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11-00376 12/21/2011 Enclosure A Commercial QADEING Airplanes MD80 Service Bulletin = ALERT Number: MD80-57A243 Original Issue: December 20, 2011 ATA System: 5710 SUBJECT: WINGS - Main Frame - Inspect/Repair Stringer 11 at the Outboard Flap, Inboard Drive Hinge 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.
ECCN: 9E991
BOLING PROPRIETARY, CONFIDENTIAL, AND/OR TRADE SECRET Copyright © 2011 The Boeing Company Unpublished Work - All Rights Reserved Boeing claims copyright in each page of this document only to the extent that the page contains copyrightable subject matter.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.
Original Issue: December 20, 2011 MD80-57A243
BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 1 of 25
2.0
BOEING SERVICE BULLETIN MD80-57A243
ALERT ALERT
BLANK PAGE Original Issue: December 20, 2011 BOEING PROPRIETARY - MD80-57A243 Copyright © Unpublished Work - See page 1 for details. 2 of 25
BOEING SERVICE BULLETIN MD80-57A243
ALERT ALERT Table of Contents Summary. 5
1. PLANNING INFORMATION 9 Effectivity . 9
1. Airplanes 9
2. Spares Affected 11 B Concurrent Requirements 17
c. Reason 11 D Description 71 E Compliance 12 F. Approval 13 G Manpower 13 Weight and Balance Changes. 14 Electrical Load Data 14 J. References . 14
1. Existing Data 14
2. Data supplied with this Service Bulletin: 15
3. Installation Drawings Used in the Preparation of this Service Bulletin: 15 K. Publications Affected . 15 Interchangeability and Intermixability of Parts 15
2. MATERIAL INFORMATION . 17 Material - Price and Availability . 17 B. Industry Support Information 17 C. Parts Necessary For Each Airplane. 17
1. Kits/Parts: 17
2. Parts and Materials Supplied by the Operator: 19
3. Parts Modified and Reidentified: 20
4. Parts Removed and Not Replaced 20 D. Parts Necessary to Change Spares. 20 E. Special Tooling - Price and Availability 20 F. Special Tooling Necessary to do this Service Bulletin . 20
3. ACCOMPLISHMENT INSTRUCTIONS 21 A. GENERAL INFORMATION 21 B. WORK INSTRUCTIONS 22 FIGURE 1: EDDY CURRENT, HIGH FREQUENCY INSPECTION - STRINGER 11 AT THE OUTBOARD
FLAP, INBOARD DRIVE HINGE AT STATION XRS=164.000 . .24
Original Issue: December 20, 2011 BOEING PROPRIETARY - MD80-57A243 Copyright © Unpublished Work - See page 1 for details. 3 of 25
BOEING SERVICE BULLETIN MD80-57A243
ALERT ALERT
BLANK PAGE Original Issue: December 20, 2011 MD80-57A243
BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 4 of 25
Commercial @ SOEING Airplanes MD80 Service Bulletin ALERT Number: MD80-57A243 Summary Original Issue: December 20, 2011 ATA System: 5710 SUBJECT: WINGS - Main Frame - Inspect/Repair Stringer 11 at the Outboard Flap, Inboard Drive Hinge 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 Three operators reported four instances of cracks found in Stringer 11 at the outboard flap, inboard drive hinge at Station Xrs=164.000. The cracking occurs at the end fastener of the wing bulkhead clip attachment to the stringer. The affected MD-80 airplanes had accrued between 27,675 through 64,279 flight-hours and 32,771 through 36,935 landing cycles when the cracks were found. The cracked stringers were found by chance, during maintenance, except in one case when the rear spar cap had been removed during a spar cap splice repair.
Boeing investigation and analysis have shown that the Stringer 11 cracking is due to fatigue. If undetected, a crack in the stringer may grow until the stringer severs, initiating a crack in the wing lower skin. Continuing damage into the wing skin may result in the wing structure not being capable of sustaining the required loads.
Inspection of the affected areas will determine the condition of the stringer, prevent any crack migration, and ensure repairs are done before additional damage occurs. A splice repair for crack found on the affected stringer can be accomplished by installing a segment of stringer. If not corrected, fuel leaks and damage to the wing skin or other structure may occur, resulting in possible loss of the structural integrity of the wing.
Boeing Fleet Team Digest (FTD) MD-80 FT MD-80-FTD-57-10001 is related to this service bulletin.
ACTION This service bulletin provides instructions to do an Eddy Current, High Frequency (ETHF) inspection for cracks in Stringer 11 at the outboard flap, inboard drive hinge at Station Xrs=164.000. Refer to Paragraph 1.D., Description, for the required corrective action based on the results of the inspection.
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.
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BOEING SERVICE BULLETIN MD80-57A243
ALERT ALERT
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.
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BOEING SERVICE BULLETIN MD80-57A243
ALERT ALERT INSPECT / REPAIR STRINGER 11
AT THE OUTBOARD FLAP , INBOARD DRIVE HINGE AT STATION Xrs=164.000 2108093 Original Issue: December 20, 2011 BOEING PROPRIETARY - MD80-57A243 Copyright © Unpublished Work - See page 1 for details. 7 of 25
BOEING SERVICE BULLETIN MD80-57A243
ALERT ALERT
BLANK PAGE Original Issue: December 20, 2011 BOEING PROPRIETARY - MD80-57A243 Copyright @ Unpublished Work - See page 1 for details. 8 of 25
Commercial @ ODEING Airplanes MD80 Service Bulletin
- ALERT Number: MD80-57A243 Original Issue: December 20, 2011 ATA System: 5710 SUBJECT: WINGS - Main Frame - Inspect/Repair Stringer 11 at the Outboard Flap, Inboard Drive Hinge 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 BULLEȚIN 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.
