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Commercial Airplanes DC8 Service Bulletin ALERT Number: DC8-53A080 Original Issue: June 22, 2004 Revision 2: September 18, 2013 ATA System: 5300 SUBJECT: FUSELAGE - Main Frame - Inspect/Repair Fuselage Skin Forward of Flat Aft Pressure Bulkhead at Longeron 28 Export of this technology is controlled under the United States Export Administration Regulations (EAR) (15 CFR 300-774). 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 © 2004 Boeing.
Unpublished Work. All Rights Reserved.
Treatment of this document and its content is governed by contract with Boeing. Rights to use this document are licensed on a per aircraft basis and such rights may not be transferable. For more information, contact The Boeing Company.
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, KC-46, KDC-10, MD-10, MD-11, MD-80, MD-88, MD-90, P-8, Poseidon and Boeing liveries 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.
Original Issue: June 22, 2004 DC8-53A080Revision 2: September 18, 2013 1 of 86
2.0
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: June 22, 2004 DC8-53A080Revision 2: September 18, 2013 2 of 86 BOEING SERVICE BULLETIN DC8-53A080
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Table of Contents
Revision Transmittal Sheet5
Summary7
1. PLANNING INFORMATION ........................................ 1 3 A. Effectivity ............................................... 1 3
1. Airplanes ............................................ 1 3
2. Spares Affected ........................................ 1 6 B. Concurrent Requirements ...................................... 1 6 C. Reason ................................................ 1 7 D. Description .............................................. 1 7 E. Compliance .............................................. 2 0 F. Approval ............................................... 6 0 G. Manpower .............................................. 6 0 H. Weight and Balance Changes .................................... 6 1 I. Electrical Load Data ......................................... 6 1 J. References .............................................. 6 1
1. Existing Data: ......................................... 6 1
2. Data Supplied with this Service Bulletin: ........................... 6 2
3. Installation Drawings Used in the Preparation of this Service Bulletin: ........... 6 2 K. Publications Affected ........................................ 6 2 L. Interchangeability and Intermixability of Parts ........................... 6 2 M. Software Accomplishment Summary ................................ 6 2
2. MATERIAL INFORMATION ........................................ 6 3 A. Material - Price and Availability ................................... 6 3 B. Industry Support Information .................................... 6 3 C. Parts Necessary for Each Airplane ................................. 6 3
1. Kits/Parts: ........................................... 6 3
2. Parts and Materials Supplied by the Operator: ........................ 6 3
3. Parts Modified and Reidentified: ............................... 6 5
4. Parts Removed and Not Replaced: .............................. 6 5 D. Parts Necessary to Change Spares ................................. 6 5 E. Special Tooling - Price and Availability ............................... 6 5 F. Special Tooling Necessary to do this Service Bulletin ....................... 6 5
3. ACCOMPLISHMENT INSTRUCTIONS .................................. 6 7 A. GENERAL INFORMATION ..................................... 6 7 B. WORK INSTRUCTIONS ....................................... 6 9 FIGURE 1: METHOD 103 REFLECTANCE TYPE SLIDING PROBE PROCEDURE REFERENCE STANDARD ........................................... 7 8 FIGURE 2: HIGH FREQUENCY EDDY CURRENT INSPECTION OF SKIN ALONG LONGERON 28 . 80 FIGURE 3: METHOD 103 REFLECTANCE TYPE SLIDING PROBE PROCEDURE .......... 8 1 FIGURE 4: METHOD 103 REFLECTANCE TYPE SLIDING PROBE PROCEDURE .......... 8 2 Appendix A: .................................................. 8 3 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: June 22, 2004 DC8-53A080Revision 2: September 18, 2013 3 of 86 BOEING SERVICE BULLETIN DC8-53A080
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Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: June 22, 2004 DC8-53A080Revision 2: September 18, 2013 4 of 86 BOEING SERVICE BULLETIN DC8-53A080
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Commercial Airplanes DC8 Service Bulletin ALERT Revision Transmittal SheetNumber: DC8-53A080Original Issue: June 22, 2004 Revision 2: September 18, 2013 ATA System: 5300 SUBJECT: FUSELAGE - Main Frame - Inspect/Repair Fuselage Skin Forward of Flat Aft Pressure Bulkhead at Longeron 28 This revision includes all pages of the service bulletin.
