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Commercial Airplanes MD80 Service Bulletin ALERT Number: MD80-57A244 Original Issue: March 03, 2016 Revision 1: October 01, 2019 ATA System: 5732 SUBJECT: WINGS - Lower Wing Skin - Inspection of Left Side and Right Side Center Wing Lower Skins and Stringers 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Unpublished Work.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: March 03, 2016 MD80-57A244Revision 1: October 01, 2019 1 of 109
20.0
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: March 03, 2016 MD80-57A244Revision 1: October 01, 2019 2 of 109 BOEING SERVICE BULLETIN MD80-57A244
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BLANK PAGE
Table of Contents
Revision Transmittal Sheet5
S u m m a r y7
1. PLANNING INFORMATION ........................................ 1 1 A . E f f e c t i v i t y ............................................... 1 1
1. Airplanes ............................................ 1 1 2 . S p a r e s A f f e c t e d ........................................ 1 3 B. Concurrent Requirements ...................................... 1 3 C. Reason ................................................ 1 4 D. Description .............................................. 1 4 E. Compliance .............................................. 1 5 F . A p p r o v a l ............................................... 3 2 G. Manpower .............................................. 3 3 H. Weight and Balance Changes .................................... 3 3 I. Electrical Load Data ......................................... 3 3 J . R e f e r e n c e s .............................................. 3 4
1. Existing Data: ......................................... 3 4
2. Data Supplied with this Service Bulletin: ........................... 3 4
3. Installation Drawings Used in the Preparation of this Service Bulletin: ........... 3 6 K. Publications Affected ........................................ 3 6 L. Interchangeability and Intermixability of Parts ........................... 3 6 M. Software Accomplishment Summary ................................ 3 6
2. MATERIAL INFORMATION ........................................ 3 7 A. Material - Price and Availability ................................... 3 7 B. Industry Support Information .................................... 3 7 C. Parts Necessary for Each Airplane ................................. 3 7 1 . K i t s / P a r t s ............................................ 3 7
2. Parts and Materials Supplied by the Operator ........................ 3 7
3. Parts Modified and Reidentified ................................ 3 7
4. Parts Removed and Not Replaced .............................. 3 7 D. Parts Necessary to Change Spares ................................. 3 7 E. Special Tooling - Price and Availability ............................... 3 8 F. Special Tooling Necessary to do this Service Bulletin ....................... 3 8
3. ACCOMPLISHMENT INSTRUCTIONS .................................. 3 9 A. GENERAL INFORMATION ..................................... 3 9 B. WORK INSTRUCTIONS ....................................... 4 1 FIGURE 1: OPEN ACCESS - LEFT SIDE ................................. 6 3 FIGURE 2: INSPECTION - LEFT SIDE .................................. 6 5 FIGURE 3: CLOSE ACCESS - LEFT SIDE ................................ 6 8 FIGURE 4: OPEN ACCESS - RIGHT SIDE ................................ 7 0 FIGURE 5: INSPECTION - RIGHT SIDE .................................. 7 2 FIGURE 6: CLOSE ACCESS - RIGHT SIDE ............................... 7 5 FIGURE 7: OPEN ACCESS - LEFT SIDE AND RIGHT SIDE ...................... 7 7 FIGURE 8: INSPECTION - LEFT SIDE AND RIGHT SIDE ........................ 7 9 FIGURE 9: CLOSE ACCESS - LEFT SIDE AND RIGHT SIDE ...................... 8 2 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
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APPENDIX A: LOGIC DIAGRAM FOR PARAGRAPH 1.E. COMPLIANCE TABLE 1: EDDY CURRENT, LOW
FREQUENCY (ETLF) AND EDDY CURRENT, HIGH FREQUENCY (ETHF) INSPECTIONS OF THE LEFT SIDE AND RIGHT SIDE CENTER WING LOWER SKINS AND STRINGERS. [Group 1, Configuration 1] ....................................... 8 5 APPENDIX B: LOGIC DIAGRAM FOR PARAGRAPH 1.E. COMPLIANCE TABLE 2: EDDY CURRENT, LOW
