Commercial McDonnell Douglas

Airplanes DC9

Service Bulletin

Number: DC9-57-223

Original Issue: July 21, 2003

Revision 1: August 13, 2009

ATA System: 5710

SUBJECT: WINGS - Main Frame - Left and Right Center Wing Rear Spar Upper Caps Inspection

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

BOEING PROPRIETARY, CONFIDENTIAL, AND/OR TRADE SECRET

Copyright © 2003 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Unpublished Work - All Rights Reserved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.

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3.0
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BOEING SERVICE BULLETIN DC9-57-223

BLANK PAGE
Table of Contents

Revision Transmittal Sheet ............................................ 5

Summary ...................................................... 7

1. PLANNING INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

A. Effectivity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

1. Airplanes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

2. Spares Affected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

B. Concurrent Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

C. Reason . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

D. Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

E. Compliance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

F. Approval . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

G. Manpower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

H. Weight and Balance Changes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

I. Electrical Load Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

J. References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

1. Existing Data: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

2. Data supplied with this Service Bulletin: . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

3. Installation Drawings Used in the Preparation of this Service Bulletin: . . . . . . . . . . . 27

K. Publications Affected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

L. Interchangeability and Intermixability of Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

2. MATERIAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

A. Material - Price and Availability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

B. Industry Support Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

C. Parts Necessary For Each Airplane . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

1. Kits/Parts: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

2. Parts and Materials Supplied by the Operator: . . . . . . . . . . . . . . . . . . . . . . . . 29

3. Parts Modified and Reidentified: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

4. Parts Removed and Not Replaced: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

D. Parts Necessary to Change Spares . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

E. Special Tooling - Price and Availability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

F. Special Tooling Necessary to do this Service Bulletin . . . . . . . . . . . . . . . . . . . . . . . 29

3. ACCOMPLISHMENT INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

A. GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

B. WORK INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

FIGURE 1: LEFT AND RIGHT WING CENTER REAR SPAR CAP - VERTICAL LEG INSPECTION . 36

FIGURE 2: LEFT AND RIGHT WING CENTER REAR SPAR CAP - UPPER FLANGE INSPECTION . 42

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BOEING SERVICE BULLETIN DC9-57-223

BLANK PAGE
Commercial McDonnell Douglas

Airplanes DC9

Service Bulletin

Revision Transmittal Sheet Number: DC9-57-223

Original Issue: July 21, 2003

Revision 1: August 13, 2009

ATA System: 5710

SUBJECT: WINGS - Main Frame - Left and Right Center Wing Rear Spar Upper Caps Inspection

This Revision includes all pages of the service bulletin.

COMPLIANCE INFORMATION RELATED TO THIS REVISION

Federal Aviation Administration (FAA) Airworthiness Directive 2004-23-11 is related to this service bulletin.

No more work is necessary on DC-9-10/-20 airplanes as shown in the original issue of this service bulletin.

More work is necessary on DC-9-30/-40/-50 airplanes changed as shown in the original issue of this service

bulletin. Inspection of the horizontal flange of the center wing rear spar upper cap at station Xcw=58.500 to be

accomplished at next repeat interval inspection.

REASON FOR REVISION

This revision is sent to add inspection of the horizontal flange of the left and right rear spar upper cap on

DC-9-30/-40/-50 airplanes.

These sections were changed:

1. In Paragraph 1.A.1., Airplanes, changed airplane groups.

2. In Paragraph 1.C., Reason, changed to include inspection of the horizontal flange on the inboard side of

the rear spar upper cap.

3. In Paragraph 1.D., Description, changed as follows:

a. Added Configurations 1, 2, and 3 to Group 1 and 2.

b. Added affected maintenance zone tables.