COMPLIANCE INFORMATION RELATED TO THIS REVISION Federal Aviation Administration (FAA) Airworthiness Directive AD 2008-06-23 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 add Options 3 and 4 for Group 1, Configuration 2 airplanes that were inadvertently omitted at the release of Revision 1.
These sections were changed:
1. In Paragraph 1.D., Description, added Options 3 and 4 for Group 1, Configuration 2 airplanes.
2. In Paragraph 3.B., Work Instructions, added Options 3 and 4 for Group 1, Configuration 2 airplanes.
Vertical lines are put on the left edge of each page, except in Paragraph 1.A., Effectivity and format changes, to show the location of all content changes.
Pages with no vertical lines have no changes.
REVISION HISTORY June 22, 2004Original Issue:
May 03, 2013Revision 1:
September 18, 2013Revision 2:
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: June 22, 2004 DC8-53A080Revision 2: September 18, 2013 5 of 86
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: June 22, 2004 DC8-53A080Revision 2: September 18, 2013 6 of 86 BOEING SERVICE BULLETIN DC8-53A080
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Commercial Airplanes DC8 Service Bulletin ALERT SummaryNumber: DC8-53A080Original Issue: June 22, 2004 Revision 2: September 18, 2013 ATA System: 5300 SUBJECT: FUSELAGE - Main Frame - Inspect/Repair Fuselage Skin Forward of Flat Aft Pressure Bulkhead at Longeron 28
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 During routine maintenance inspections, three operators reported finding three instances of cracks in the upper aft skin panel. The cracks were located along the upper row of rivets common to the longeron 28 skin splice, near the flat aft pressure bulkhead. Cracks were detected on airplanes which had accumulated between 27,072 and 46,176 flight cycles. If not corrected, in-flight fuselage decompression and unscheduled maintenance for repairs may be required. Inspecting fuselage skin for cracks will determine condition of skin. Inspecting fuselage skin for cracks, and repairing if necessary, will minimize the possibility of in-flight decompression and unscheduled maintenance.
The fuselage skin has been determined to be structure that is susceptible to Widespread Fatigue Damage (WFD).
This table is provided to operators for planning purposes only. Refer to the applicable sections for more information.
ReferenceAffectedPlanning Data Paragraph 1.A.2., Spares AffectedNoSpares Affected Paragraph 1.E., Compliance and Paragraph
1.F., Approval YesAD Related Paragraph 1.H., Weight and Balance ChangesNoWeight and Balance Change Paragraph 1.I., Electrical Load DataNoElectrical Load Changed Paragraph 1.K., Publications AffectedNoPublications Affected Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: June 22, 2004 DC8-53A080Revision 2: September 18, 2013 7 of 86
ReferenceAffectedPlanning Data Paragraph 1.K., Publications AffectedNoAirplane Flight Operations Affected (Flight Crew Operations Manual and/or FAA Approved Airplane Flight Manual) Paragraph 2.C.1., Kits/PartsNoKits/Parts Required Paragraph 2.C.2., Parts and Materials Supplied by the Operator NoOperator Supplied Parts/Material Paragraph 2.F., Special Tooling Necessary to do this Service Bulletin NoSpecial Tooling Required ACTION Group 1, Configuration 1:
1. This service bulletin accomplishes a general visual and a High Frequency Eddy Current inspection of the fuselage skin for cracks or failed fasteners at longeron 28 forward of flat aft pressure bulkhead, left and right sides, and accomplishes the following based on condition:
a. Condition 1 (No Crack(s) or Failed Fasteners Found) Option 1 Does repetitive inspections.
Installs full length improvement modification with finger doubler at a later time.
Option 2 Does repetitive inspections.
Installs full length improvement modification at a later time.
b. Condition 2 (Any Failed Fasteners) Option 1 Replaces failed fasteners and does repetitive inspections.
Installs full length improvement modification with finger doubler at a later time.
Option 2 Replaces failed fasteners and does repetitive inspections.