FREQUENCY (ETLF) AND EDDY CURRENT, HIGH FREQUENCY (ETHF) INSPECTIONS OF THE LEFT SIDE AND RIGHT SIDE CENTER WING LOWER SKINS AND STRINGERS. [Group 1, Configuration 1] ....................................... 8 9 APPENDIX C: LOGIC DIAGRAM FOR PARAGRAPH 1.E. COMPLIANCE TABLE 3: EDDY CURRENT, LOW
FREQUENCY (ETLF) AND EDDY CURRENT, HIGH FREQUENCY (ETHF) INSPECTIONS OF THE LEFT SIDE AND RIGHT SIDE CENTER WING LOWER SKINS AND STRINGERS. [Group 1, Configuration 2] ....................................... 9 5 APPENDIX D: LOGIC DIAGRAM FOR PARAGRAPH 1.E. COMPLIANCE TABLE 4: EDDY CURRENT, LOW
FREQUENCY (ETLF) AND EDDY CURRENT, HIGH FREQUENCY (ETHF) INSPECTIONS OF THE LEFT SIDE AND RIGHT SIDE CENTER WING LOWER SKINS AND STRINGERS. [Group 1, Configuration 2] ....................................... 9 9 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
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Commercial Airplanes MD80 Service Bulletin ALERT Revision Transmittal SheetNumber: MD80-57A244Original Issue: March 03, 2016 Revision 1: October 01, 2019 ATA System: 5732 SUBJECT: WINGS - Lower Wing Skin - Inspection of Left Side and Right Side Center Wing Lower Skins and Stringers This revision includes all pages of the service bulletin.
COMPLIANCE INFORMATION RELATED TO THIS REVISION Federal Aviation Administration (FAA) Airworthiness Directive AD 2016-07-28 is related to this service bulletin.
Effects of this Revision on airplanes on which Original Issue was previously done:
None.
Refer to Paragraph 1.E., Compliance for changes to Compliance actions and times.
REASON FOR REVISION Revision 1 is sent to expand the inspection of the stringers by doing an external Eddy Current, Low Frequency (ETLF) inspection of the left and right side wing fastener holes common to stringers 11 thru 22 and the forward and aft skins and an Eddy Current, High Frequency (ETHF) inspection of the lower skin at stringers 18 thru 20 for any crack.
These sections were changed:
1. Summary, Background, added Revision information.
2. Summary, Action, added new inspection information.
3. Summary, Compliance, added Federal Aviation Authority (FAA) Airworthiness Directive (AD) reference.
4. Summary, Illustration, revised to include new inspections.
5. Paragraph 1.C., Reason, added Revision information.
6. Paragraph 1.D., Description, added new inspection information and effects of this revision statement.
7. Paragraph 1.E., Compliance, added FAA AD reference, logic diagram reference, added new inspection and revised compliance information.
8. Paragraph 1.F., Approval, added FAA AD Alternative Method of Compliance (AMOC) statement.
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: March 03, 2016 MD80-57A244Revision 1: October 01, 2019 5 of 109
9. Paragraph 1.J., References, added new references and new draw ing reference.
10. Paragraph 2.C., Parts and Materials Supplied by the Operator , added footnote.
11. Paragraph 3.A., General Information, added logic diagram inf ormation.
12. Paragraph 3.B., Work Instructions, added new inspection inst ructions.
13. Figure 7: Added information for new inspection.
14. Figure 8: Added instructions for new inspection.
15. Figure 9: Added close access information for new inspection criteria.
16. Appendix A: Added logic diagram.
17. Appendix B: Added logic diagram.
18. Appendix C: Added logic diagram.
19. Appendix D: Added logic diagram.
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 March 03, 2016Original Issue:
October 01, 2019Revision 1:
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
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Commercial Airplanes MD80 Service Bulletin ALERT SummaryNumber: MD80-57A244Original Issue: March 03, 2016 Revision 1: October 01, 2019 ATA System: 5732 SUBJECT: WINGS - Lower Wing Skin - Inspection of Left Side and Right Side Center Wing Lower Skins and Stringers
THIS DOCUMENT 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 DOCUMENT TO THE NEW OPERATOR. IF APPLICABLE SPARES HAVE BEEN SOLD, SEND THIS DOCUMENT TO THE NEW OWNER.
CONCURRENT REQUIREMENTS None.