4. In Paragraph 1.E., Compliance, added compliance tables.

5. In Paragraph 1.F., Approval, added Revision 1 and Airworthiness Directive No. 2004-23-11.

6. In Paragraph 1.G., Manpower, added note.

7. In Paragraph 1.H., Weight and Balance Changes, added statement for variable weight changes.

8. In Paragraph 1.J.1, Existing Data, added references previously omitted.

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9. In Paragraph 3.A., General Information, added new notes 1, 5, and 6.

10. In Paragraph 3.B., Work Instructions, added Configurations 1, 2, and 3 to Groups 1 and 2.

11. In Figure 1, added outboard view.

12. Added Figure 2 for horizontal flange inspection.

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

Original Issue: July 21, 2003

Revision 1: August 13, 2009

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BOEING SERVICE BULLETIN DC9-57-223
Commercial McDonnell Douglas

Airplanes DC9

Service Bulletin

Summary Number: DC9-57-223

Original Issue: July 21, 2003

Revision 1: August 13, 2009

ATA System: 5710

SUBJECT: WINGS - Main Frame - Left and Right Center Wing Rear Spar Upper Caps Inspection

CONCURRENT REQUIREMENTS

None.

BACKGROUND

Eleven operators have reported 12 instances of cracking in the vertical leg of the center wing rear spar upper

cap at station Xcw=58.500. Further investigation by one operator reported finding two cracks in the horizontal

flange on the inboard side of the rear spar upper cap. Investigation by Boeing has determined that cracks resulted

from stress corrosion. Inspection of the center wing rear spar upper cap will determine if crack(s) exist. If any

crack found is not corrected, fuel leaks and damage to the wing skin or other structure may occur resulting in

flight disruptions and unscheduled maintenance.

Service History

Flight-Hours Landing Cycles

20,100 to 76,183 25,150 to 88,029

ACTION

Refer to Paragraph 1.D., for Description.

EFFECTIVITY

DC-9-14, DC-9-15, DC-9-15F, DC-9-21, DC-9-31, DC-9-32, DC-9-32(VC-9C), DC-9-32F,

DC-9-32F(C-9A),DC-9-32F(C-9B), DC-9-33F, DC-9-34, DC-9-34F, DC-9-41 and DC-9-51 Airplanes. Refer to

Paragraph 1.A.1., Airplanes for the list of affected airplanes.

COMPLIANCE

Federal Aviation Administration (FAA) Airworthiness Directive 2004-23-11 is related to this service bulletin.

Refer to Paragraph 1.E., Compliance.

INDUSTRY SUPPORT INFORMATION

Boeing warranty remedies are not available for the inspection and repairs given in this service bulletin.

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MANPOWER

Refer to Paragraph 1.G., Manpower.

MATERIAL INFORMATION

None.

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BOEING SERVICE BULLETIN DC9-57-223

BLANK PAGE
Commercial McDonnell Douglas

Airplanes DC9

Service Bulletin

Number: DC9-57-223

Original Issue: July 21, 2003

Revision 1: August 13, 2009

ATA System: 5710

SUBJECT: WINGS - Main Frame - Left and Right Center Wing Rear Spar Upper Caps Inspection

1. PLANNING INFORMATION

A. Effectivity

1. Airplanes

This service bulletin is for the airplanes shown below.

GROUP CONFIGURATION DESCRIPTION

1 - DC-9-10 Airplanes

Airplanes that have accomplished this service bulletin and no crack

found

1

Airplanes that have accomplished this service bulletin and did crack

repair

2

3 Airplanes that have not accomplished this service bulletin

2 - DC-9-20, 31, -32, -33, -34, -41, -51 Airplanes

Airplanes that have accomplished this service bulletin and no crack

found

1

Airplanes that have accomplished this service bulletin and did crack

repair

2

3 Airplanes that have not accomplished this service bulletin

Airplane Models:

