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Commercial Airplanes MD80 Service Bulletin ALERT Number: MD80-55A070 Original Issue: May 22, 2013 Revision 1: December 17, 2013 ATA System: 5510 SUBJECT: STABILIZERS - Horizontal Stabilizer - Inspect/Replace Upper Rear Spar Cap at Aft Barrel Nut Holes 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 © 2013 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Unpublished Work.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: May 22, 2013 MD80-55A070Revision 1: December 17, 2013 1 of 53
3.0
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: May 22, 2013 MD80-55A070Revision 1: December 17, 2013 2 of 53 BOEING SERVICE BULLETIN MD80-55A070
ALERTALERT
BLANK PAGE
Table of Contents
Revision Transmittal Sheet5
Summary7
1. PLANNING INFORMATION ........................................ 1 1 A. Effectivity ............................................... 1 1
1. Airplanes ............................................ 1 1
2. Spares Affected ........................................ 1 5 B. Concurrent Requirements ...................................... 1 6 C. Reason ................................................ 1 6 D. Description .............................................. 1 6 E. Compliance .............................................. 1 7 F. Approval ............................................... 2 2 G. Manpower .............................................. 2 2 H. Weight and Balance Changes .................................... 2 5 I. Electrical Load Data ......................................... 2 5 J. References .............................................. 2 5
1. Existing Data: ......................................... 2 5
2. Data Supplied with this Service Bulletin: ........................... 2 5
3. Installation Drawings Used in the Preparation of this Service Bulletin: ........... 2 6
4. Process Data: ......................................... 2 6 K. Publications Affected ........................................ 2 6 L. Interchangeability and Intermixability of Parts ........................... 2 6 M. Software Accomplishment Summary ................................ 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 6
3. Parts Modified and Reidentified ................................ 3 6
4. Parts Removed and Not Replaced .............................. 3 6 D. Parts Necessary to Change Spares ................................. 3 7 E. Special Tooling - Price and Availability ............................... 3 7 F. Special Tooling Necessary to do this Service Bulletin ....................... 3 7
3. ACCOMPLISHMENT INSTRUCTIONS .................................. 3 9 A. GENERAL INFORMATION ..................................... 3 9 B. WORK INSTRUCTIONS ....................................... 4 0 FIGURE 1: REMOVE SKIN FILLER .................................... 4 5 FIGURE 2: INSPECTION SURFACE AREA - PREPARATION ...................... 4 8 FIGURE 3: HIGH FREQUENCY EDDY CURRENT INSPECTION .................... 5 1 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: May 22, 2013 MD80-55A070Revision 1: December 17, 2013 3 of 53 BOEING SERVICE BULLETIN MD80-55A070
ALERTALERT
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: May 22, 2013 MD80-55A070Revision 1: December 17, 2013 4 of 53 BOEING SERVICE BULLETIN MD80-55A070
ALERTALERT
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Commercial Airplanes MD80 Service Bulletin ALERT Revision Transmittal SheetNumber: MD80-55A070Original Issue: May 22, 2013 Revision 1: December 17, 2013 ATA System: 5510 SUBJECT: STABILIZERS - Horizontal Stabilizer - Inspect/Replace Upper Rear Spar Cap at Aft Barrel Nut Holes This revision includes all pages of the service bulletin.
COMPLIANCE INFORMATION RELATED TO THIS REVISION The Federal Aviation Administration (FAA) will possibly release an Airworthiness Directive related to this service bulletin. The Airworthiness Directive will make the compliance tasks and times given in this service bulletin mandatory.
No more work is necessary on the airplane(s) changed or inspected in accordance with the original issue of this service bulletin.
REASON FOR REVISION Revision 1 is sent to correct Paragraph 1.E., Compliance Tables 1 and 2 group configuration headings and Table 1 initial inspections thresholds.
Terminology has been changed in the Work Instructions to agree with the terminology defined in Paragraph
3.A., General Information - Notes.
These sections were changed:
1. In Paragraph 1.E., Compliance, changed Table 1 and Table 2 group configuration headings and Table 1 initial inspection thresholds.
2. Figure 2, changed art and split footnote (a) into footnote (a) and (b).
3. Figure 3, changed art and footnoe (c).
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 May 22, 2013Original Issue:
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: May 22, 2013 MD80-55A070Revision 1: December 17, 2013 5 of 53
December 17, 2013Revision 1:
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: May 22, 2013 MD80-55A070Revision 1: December 17, 2013 6 of 53 BOEING SERVICE BULLETIN MD80-55A070
ALERTALERT
Commercial Airplanes MD80 Service Bulletin ALERT SummaryNumber: MD80-55A070Original Issue: May 22, 2013 Revision 1: December 17, 2013 ATA System: 5510 SUBJECT: STABILIZERS - Horizontal Stabilizer - Inspect/Replace Upper Rear Spar Cap at Aft Barrel Nut Holes
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 the inspections called for in Service Bulletin MD80-55A065, two operators reported finding cracks emanating from the left and right upper rear spar cap aft-most barrel nut holes of the horizontal stabilizer. One airplane had accumulated 40,144 flight hours and 32,253 landing cycles, while the other airplane had accumulated 58,296 flight hours and 43,512 landing cycles. In both cases, the affected part was removed from the airplane and submitted to Boeing for evaluation. Investigation by Boeing has determined that the cracks are caused by fatigue. In both cases, the cracks originated inside the barrel nut holes, and radiated vertically and in the aft direction from the barrel nut holes. If not corrected, these cracks may propagate until it severs the upper rear spar cap which may result in the failure of the horizontal stabilizer upper center or aft skin panel, adversely affecting the structural integrity of the airplane.
