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Commercial Airplanes MD80 Service Bulletin ALERT Number: MD80-55A072 Original Issue: April 08, 2016 ATA System: 5510 SUBJECT: STABILIZERS - Horizontal Stabilizer - Rear Spar Lower Cap Inspection, Repair, and Replacement 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 © 2016 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Unpublished Work.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: April 08, 2016 MD80-55A072 1 of 88
3.0
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: April 08, 2016 MD80-55A072 2 of 88 BOEING SERVICE BULLETIN MD80-55A072
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BLANK PAGE
Table of Contents
Summary5
1. PLANNING INFORMATION9
A. Effectivity9
1. Airplanes9
2. Spares Affected12
B. Concurrent Requirements13
C. Reason13
D. Description13
E. Compliance13
F. Approval26
G. Manpower26
H. Weight and Balance Changes30
I. Electrical Load Data30
J. References30
1. Existing Data:30
2. Data Supplied with this Service Bulletin:30
3. Installation Drawings Used in the Preparation of this Service Bulletin:31
K. Publications Affected31
L. Interchangeability and Intermixability of Parts31
M. Software Accomplishment Summary31
2. MATERIAL INFORMATION33
A. Material - Price and Availability33
B. Industry Support Information34
C. Parts Necessary for Each Airplane34
1. Kits/Parts34
2. Parts and Materials Supplied by the Operator43
3. Parts Modified and Reidentified44
4. Parts Removed and Not Replaced44
D. Parts Necessary to Change Spares44
E. Special Tooling - Price and Availability44
F. Special Tooling Necessary to do this Service Bulletin44
3. ACCOMPLISHMENT INSTRUCTIONS45
A. GENERAL INFORMATION45
B. WORK INSTRUCTIONS47
FIGURE 1: HORIZONTAL STABILIZER REAR SPAR LOWER CAP OPEN HOLE EDDY CURRENT HIGH
FREQUENCY INSPECTION59
FIGURE 2: HORIZONTAL STABILIZER REAR SPAR LOWER CAP SURFACE EDDY CURRENT HIGH
FREQUENCY INSPECTION64
FIGURE 3: HORIZONTAL STABILIZER REAR SPAR LOWER CAP BOLT INSTALLATION67
APPENDIX A: LOGIC DIAGRAM FOR PARAGRAPH 1.E. COMPLIANCE: TABLE 1: HORIZONTAL STABILIZER REAR SPAR LOWER CAP EDDY CURRENT HIGH FREQUENCY (ETHF) INSPECTION. 70 APPENDIX B: LOGIC DIAGRAM FOR PARAGRAPH 1.E. COMPLIANCE: TABLE 2: POST BUSHING REPAIR
OR FATIGUE LIFE ENHANCEMENT MODIFICATION ETHF INSPECTION FOR HORIZONTAL
STABILIZER REAR SPAR LOWER CAPS WITH NO SPLICE REPAIR74
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
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APPENDIX C: LOGIC DIAGRAM FOR PARAGRAPH 1.E. COMPLIANCE: TABLE 3: POST BUSHING REPAIR
OR FATIGUE LIFE ENHANCEMENT MODIFICATION ETHF INSPECTION FOR HORIZONTAL
STABILIZER REAR SPAR LOWER CAPS WITH A SPLICE REPAIR77
APPENDIX D: LOGIC DIAGRAM FOR PARAGRAPH 1.E. COMPLIANCE: TABLE 4: POST HORIZONTAL
STABILIZER REAR SPAR LOWER CAP SPLICE REPAIR ETHF INSPECTIONS79
APPENDIX E: LOGIC DIAGRAM FOR PARAGRAPH 1.E. COMPLIANCE: TABLE 5: POST HORIZONTAL
STABILIZER REAR SPAR LOWER CAP REPLACEMENT ETHF INSPECTIONS82
APPENDIX F: LOGIC DIAGRAM FOR PARAGRAPH 1.E. COMPLIANCE: TABLE 6: POST HORIZONTAL
STABILIZER REAR SPAR LOWER CAP SPLICE REPAIR OR REPLACEMENT WITH FATIGUE
LIFE ENHANCEMENT MODIFICATION ETHF INSPECTIONS86
APPENDIX G: ADDITIONAL ACCESS87
APPENDIX H: PART DEMAND INTENT88
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: April 08, 2016 MD80-55A072 4 of 88 BOEING SERVICE BULLETIN MD80-55A072
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Commercial Airplanes MD80 Service Bulletin ALERT SummaryNumber: MD80-55A072Original Issue: April 08, 2016 ATA System: 5510 SUBJECT: STABILIZERS - Horizontal Stabilizer - Rear Spar Lower Cap Inspection, Repair, and Replacement
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 normal maintenance, one operator found cracking in an MD-88 horizontal stabilizer rear spar lower cap.