DC-9-14, DC-9-15, DC-9-15F, DC-9-21, DC-9-31, DC-9-32, DC-9-32(VC-9C), DC-9-32F,

DC-9-32F(C-9A), DC-9-32F(C-9B), DC-9-33F, DC-9-34, DC-9-34F, DC-9-41, DC-9-51

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Fuselage Num- Group

ber

10 1

101 1

1014 2

1017 2

102 1

1021 2

1024 2

1027 2

103 2

1030 2

1033 2

1039 2

104 2

1042 2

1044 2

1046 2

1048 2

1050 2

1052 2

1054 2

1056 2

1058 2

108 2

1081 2

1084 2

115 1

117 2

123 - 124 2

125 1

127 1

129 1

130 2

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Fuselage Num- Group

ber

132 - 133 2

135 - 138 2

139 - 141 1

144 - 145 2

147 1

15 1

150 - 151 2

154 2

156 1

159 2

16 1

165 1

167 - 169 2

17 1

170 1

172 2

174 2

177 2

178 1

179 2

18 1

180 2

183 2

184 - 186 1

187 2

189 2

19 1

190 - 191 2

193 2

194 1

195 2

198 2

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Fuselage Num- Group

ber

2 1

200 2

205 2

207 1

208 2

213 - 214 2

216 1

218 2

219 1

220 - 221 2

224 1

227 2

228 1

229 2

23 1

230 2

232 - 233 2

234 1

235 - 237 2

239 - 240 2

243 2

246 - 247 2

249 2

251 - 252 2

255 - 256 2

258 - 259 2

261 2

263 - 264 2

266 - 268 2

270 2

272 - 273 2

275 - 276 2

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Fuselage Num- Group

ber

278 - 283 2

286 2

29 1

292 2

294 - 298 2

30 1

300 - 302 2

304 2

308 - 312 2

314 2

317 - 319 2

32 1

320 - 324 2

326 2

329 2

331 2

335 2

337 2

339 2

34 1

340 2

342 - 343 2

347 2

35 1

351 2

353 - 354 2

359 2

364 - 365 2

367 2

369 2

37 1

370 2

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Fuselage Num- Group

ber

376 - 377 2

382 - 387 2

389 2

39 1

390 - 391 2

394 - 395 2

397 2

399 2

4 1

401 - 402 2

405 1

41 1

411 2

413 2

415 - 416 2

421 2

423 2

425 2

427 2

429 2

438 - 439 2

444 - 447 2

45 1

450 - 452 2

458 - 459 2

46 1

460 2

462 2

464 - 465 2

467 - 469 2

474 2

476 2

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Fuselage Num- Group

ber

479 - 480 2

482 - 483 2

485 - 492 2

497 - 499 2

50 1

501 - 502 2

505 2

507 2

51 1

511 - 512 2

514 - 515 2

517 - 518 2

520 - 521 2

525 2

527 2

529 - 530 2

533 - 536 2

538 - 539 2

54 1

540 - 541 2

543 - 545 2

547 - 548 2

55 1

550 - 552 2

554 - 555 2

557 2

559 2

56 1

560 2

562 2

564 2

566 2

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Fuselage Num- Group

ber

568 - 569 2

57 1

573 2

575 - 576 2

583 - 584 2

589 2

59 1

593 2

596 - 599 2

601 - 602 2

604 - 607 2

609 2

61 1

610 - 611 2

616 - 619 2

62 1

621 - 624 2

630 2

632 - 633 2

637 - 638 2

64 1

641 - 647 2

650 2

653 - 656 2

658 - 659 2

661 - 662 2

664 - 665 2

668 - 669 2

67 1

670 - 671 2

673 2

675 2

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Fuselage Num- Group

ber

677 - 679 2

68 1

683 - 684 2

686 2

69 1

691 - 692 2

694 2

696 2

698 2

7 1

700 2

702 2

704 2

706 - 709 2

71 1

711 - 712 2

714 - 715 2

718 - 719 2

72 1

721 2

723 - 724 2

726 - 728 2

732 2

736 2

740 2

742 - 743 2

747 2

75 1

750 - 751 2

754 2

757 2

759 2

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Fuselage Num- Group

ber

76 1

760 - 761 2

763 2

765 2

768 - 769 2

771 - 774 2

777 - 781 2

783 - 784 2

786 - 788 2

79 1

793 2

795 - 796 2

798 2

801 2

805 - 809 2

81 2

810 - 811 2

813 - 815 2

817 - 819 2

82 1

820 - 823 2

825 - 830 2

833 - 835 2

837 - 838 2

84 1

841 - 843 2

845 2

847 - 848 2

852 - 854 2

857 2

859 2

86 2

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Fuselage Num- Group

