August 23, 2011 4 of 47 BOEING SERVICE BULLETIN DC10-57A156
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Commercial Airplanes DC10 Service Bulletin ALERT Revision Transmittal SheetNumber: DC10-57A156Original Issue: September 16, 2009 Revision 2: August 23, 2011 ATA System: 5711 SUBJECT: WINGS - Spars - Inspect/Repair Left and Right Wing Rear Spar Lower Cap Between Stations Xors=400 and Xors=417 This revision includes all pages of the service bulletin.
COMPLIANCE INFORMATION RELATED TO THIS REVISION Federal Aviation Administration (FAA) Notice of Proposed Rule Making NPRM 2009-NM-216-AD, is related to this service bulletin.
No more work is necessary on the airplane(s) changed in accordance with Revision 1 of this service bulletin.
REASON FOR REVISION This revision is sent to instruct operators to contact The Boeing Company for repair instructions if cracks that can not be removed by enlarging fastener hole(s) are found between Stations Xors=400 and inboard of Xors=408.
The data given in Information Notice DC10-57A156 IN 01 is included in this revision.
These sections were changed:
1. In Paragraph 1.D., Description, added new conditions to reflect station location limitations.
2. In Paragraph 1.E., Compliance, added NPRM information and added Compliance Tables to show added conditions.
3. In Paragraph 1.F., Approval, changed approval statement.
4. In Paragraph 1.J.1., References, added NPRM information.
5. In Paragraph 1.J.2., Data supplied with this Service Bulletin, changed drawing revision level as applicable.
6. In Paragraph 2.A., Material - Price and Availability, added pricing and Reorder Lead Time (ROLT) information.
7. In Paragraph 2.C.1., Kits/Parts, corrected part numbers.
8. In Paragraph 3.A., General Information, added new notes and renumbered existing notes.
9. In Paragraph 3.B., Accomplishment Instructions, added new conditions and work steps.
BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: September 16, 2009 DC10-57A156Revision 2: August 23, 2011 5 of 47
Vertical lines are put on the left edge of each page, except in Paragraph 1.A., Effectivity, to show the location of important changes.
Pages with no vertical lines have no important changes.
REVISION HISTORY September 16, 2009Original Issue:
March 10, 2010Revision 1:
August 23, 2011Revision 2:
BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: September 16, 2009 DC10-57A156Revision 2: August 23, 2011 6 of 47 BOEING SERVICE BULLETIN DC10-57A156
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Commercial Airplanes DC10 Service Bulletin ALERT SummaryNumber: DC10-57A156Original Issue: September 16, 2009 Revision 2: August 23, 2011 ATA System: 5711 SUBJECT: WINGS - Spars - Inspect/Repair Left and Right Wing Rear Spar Lower Cap Between Stations Xors=400 and Xors=417
THIS BULLETIN IS SENT TO THE OPERATORS OF RECORD OF THE AIRPLANES SHOWN IN PARAGRAPH
1.A., EFFECTIVITY. IF AN AIRPLANE HAS BEEN LEASED OR SOLD, SEND THIS SERVICE BULLETIN TO THE NEW OPERATOR. IF APPLICABLE SPARES HAVE BEEN SOLD, SEND THIS SERVICE BULLETIN TO THE NEW OWNER.
CONCURRENT REQUIREMENTS None.
BACKGROUND Operators have reported 3 instances of DC-10-10F/MD-10-10F airplanes having a fuel leak in the wing rear spar lower cap at Station Xors=409. Affected airplanes had the gross weight doublers installed and operators had previously accomplished Service Bulletin DC10-57-138. Investigation revealed the fuel leak was due to a crack in the lower cap. This crack extended into all three legs (aft, forward, and vertical) of the spar cap.
Metallurgical analysis of the cracked portion of the spar cap determined that the crack was due to fatigue and began at a fastener hole in the aft leg of the spar cap. Inspecting spar cap fastener holes for cracks, will determine the condition of spar cap. Repairing cracks in the spar cap, will minimize crack migration. If not corrected, an undetected crack in spar cap may lead to fuel leaks or cracking of the lower wing skin and structure causing extensive spar cap repairs or replacement and possible inability to sustain the limit load.
ACTION Refer to Paragraph 1.D., for Description.
EFFECTIVITY DC-10-10, DC-10-10F, and MD-10-10F Airplanes. Refer to Paragraph 1.A.1., Airplanes, for the list of affected airplanes.
COMPLIANCE Federal Aviation Administration (FAA) Notice of Proposed Rule Making NPRM 2009-NM-216-AD, is related to this service bulletin.
Refer to Paragraph 1.E., for Compliance.
BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: September 16, 2009 DC10-57A156Revision 2: August 23, 2011 7 of 47
INDUSTRY SUPPORT INFORMATION Boeing warranty remedies are not available for the configuration changes given in this service bulletin.
MANPOWER Refer to Paragraph 1.G., Manpower.
MATERIAL INFORMATION Boeing Supplied Kits/Parts.
Refer to Paragraph 2.A., Material - Price and Availability.
BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: September 16, 2009 DC10-57A156Revision 2: August 23, 2011 8 of 47 BOEING SERVICE BULLETIN DC10-57A156
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BOEING SERVICE BULLETIN DC10-57A156
ALERT ALERT
INSPECT/REPAIR WING REAR SPAR
LOWER CAP BETWEEN STATIONS XORS=400 AND XORS=417 1859290 Original Issue: September 16, 2009 Revision 2: August 23, 2011 DC10-57A156
BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 9 of 47
BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: September 16, 2009 DC10-57A156Revision 2: August 23, 2011 10 of 47 BOEING SERVICE BULLETIN DC10-57A156
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Commercial Airplanes DC10 Service Bulletin ALERT Number: DC10-57A156 Original Issue: September 16, 2009 Revision 2: August 23, 2011 ATA System: 5711 SUBJECT: WINGS - Spars - Inspect/Repair Left and Right Wing Rear Spar Lower Cap Between Stations Xors=400 and Xors=417
THIS BULLETIN IS SENT TO THE OPERATORS OF RECORD OF THE AIRPLANES SHOWN IN PARAGRAPH
1.A., EFFECTIVITY. IF AN AIRPLANE HAS BEEN LEASED OR SOLD, SEND THIS SERVICE BULLETIN TO THE NEW OPERATOR. IF APPLICABLE SPARES HAVE BEEN SOLD, SEND THIS SERVICE BULLETIN TO THE NEW OWNER.
1. PLANNING INFORMATION A. Effectivity
1. Airplanes
DESCRIPTIONCONFIGURATIONGROUP MD-10 airplane fuselages 6 and 8 that were modified in accordance with Service Modification Drawing SM10570022.
-1 DC-10/MD-10 airplanes except for fuselages 6 and 8 that have been modified in accordance with Service Modification Drawing SM10570022.
-2 Airplane Models:
DC-10-10, DC-10-10F, MD-10-10F GroupFuselage Number 16 18 215 217 225 - 27
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Original Issue: September 16, 2009 DC10-57A156Revision 2: August 23, 2011 11 of 47
GroupFuselage Number 232 - 35 239 - 43 255 259 261 - 62 270 272 276 278 286 289 2112 2119 2138 - 140 2142 2144 - 145 2148 2153 - 155 2173 2177 2198 2203 2205 2207 - 210 2247 2249 - 250 2269 - 273 2294 2297 - 298 2307 2309 2319
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Original Issue: September 16, 2009 DC10-57A156Revision 2: August 23, 2011 12 of 47 BOEING SERVICE BULLETIN DC10-57A156