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Commercial Airplanes MD80 Service Bulletin ALERT Number: MD80-57A242 Original Issue: May 08, 2009 Revision 1: January 07, 2011 ATA System: 5710 SUBJECT: WINGS - Main Frame - Inspect/Repair Upper and Lower Rear Spar Caps at Station Xrs=164.000 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BOEING PROPRIETARY, CONFIDENTIAL, AND/OR TRADE SECRET Copyright © 2009 The Boeing Company Unpublished Work - All Rights Reserved Boeing claims copyright in each page of this document only to the extent that the page contains copyrightable subject matter.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BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.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: May 08, 2009 MD80-57A242Revision 1: January 07, 2011 1 of 71
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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 5 B. Concurrent Requirements ...................................... 1 5 C. Reason ................................................ 1 5 D. Description .............................................. 1 6 E. Compliance .............................................. 1 9 F. Approval ............................................... 2 5 G. Manpower .............................................. 2 5 H. Weight and Balance Changes .................................... 2 7 I. Electrical Load Data ......................................... 2 7 J. References .............................................. 2 7
1. Existing Data: ......................................... 2 7
2. Data supplied with this Service Bulletin: ........................... 2 7
3. Installation Drawings Used in the Preparation of this Service Bulletin: ........... 2 8 K. Publications Affected ........................................ 2 8 L. Interchangeability and Intermixability of Parts ........................... 2 8
2. MATERIAL INFORMATION ........................................ 2 9 A. Material - Price and Availability ................................... 2 9 B. Industry Support Information .................................... 3 0 C. Parts Necessary For Each Airplane ................................. 3 0
1. Kits/Parts: ........................................... 3 0
2. Parts and Materials Supplied by the Operator: ........................ 5 4
3. Parts Modified and Reidentified: ............................... 5 4
4. Parts Removed and Not Replaced: .............................. 5 5 D. Parts Necessary to Change Spares ................................. 5 5 E. Special Tooling - Price and Availability ............................... 5 5 F. Special Tooling Necessary to do this Service Bulletin ....................... 5 5
3. ACCOMPLISHMENT INSTRUCTIONS .................................. 5 7 A. GENERAL INFORMATION ..................................... 5 7 B. WORK INSTRUCTIONS ....................................... 5 9 FIGURE 1: WING REAR SPAR LOWER CAP - LEFT AND RIGHT - EDDY CURRENT TESTING HIGH FREQUENCY INSPECTION .................................. 7 0
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Commercial Airplanes MD80 Service Bulletin ALERT Revision Transmittal SheetNumber: MD80-57A242Original Issue: May 08, 2009 Revision 1: January 07, 2011 ATA System: 5710 SUBJECT: WINGS - Main Frame - Inspect/Repair Upper and Lower Rear Spar Caps at Station Xrs=164.000 This revision includes all pages of the service bulletin.
COMPLIANCE INFORMATION RELATED TO THIS REVISION No more work is necessary on airplanes changed in accordance with the original issue of this service bulletin.
Federal Aviation Administration (FAA) Airworthiness Directive AD 2004-11-07 is related to this service bulletin.
REASON FOR REVISION This revision is sent to incorporate engineering released subsequent to original release of this service bulletin, which incorporates an option to do a splice repair of the upper and/or lower rear spar caps.
The information provided in Information Notices MD80-57A242 IN 01 and MD80-57A242 IN 02 are included in this revision.
These sections were changed:
1. In Paragraph 1.A.1., Airplanes, added Groups 3 and 4.
2. In Paragraph 1.C., Reason, added spar splice option.
3. In Paragraph 1.D., Description, added Condition titles, Option 1 heading and Option 2 splice repair, and added repair options for Condition 3.
4. In Paragraph 1.E., Compliance, added calender time information, Option 1 heading, Option 2 splice repair, repair options for Condition 3, and Federal Aviation Administration (FAA) Airworthiness Directive information.
5. In Paragraph 1.F., Approval, added Alternative Method of Compliance statement.
6. In Paragraph 1.G., Manpower, added Groups 3 and 4 and a table for splice repair hours.
7. In Paragraph 1.J.1., Existing Data, changed Aircraft Maintenance Manual (AMM) references to reflect correct chapter references.