ber

860 - 864 2

87 2

871 - 877 2

879 - 881 2

883 - 884 2

887 - 895 2

899 2

9 1

90 1

900 - 902 2

904 - 905 2

908 2

912 - 915 2

918 - 919 2

921 - 923 2

926 - 927 2

929 2

93 1

930 - 932 2

934 - 937 2

939 2

94 1

940 2

942 - 943 2

945 2

947 2

949 2

95 2

951 2

954 2

956 2

959 2

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Fuselage Num- Group

ber

96 2

961 2

964 2

968 2

97 1

98 2

980 2

982 2

984 2

987 2

99 2

990 2

993 2

2. Spares Affected

None.

B. Concurrent Requirements

None.

C. Reason

Eleven operators have reported 12 instances of cracking in the vertical leg of the center wing rear spar

upper cap at station Xcw=58.500. Further investigation by one operator reported finding two cracks in

the horizontal flange on the inboard side of the rear spar upper cap. Investigation by Boeing has

determined that cracks resulted from stress corrosion. Inspection of the center wing rear spar upper

cap will determine if crack(s) exist. If any crack found is not corrected, fuel leaks and damage to the

wing skin or other structure may occur resulting in flight disruptions and unscheduled maintenance.

Service History

Flight-Hours Landing Cycles

20,100 to 76,183 25,150 to 88,029

Revision 1 is sent to add inspection of the horizontal flange of the left and right rear spar upper cap on

DC-9 airplanes.

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BOEING SERVICE BULLETIN DC9-57-223
D. Description

This service bulletin provides instructions for a high frequency eddy current inspection of the left and

right center wing rear spar upper cap at station Xcw=58.500 and accomplishes the following:

Group 1, Configuration 1, 3; Group 2, Configuration 1, 3:

1. Do an Eddy Current, High Frequency (ETHF) inspection of the left and right rear spar upper cap

vertical leg and horizontal flange on the inboard and outboard sides of station Xcw=58.500 bulkhead

for crack(s) and based on inspection results do as follows:

a. Condition 1 (No Crack)

Do repetitive ETHF inspection at interval specified in Paragraph 1.E., Compliance.

b. Condition 2 (Crack)

Contact Boeing for repair instructions and do the repair.

Group 1-2, Configuration 2:

1. Do an Eddy Current, High Frequency (ETHF) inspection of the left and right rear spar upper cap

horizontal flange on the inboard and outboard sides of station Xcw=58.500 bulkhead for crack(s)

and based on inspection results do as follows:

a. Condition 1 (No Crack)

Do repetitive ETHF inspection at interval specified in Paragraph 1.E., Compliance.

b. Condition 2 (Crack)

Contact Boeing for repair instructions and do the repair.

Revision 1 - More work is necessary on DC-9 airplanes changed as shown in the original issue of this

service bulletin. Inspection of the horizontal flange of the center wing rear spar upper cap at station

Xcw=58.500 to be accomplished at next repeat interval inspection.

The work in this service bulletin is done in the maintenance zone(s) given below.

Group 1:

Affected Maintenance Zones

Model Zone

DC-9-14, DC-9-15, DC-9-15F 13, 14, 21, 22, 23

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BOEING SERVICE BULLETIN DC9-57-223
Group 2:

Affected Maintenance Zones

Model Zone

DC-9-21, DC-9-31, DC-9-32, 13, 14, 21, 22, 23

DC-9-32(VC-9C), DC-9-32F,

DC-9-32F(C-9A), DC-9-32F(C9B), DC-9-33F, DC-9-34, DC-9-

34F, DC-9-41, DC-9-51

E. Compliance

Federal Aviation Administration (FAA) Airworthiness Directive 2004-23-11 is related to this service

bulletin.