The affected airplane had accumulated 61,741 flight-hours and 45,985 landing cycles. Although the origin of the crack was destroyed from heavy rubbing and oxidation, lab analysis on the area adjacent to the crack shows that the crack was caused by fatigue. Such fatigue cracking, paired with cracking in the horizontal stabilizer upper and/or lower skin panels, rear spar upper cap inboard end, upper center skin panel, or rear spar upper cap barrel nut holes, could adversely affect the structural integrity of the airplane.
This service bulletin gives instructions to inspect for cracking in the vertical flange of the horizontal stabilizer rear spar lower cap on MD-80 airplanes and gives subsequent corrective action if any crack is found. The inspections are similar to the inspections of the horizontal stabilizer rear spar upper caps in alert service bulletin MD80-55A065 R01.
Boeing Fleet Team Digest (FTD) MD-80 FTD 55-15001 is related to this service bulletin.
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 ChangesYesWeight 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: April 08, 2016 MD80-55A072 5 of 88
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/PartsYesKits/Parts Required Paragraph 2.C.2., Parts and Materials Supplied by the Operator YesOperator Supplied Parts/Material Paragraph 2.F., Special Tooling Necessary to do this Service Bulletin YesSpecial Tooling Required ACTION Do an open hole or surface Eddy Current High Frequency (ETHF) inspection for any crack in the horizontal stabilizer rear spar lower caps. If no crack is found, do repeat ETHF inspection for any crack or do a fatigue life enhancement modification. If any crack is found, do one of the following based on inspection findings:
1. Bushing repair
2. Lower cap splice repair
3. Lower cap replacement
4. Lower cap splice repair with fatigue life enhancement modification
5. Lower cap replacement with fatigue life enhancement modification
EFFECTIVITY All DC-9-81 (MD-81), DC-9-82 (MD-82), DC-9-83 (MD-83), DC-9-87 (MD-87), and MD-88 Airplanes. Refer to Paragraph 1.A.1., Airplanes, for the list of affected airplanes.
COMPLIANCE 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.
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Operators are encouraged to complete the survey provided in APPENDIX H of this service bulletin to help Boeing predict the quantity and timing of the Boeing Supplied Kits/Parts.
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: April 08, 2016 MD80-55A072 7 of 88 BOEING SERVICE BULLETIN MD80-55A072
ALERTALERT
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: April 08, 2016 MD80-55A072 8 of 88 BOEING SERVICE BULLETIN MD80-55A072
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BLANK PAGE
Commercial Airplanes MD80 Service Bulletin ALERT Number: MD80-55A072 Original Issue: April 08, 2016 ATA System: 5510 SUBJECT: STABILIZERS - Horizontal Stabilizer - Rear Spar Lower Cap Inspection, Repair, and Replacement
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 All DC-9-81 (MD-81), DC-9-82 (MD-82), DC-9-83 (MD-83), DC-9-87 (MD-87), and MD-88 Airplanes.
-1 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 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: April 08, 2016 MD80-55A072 9 of 88
GroupFuselage Number 1950 1952 - 953 1955 1957 - 958 1960 1962 - 963 1965 - 967 1969 1970 - 971 1973 - 975 1977 - 979 1981 1983 1985 - 986 1988 - 989 1991 - 992 1994 - 999 11000 - 1013 11015 - 1016 11018 - 1020 11022 - 1023 11025 - 1026 11028 - 1029 11031 - 1032 11034 - 1035 11037 - 1038 11040 - 1041 11043 11045 11047 11049 11051 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
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GroupFuselage Number 11053 11055 11057 11059 - 1080 11082 - 1083 11085 - 1099 11100 - 1199 11200 - 1299 11300 - 1399 11400 - 1499 11500 - 1599 11600 - 1699 11700 - 1799 11800 - 1899 11900 - 1999 12000 - 2007 12009 - 2016 12019 - 2034 12036 - 2069 12071 - 2093 12101 - 2114 12116 12118 - 2119 12121 12124 12127 - 2128 12130 12132 12134 - 2135 12137 12139 12145 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
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GroupFuselage Number 12148 12151 - 2152 12155 12167 12174 12176 12178 12180 12183 12185 12187 12189 12192 12196 12199 12201 12204 12206 12208 12214 12218 12234 12239 12241 12244 12247 12249 12252 12254 12264 - 2287
2. Spares Affected None.
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: April 08, 2016 MD80-55A072 12 of 88 BOEING SERVICE BULLETIN MD80-55A072