8. In Paragraph 1.J.2., Data supplied with this Service Bulletin, added drawings and updated DCN/REV column.
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9. In Paragraph 1.K., Publications Affected, added Damage Tolerance Based Structural Inspection information.
10. In Paragraph 2.A., Material - Price and Availability, added Service Kits, expiration date, and unit price.
11. In Paragraph 2.C.1., Kits/Parts, changed Service Kit applicability table to add new kits, changed kit descriptions, and added new kit parts list.
12. In Paragraph 2.C.2., Parts and Materials Supplied by the Operator, changed supplier address.
13. In Paragraph 2.C.3., Parts Modified and Reidentified, added parts changed based on repair configuration.
14. In Paragraph 3.A., General Information, added notes.
15. In Paragraph 3.B., Work Instructions, added Groups 3 and 4, Option 1 heading, Option 2 splice repair, and repair options for Condition 3, removed one work step, resequenced work steps, and corrected Aircraft Maintenance Manual Chapter references.
16. Changed note and scope of inspection in Figure 1 for clarity of work required.
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 May 08, 2009Original Issue:
January 07, 2011Revision 1:
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Commercial Airplanes MD80 Service Bulletin ALERT SummaryNumber: MD80-57A242Original Issue: May 08, 2009 Revision 1: January 07, 2011 ATA System: 5710 SUBJECT: WINGS - Main Frame - Inspect/Repair Upper and Lower Rear Spar Caps at Station Xrs=164.000
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 Two operators, while doing an investigation for fuel leaks, reported four instances of cracking of the wing rear spar lower cap at the outboard flap, inboard drive hinge at station Xrs=164.000. Boeing has determined that cracks are the result of material fatigue from normal flap operating loads. Inspecting this area for cracks will stop any crack migration and ensure repairs are done before additional damage occurs. Installation of doublers or doing a spar lower cap splice will help insure the structural integrity of the rear spar. If not corrected, fuel leaks and damage to the wing skin or other structure may occur, resulting in flight disruptions and possible loss of the structural integrity of the wing.
Service History Landing CyclesFlight-Hours 35,286 to 39,33851,193 to 69,453 ACTION Refer to Paragraph 1.D., for Description.
EFFECTIVITY 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.
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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.
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BOEING SERVICE BULLETIN MD80-57A242
ALERT ALERT
NSPECT / REPAIR UPPER ANI
LOWER REAR SPAR CAPS AT STA Xrs=164.000 1676759 Original Issue: May 08, 2009 Revision 1: January 07, 2011 MD80-57A242
BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 9 of 71
BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
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Commercial Airplanes MD80 Service Bulletin ALERT Number: MD80-57A242 Original Issue: May 08, 2009 Revision 1: January 07, 2011 ATA System: 5710 SUBJECT: WINGS - Main Frame - Inspect/Repair Upper and Lower Rear Spar Caps at Station Xrs=164.000
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 Airplanes with a multi-component bulkhead with bolts at wing station Xrs=137.750 and affected by Service Bulletin MD80-57-184.
-1 Airplanes that accomplished Service Bulletin MD80-57-184 temporary repair.
1 Airplanes that did not accomplish Service Bulletin MD80-57-184 temporary repair.
2 Airplanes with a multi-component bulkhead with bolts at wing station Xrs=137.750 and not affected by Service Bulletin MD80-57-184.
-2 Airplanes with a multi-component bulkhead without bolts at wing station Xrs=137.750 and not affected by Service Bulletin MD80-57-184.
-3 Airplanes with a machined bulkhead at wing station Xrs=137.750 and not affected by Service Bulletin MD80-57-184.
-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
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GroupFuselage Number 1938 1941 1944 1948 1950 1952 - 953 1957 1962 1966 - 967 1969 - 971 1973 1978 1981 1986 1988 1992 1994 - 995 1999 - 1001 11004 - 1006 11011 - 1012 11016 11018 - 1019 11028 11031 11034 11043 11045 11047 11049 11051 11053 11055
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