Group 1-2, Configuration 1:

Table 1: Inspection for Crack(s) on the Left and Right Rear Spar Upper Cap Vertical Leg and Horizontal

Flange

Repeat Interval

(Not to Exceed)

Condition Action Compliance Time (Whichever Occurs First)

Within 5 years after accomplishing ETHF inspection in accordance

with the original issue

of this service bulletin.

Before the accumulation of 15,000 flight cycles after accomplishing ETHF inspection in

accordance with the

original issue of this

service bulletin.

Do Eddy Current, High

Frequency (ETHF) inspection of the left and

right rear spar upper

cap horizontal flange on

the inboard and outboard sides of station

Xcw=58.500 bulkhead

for crack(s) in accordance with Accomplishment Instructions 3.B.

All Airplanes

AND

Do an ETHF inspection

of the left and right rear

spar upper cap vertical

leg on the inboard and

outboard sides of station Xcw=58.500 bulkhead for crack(s) in accordance with Accomplishment Instructions

3.B.

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BOEING SERVICE BULLETIN DC9-57-223
Group 1-2, Configuration 1:

Table 1: Inspection for Crack(s) on the Left and Right Rear Spar Upper Cap Vertical Leg and Horizontal

Flange

Repeat Interval

(Not to Exceed)

Condition Action Compliance Time (Whichever Occurs First)

15,000 flight cycles

or 5 years,

whichever occurs

first.

Do repeat ETHF inspection of the left and right

rear spar upper cap

vertical leg and horizontal flange on the inboard and outboard

sides of station

Xcw=58.500 bulkhead

for crack(s) in accordance with Accomplishment Instructions 3.B.

Condition 1

No crack

Contact Boeing for re- Before further flight.

pair instructions and do

the repair.

Condition 2

Crack

Group 1-2, Configuration 2:

Table 2: Inspection for Crack(s) on the Left and Right Rear Spar Upper Cap Horizontal Flange

Repeat Interval

(Not to Exceed)

Compliance Time (Whichever Occurs

First)

Condition Action

Within 5 years after

accomplishing

ETHF inspection in

accordance with

the original issue of

this service bulletin.

Before the accumulation of 15,000

flight cycles after

accomplishing

ETHF inspection in

accordance with

the original issue of

this service bulletin.

Do Eddy Current, High Frequency (ETHF) inspection

of horizontal flange in accordance with Accomplishment

Instructions 3.B.

All Airplanes

15,000 flight cycles

or 5 years,

whichever occurs

first.

Do repeat ETHF inspection

of horizontal flange in accordance with Accomplishment

Instructions 3.B.

Condition 1

No crack

Contact Boeing for repair Before further flight.

instructions and do the repair.

Condition 2

Crack

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BOEING SERVICE BULLETIN DC9-57-223
Group 1-2, Configuration 3:

Table 6: Inspection for Crack(s) on the Left and Right Rear Spar Upper Cap Vertical Leg and Horizontal

Flange

Repeat Interval

(Not to Exceed)

Compliance Time (Whichever Occurs

First)

Condition Action

Within 15,000 flight

cycles

Before the accumulation of 25,000 total flight cycles.Do Eddy Current, High Frequency (ETHF) inspection

of the left and right rear

spar upper cap vertical leg

and horizontal flange on the

inboard and outboard sides

of station Xcw=58.500

bulkhead for crack(s) in accordance with Accomplishment Instructions 3.B.

All Airplanes

OR

5 years after the effective date of AD

2004-23-11.

15,000 flight cycles

or 5 years,

whichever occurs

first.