BACKGROUND This service bulletin gives instructions to do an Eddy Current, Low Frequency (ETLF) inspection of the left and right side fastener holes common to stringers 11 thru 22 and the forward and aft skins and do an Eddy Current, High Frequency (ETHF) inspection of the lower skin at stringers 18 thru 20 for any crack. If the inspection in this service bulletin is not done, fatigue cracks could grow to a critical length before being found by routine maintenance inspections which could cause structural failure of the wings.
There have been five reports of cracks at Stringers S-15, S-16, or S-17, associated end fittings and skins in the center wing fuel tank where the stringers meet the end fittings near Xcw=13 and Xcw=15. The table below shows, for each reported case of cracks, where the cracks occurred, and the flight cycles and hours of the airplane at the time of the crack. In four of the five reports, the cracks were discovered while doing Maintenance Planning Document (MPD) item 57-086-02 during scheduled maintenance. The cause of the cracks is determined to be fatigue.
NotesFlight Cycles/ Flight Hours Structure CrackedDateReport Scheduled Maintenance42,247 / 78,873Stringer 17 RightJuly 20141 Found during fuel leak investigation 44,147 / 61,208Stringer 17 Left, Fwd Skin, Aft SkinApril 20152 Scheduled Maintenance56,908 / 74,240Stringer 17 Right, Fwd Skin, Aft Skin July 20153 Scheduled Maintenance43,756 / 60,690Stringer 15 and 16 Right, four end fittings (two per stringer) August 20154 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
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NotesFlight Cycles/ Flight Hours Structure CrackedDateReport Scheduled Maintenance45,421 / 63,168Stringer 17 Left and Stringer 17 Right January 20165 After the release of the Original Issue of this service bulletin there have been 10 additional reports of cracks at Stringers S-15, S-16, or S-17, three of these with forward and aft skin cracks at S-17. In addition, on one of these aircraft a crack was reported at Stringer S-13 location. Boeing has determined the inspections given in the Original Issue of this service bulletin requires an expansion of the inspection to adjacent stringers with similar stress levels and requires an inspection with increased sensitivity for crack detection in the area. This revision is sent to replace and expand the inspection of the stringers by doing an external Eddy Current, Low Frequency (ETLF) inspection of the left and right side wing fastener holes common to stringers 11 thru 22 and the forward and aft skins and an Eddy Current, High Frequency (ETHF) inspection of the lower skin at stringers 18 thru 20 for any crack.
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 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 YesOperator Supplied Parts/Material Paragraph 2.F., Special Tooling Necessary to do this Service Bulletin NoSpecial Tooling Required Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
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ACTION Get access to the left and right center wing lower skins, stringers S-11 thru S-22 between Xcw=0 and Xcw=20 under the wing/fuselage fillet panels. This service bulletin gives instructions to do an Eddy Current, Low Frequency (ETLF) inspection of the left and right side fastener holes common to stringers 11 thru 22 and the forward and aft skins and do an Eddy Current, High Frequency (ETHF) inspection of the lower skin at stringers 18 thru 20 for any crack. If any crack is found, contact The Boeing Company for repair instructions and do the repair; and repeat the inspections for any crack in the unrepaired area. If no crack is found, repeat the inspections for any crack.
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 airplane(s).
COMPLIANCE Federal Aviation Administration (FAA) Airworthiness Directive AD 2016-07-28 is related to this service bulletin.
The effective date of AD 2016-07-28 is April 26, 2016.
Refer to Paragraph 1.E., Compliance.
INDUSTRY SUPPORT INFORMATION Boeing warranty remedies are not available for the inspection given in this service bulletin.
MANPOWER Refer to Paragraph 1.G., Manpower.
MATERIAL INFORMATION Operator Supplied Parts/Materials.
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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BOEING SERVICE BULLETIN MD80-57A244
ALERT ALERT
DO AN EDDY CURRENT, LOW FREQUENCY (ETLF)
INSPECTION OF FASTENER HOLES COMMON TO STRINGERS 11 THRU 22 AND THE FORWARD AND AFT SKINS FOR ANY CRACK.