Boeing Fleet Team Digest (FTD) MD-80 FTD 55-12002 is related to this service bulletin.
ACTION This service bulletin provides instructions to perform a High Frequency Eddy Current (ETHF) inspection on the left and right upper rear spar cap aft-most barrel nut holes for crack(s), and does as follows:
Group 1, Configuration 1, 3:
Condition 1 - No Crack Found Repeats ETHF inspection at defined intervals.
Condition 2 - Any Crack Found Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: May 22, 2013 MD80-55A070Revision 1: December 17, 2013 7 of 53
NOTE: Both Options affect the inspection requirements contained in Service Bulletin MD80-55A065, and will affect compliance with Federal Aviation Administration Airworthiness Directive AD 2007-10-04 as it relates to the upper rear spar cap. Operators are urged to consider both this service bulletin and Service Bulletin MD80-55A065 while choosing an option.
Option 1
1) Does a splice repair of the horizontal stabilizer upper rear spar cap.
2) Repeats ETHF inspection at defined intervals until replacement of upper rear spar cap.
Option 2
1) Replaces the horizontal stabilizer upper rear spar cap.
2) Repeats ETHF inspection at defined intervals.
Group 1, Configuration 2, 4:
Condition 1 - No Crack Found Repeats ETHF inspection at defined intervals.
Condition 2 - Any Crack Found NOTE: Both Options affect the inspection requirements contained in Service Bulletin MD80-55A065, and will affect compliance with FAA AD 2007-10-04 as it relates to the upper rear spar cap. Operators are urged to consider both this service bulletin and Service Bulletin MD80-55A065 while choosing an option.
Option 1
1) Does a splice repair of the horizontal stabilizer upper rear spar cap.
2) Installs new Forcemate bushing
3) Repeats ETHF inspection at defined intervals until replacement of upper rear spar cap.
Option 2
1) Replaces the horizontal stabilizer upper rear spar cap.
2) Installs new Forcemate bushing
3) Repeats ETHF inspection at defined intervals.
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: May 22, 2013 MD80-55A070Revision 1: December 17, 2013 8 of 53 BOEING SERVICE BULLETIN MD80-55A070
ALERTALERT
EFFECTIVITY All DC-9-81 (MD-81), DC-9-82 (MD-82), DC-9-83 (MD-83), DC-9-87 (MD-87), MD-88 Airplane(s). Refer to Paragraph 1.A.1., Airplanes, for the list of affected airplane(s).
COMPLIANCE The Federal Aviation Administration (FAA) will possibly release an Airworthiness Directive related to this service bulletin. The Airworthiness Directive will make the compliance tasks and times given in this service bulletin mandatory.
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 Boeing Supplied Kits/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: May 22, 2013 MD80-55A070Revision 1: December 17, 2013 9 of 53 BOEING SERVICE BULLETIN MD80-55A070
ALERTALERT
BOEING SERVICE BULLETIN MD80-55A070
ALERT ALERT
INSPECT/REPLACE UPPER REAR SPAR
CAP AT AFT BARREL NUT HOLES 2244834 Original Issue: May 22, 2013 Revision 1: December 17, 2013 PROPRIETARY - Copyright © Unpublished Export Controlled ECCN: 9E991 - BOEING MD80-55A070 Work - See page 1 for details. 10 of 53
Commercial Airplanes MD80 Service Bulletin ALERT Number: MD80-55A070 Original Issue: May 22, 2013 Revision 1: December 17, 2013 ATA System: 5510 SUBJECT: STABILIZERS - Horizontal Stabilizer - Inspect/Replace Upper Rear Spar Cap at Aft Barrel Nut Holes
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 This service bulletin is for the airplanes shown below.
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: May 22, 2013 MD80-55A070Revision 1: December 17, 2013 11 of 53
DESCRIPTIONCONFIGURATIONGROUP All Airplanes-1 Airplanes Not Having Accomplished an Upper Rear Spar Cap Splice Repair or Upper Rear Spar Cap Replacement in Accordance With Service Bulletin MD80-55A065 or other service action 1 Airplanes Not Having Accomplished an Upper Rear Spar Cap Splice Repair or Upper Rear Spar Cap Replacement And Having Forcemate Bushings Installed in Spar Web in Accordance With Service Bulletin MD80-55A065 Revision 1 or other service action 2 Airplanes Having Accomplished an Upper Rear Spar Cap Splice Repair or Upper Rear Spar Cap Replacement in Accordance With Service Bulletin MD80-55A065 or other service action 3 Airplanes Having Accomplished an Upper Rear Spar Cap Splice Repair or Upper Rear Spar Cap Replacement And Having Forcemate Bushings Installed in Spar Web in Accordance With Service Bulletin MD80-55A065 Revision 1 or other service action 4 Airplane Models:
DC-9-81 (MD-81), DC-9-82 (MD-82), DC-9-83 (MD-83), DC-9-87 (MD-87), MD-88 GroupFuselage Number 1909 1917 1924 1938 1941 1944 1946 1948 1950 1952 - 953 1955 1957 - 958 1960 1962 - 963 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: May 22, 2013 MD80-55A070Revision 1: December 17, 2013 12 of 53 BOEING SERVICE BULLETIN MD80-55A070