GROUP CONFIGURATION | DESCRIPTION 1 Inspect/Repair Stringer 11 at the Outboard Flap, Inboard Drive Hinge at Station Xrs=164.000 Airplane Models:
DC-9-81 (MD-81), DC-9-82 (MD-82), DC-9-83 (MD-83), DC-9-87 (MD-87), MD-88 Fuselage Num- Group ber 1326 - 2007 2009 - 2016 2019 - 2034 2036 - 2069 2071 - 2093 2101 - 2114 2116 Original Issue: December 20, 2011 MD80-57A243
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BOEING SERVICE BULLETIN MD80-57A243
ALERT ALERT Fuselage Num- Group ber 2118 - 2119 1 2121 2124 1 2127 - 2128 1 2130 2132 2134 - 2135 1 2137 1 2139 1 2145 2148 1 2151 - 2152 1 2155 1 2167 2174 1 2176 1 2178 1 2180 1 2183 1 2185 1 2187 2189 2192 2196 2199 1 2201 1 2204 2206 1 2208 2214 1 2218 1 2234 Original Issue: December 20, 2011 MD80-57A243
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BOEING SERVICE BULLETIN MD80-57A243
ALERT ALERT Fuselage Num- Group ber 2239 2241 2244 2247 2249 2252 2254 2264 - 2287
2. Spares Affected None.
B. Concurrent Requirements None.
C. Reason Three operators reported four instances of cracks found in Stringer 11 at the outboard flap, inboard drive hinge at Station Xrs= 164.000. The cracking occurs at the end fastener of the wing bulkhead clip attachment to the stringer. The affected MD-80 airplanes had accrued between 27,675 through 64,279 flight-hours and 32,771 through 36,935 landing cycles when the cracks were found. The cracked stringers were found by chance, during maintenance, except in one case when the rear spar cap had been removed during a spar cap splice repair. Boeing investigation and analysis have shown that the Stringer 11 cracking is due to fatigue. If undetected, a crack in the stringer may grow until the stringer severs, initiating a crack in the wing lower skin. Continuing damage into the wing skin may result in the wing structure not being capable of sustaining the required loads. Inspection of the affected areas will determine the condition of the stringer, prevent any crack migration, and ensure repairs are done before additional damage occurs. A splice repair for crack found on the affected stringer can be accomplished by installing a segment of stringer. If not corrected, fuel leaks and damage to the wing skin or other structure may occur, resulting in possible loss of the structural integrity of the wing.
Boeing Fleet Team Digest (FTD) MD-80 FTD MD-80-FTD-57-10001 is related to this service bulletin.
D. Description This service bulletin provides instructions to do an Eddy Current, High Frequency (ETHF) inspection for cracks in Stringer 11 at the outboard flap, inboard drive hinge at Station Xrs=164.000, and based on inspection results does as follows:
Condition 1 (No Crack Found) Does repeat ETHF inspection for cracks in Stringer 11 at the outboard flap, inboard drive hinge at Station Xrs= 164:000.
Original Issue: December 20, 2011 MD80-57A243 BOEING PROPRIETARY .
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BOEING SERVICE BULLETIN MD80-57A243
ALERT ALERT Condition 2 (Crack Found)
1. Does splice repair.
2. Does ETHF inspection for cracks in Stringer 11 at the outboard flap, inboard drive hinge at Station Xrs=164.000.
The work in this service bulletin is done in the maintenance zone(s) given below.
Affected Maintenance Zones Model Zone DC-9-81 (MD-81), DC-9-82 13,14 (MD-82), DC-9-83 (MD-83), DC- 9-87 (MD-87), MD-88 E. 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.
Accomplish the required actions, based on the applicable conditions, in Table 1, in accordance with Paragraph 3. Accomplishment Instructions.
Table 1: Inspect Stringer 11 for Crack at the Outboard Flap. Inboard Drive Hinge at Station Xrs=164.000 Condition Action Compliance Time Repeat (Whichever Occurs Later) Interval (Not to Exceed) All airplanes Do Eddy Current, High Frequency Before the accumula- Within 8,710 flight cy- (ETHF) inspection for cracks in tion of 19,000 total cles after the original Stringer 11 at the outboard flap, flight cycles. issue date on this inboard drive hinge at Station service bulletin.
Xrs=164.000.
Condition 1: Do ETHF inspection for cracks in - 29,000 flight (No Crack Stringer 11 at the outboard flap, cycles.
Found) inboard drive hinge at Station Xrs=164.000. (a) Condition 2: Do splice repair. Before further flight.
(Crack Found) AND Do ETHF inspection for cracks in | 60,000 flight cycles 29,000 flight Stringer 11 at the outboard flap, after splice repair. cycles.
inboard drive hinge at Station Xrs-164.000. (b) Original Issue: December 20, 2011 MD80-57A243
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