DO AN EDDY CURRENT, HIGH FREQUENC
ETHF) INSPECTION OF THE LOWER SKIN AT STRINGERS 18 THRU 20 FOR ANY CRACK Xcw=0.000 Xcw=20.000
INSPECTION AREA STRINGERS 11-22 STRINGER 22
- STRINGER 21
- STRINGER 20
- STRINGER 19 STRINGER 18
• STRINGER 17
•STRINGER 16 STRINGER 15 STRINGER 14
• STRINGER 13
• STRINGER 12 STRINGER 11
- REAR SPAR — SKIN
STRINGER
INSPECTION AREA LEFT SIDE SHOWN, RIGHT SIDE OPPOSITE LOWER WING SKINS AND STRINGERS 2481761 (VIEW LOOKING DOWN) Original Issue: March 03, 2016 Revision 1: October 01, 2019 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished MD80-57A244 Work - See page 1 for details. 10 of 109
Commercial Airplanes MD80 Service Bulletin ALERT Number: MD80-57A244 Original Issue: March 03, 2016 Revision 1: October 01, 2019 ATA System: 5732 SUBJECT: WINGS - Lower Wing Skin - Inspection of Left Side and Right Side Center Wing Lower Skins and Stringers
THIS DOCUMENT 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 DOCUMENT TO THE NEW OPERATOR. IF APPLICABLE SPARES HAVE BEEN SOLD, SEND THIS DOCUMENT TO THE NEW OWNER.
1. PLANNING INFORMATION A. Effectivity
1. Airplanes This bulletin is applicable to DC-9-81 (MD-81), DC-9-82 (MD-82), DC-9-83 (MD-83), DC-9-87 (MD-87), MD-88 Airplane(s), line number(s) 909, 917, 924, 938, 941, 944, 946, 948, 950, 952-953, 955, 957-958, 960, 962-963, 965-967, 969-971, 973-975, 977-979, 981, 983, 985-986, 988-989, 991-992, 994-999, 1000-1013, 1015-1016, 1018-1020, 1022-1023, 1025-1026, 1028-1029, 1031-1032, 1034-1035, 1037-1038, 1040-1041, 1043, 1045, 1047, 1049, 1051, 1053, 1055, 1057, 1059-1080, 1082-1083, 1085-2007, 2009-2016, 2019-2034, 2036-2069, 2071-2093, 2101-2114, 2116, 2118-2119, 2121, 2124, 2127-2128, 2130, 2132, 2134-2135, 2137, 2139, 2145, 2148, 2151-2152, 2155, 2167, 2174, 2176, 2178, 2180, 2183, 2185, 2187, 2189, 2192, 2196, 2199, 2201, 2204, 2206, 2208, 2214, 2218, 2234, 2239, 2241, 2244, 2247, 2249, 2252, 2254, 2264-2287 in 1 Group(s). Where the effectivity is presented with hyphens between line numbers, the airplane applicability means "through" and "inclusive", e.g. line numbers 1-9 means line numbers 1 through 9 inclusive.
The Variable Numbers and Group Information for the applicable airplanes is given below.
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: March 03, 2016 MD80-57A244Revision 1: October 01, 2019 11 of 109
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 DC-9-81 (MD-81), DC-9-82 (MD-82), DC-9-83 (MD-83), DC-9-87 (MD-87), and MD-88 airplanes that have not done any inspection in accordance with the Original Issue of this service bulletin.
1 DC-9-81 (MD-81), DC-9-82 (MD-82), DC-9-83 (MD-83), DC-9-87 (MD-87), and MD-88 airplanes that have done the inspection in accordance with the Original Issue of this service bulletin.
2 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 1965 - 967 1969 - 971 1973 - 975 1977 - 979 1981 1983 1985 - 986 GroupFuselage Number 1988 - 989 1991 - 992 1994 - 1013 11015 - 1016 11018 - 1020 11022 - 1023 11025 - 1026 11028 - 1029 11031 - 1032 11034 - 1035 11037 - 1038 11040 - 1041 11043 11045 11047 11049 11051 11053 11055 11057 11059 - 1080 GroupFuselage Number 11082 - 1083 11085 - 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 12148 12151 - 2152 12155 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: March 03, 2016 MD80-57A244Revision 1: October 01, 2019 12 of 109 BOEING SERVICE BULLETIN MD80-57A244