Installs full length improvement modification at a later time.
Option 3 Installs full length improvement modification with finger doubler.
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
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Option 4 Installs full length improvement modification.
c. Condition 3 (Any Crack(s) Found in Skin) Option 1 Repairs cracked skin locally, and does repetitive inspections.
Installs full length repair with finger doubler at a later time.
Option 2 Repairs cracked skin locally, and does repetitive inspections.
Installs full length repair at a later time.
Option 3 Installs full length repair with finger doubler.
Option 4 Installs full length repair.
Group 1, Configuration 2:
1. This service bulletin accomplishes a general visual and a High Frequency Eddy Current inspection of the fuselage skin for cracks or failed fasteners at longeron 28 forward of flat aft pressure bulkhead, left and right sides, and accomplishes the following based on condition:
a. Condition 1 (No Crack(s) or Failed Fasteners Found) Option 1 Does repetitive inspections of accessible skin.
Replaces previously installed local skin repairs with new local skin repairs defined in this service bulletin.
Installs full length repair with finger doubler at a later time.
Option 2 Does repetitive inspections of accessible skin.
Replaces previously installed local skin repairs with new local skin repairs defined in this service bulletin.
Installs full length repair at a later time.
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
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Option 3 Removes previously installed local skin repairs.
Installs full length repair with finger doubler Option 4 Removes previously installed local skin repairs.
Installs full length repair.
b. Condition 2 (Any Failed Fasteners) Option 1 Replaces all failed fasteners.
Does repetitive inspections of accessible skin.
Replaces previously installed local skin repairs with new local skin repairs as defined in this service bulletin.
Removes previously installed local repairs and installs full length repair with finger doubler at a later time.
Option 2 Replaces all failed fasteners.
Replaces previously installed local skin repairs with new local skin repairs as defined in this service bulletin.
Removes previously installed local repairs and does full length repair at a later time.
Option 3 Removes previously installed local repairs and installs full length repair with finger doubler.
Option 4 Removes previously installed local repairs and installs full length repair.
c. Condition 3 (Any Crack(s) Found in Skin) Option 1 Repairs cracks with local skin repairs as defined in this service bulletin.
Does repetitive inspections of accessible skin.
Replaces previously installed local skin repairs with new local skin repairs as defined in this service bulletin.
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: June 22, 2004 DC8-53A080Revision 2: September 18, 2013 10 of 86 BOEING SERVICE BULLETIN DC8-53A080
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Removes previously installed local repairs and does full length repair with finger doubler at a later time.
Option 2 Repairs cracks with local skin repairs as defined in this service bulletin.
Does repetitive inspections of accessible skin.
Replaces previously installed local skin repairs with new local skin repairs as defined in this service bulletin.
Removes previously installed local repairs and does full length repair at a later time.
Option 3 Removes previously installed local repairs and does full length repair with finger doubler.
Option 4 Removes previously installed local repairs and does full length repair.
EFFECTIVITY DC-8-55, DC-8-61, DC-8-61F, DC-8-62, DC-8-62F, DC-8-63, DC-8-63F, DC-8-71, DC-8-71F, DC-8-72, DC-8-72F, DC-8-73, DC-8-73F, DC-8F-54, DC-8F-55 airplanes with flat aft pressure bulkhead. Refer to Paragraph 1.A.1.
for detailed effectivity.
COMPLIANCE Federal Aviation Administration (FAA) Airworthiness Directive AD 2008-06-23 is related to this service bulletin.
Refer to Paragraph 1.E., Compliance.
INDUSTRY SUPPORT INFORMATION Boeing warranty remedies are not available for the inspection and/or repair procedures given in this service bulletin.
MANPOWER Refer to Paragraph 1.G., Manpower.
MATERIAL INFORMATION Operator Supplied Parts.
Refer to Paragraph 2.A., Material - Price and Availability.
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: June 22, 2004 DC8-53A080Revision 2: September 18, 2013 11 of 86 BOEING SERVICE BULLETIN DC8-53A080
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Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: June 22, 2004 DC8-53A080Revision 2: September 18, 2013 12 of 86 BOEING SERVICE BULLETIN DC8-53A080