Do repeat ETHF inspection

of the left and right rear

spar upper cap vertical leg

and horizontal flange on the

inboard and outboard sides

of station Xcw=58.500

bulkhead for crack(s) in accordance with Accomplishment Instructions 3.B.

Condition 1

No crack

Contact Boeing for repair Before further flight.

instructions and do the repair.

Condition 2

Crack

F. Approval

The resultant modification described in Paragraph 1.D has been shown to comply with the applicable

Federal Aviation Regulations, and Revision 1 is approved by the Manager, Los Angeles Aircraft

Certification Office, FAA Northwest Mountain Region, and is approved as an alternative method of

compliance with Paragraphs (c), (f), and (i) of Airworthiness Directive No. 2004-23-11.

G. Manpower

The table below shows an estimate of the task hours necessary to do this inspection for each airplane.

This estimate is for direct labor only, done by an experienced crew. Adjust the estimate with operator

task hour data if necessary. The estimate does not include lost time. These are some examples of lost

time:

— Time to adjust to the workplace

— Time to schedule the work

— Time to examine the work

— Time to cure the materials

— Time to make the parts

— Time to find the tools.

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BOEING SERVICE BULLETIN DC9-57-223
Elapsed

Hours

Number of Task Hours

Persons

Task

Defuel 2 4.0 2.0

Purge 2 8.0 4.0

Open Access 2 1.0 0.5

Inspect 2 3.0 1.5

Close Access 2 1.0 0.5

TOTAL FOR EACH AIRPLANE 17.0 8.5

NOTE: If repair required, actual task hours and elapsed hours are contingent upon

inspection findings and Boeing disposition and are to be estimated by the operator.

H. Weight and Balance Changes

Weight and balance changes affected by incorporation of this service bulletin are contingent upon the

changes to each particular airplane. Weight data is to be computed by the operator by weighing parts

removed and parts installed during this change. Necessary revisions should be made to the appropriate

airplane weight and balance report.

I. Electrical Load Data

Not changed.

J. References

1. Existing Data:

a. Non-Destructive Test Standard Practices Manual (NDTSPM) 01-00-03, 06-00-03, 06-00-04,

06-10-01.001 and 06-20-01.

b. Standard Wiring Practices Manual (SWPM) 20-10-01.

c. DC9 Aircraft Maintenance Manual (AMM) 06-11-01, 06-11-02, 28-00-00 and 28-10-01.

d. Federal Aviation Administration (FAA) Airworthiness Directive 2004-23-11 is related to this

service bulletin.

2. Data supplied with this Service Bulletin:

None.

3. Installation Drawings Used in the Preparation of this Service Bulletin:

Document Number Title Sheet DCN/REV ADCN

5911304 Spar Cap-Rear Upper Center Wing DWG T -

9910010 Spar Instl-Rear, Wing DWG HW HZ

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BOEING SERVICE BULLETIN DC9-57-223
These drawings were used to prepare this service bulletin. These drawings are not necessary to

make the specified changes, and are not supplied with this service bulletin. These drawings may

not be applicable to all airplane configurations or operators.

K. Publications Affected

None.

L. Interchangeability and Intermixability of Parts

Accomplishment of this service bulletin does not affect interchangeability or intermixability of parts.

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BOEING SERVICE BULLETIN DC9-57-223
2. MATERIAL INFORMATION

A. Material - Price and Availability

None.

B. Industry Support Information

Boeing warranty remedies are not available for the inspection given in this service bulletin.

C. Parts Necessary For Each Airplane

1. Kits/Parts:

None.

2. Parts and Materials Supplied by the Operator:

None.

3. Parts Modified and Reidentified:

None.

4. Parts Removed and Not Replaced:

None.

D. Parts Necessary to Change Spares

None.

E. Special Tooling - Price and Availability

The operator can supply the tools shown in Paragraph 2.F., Special Tooling Necessary to do this

Service Bulletin. Tool price and supply data are not given.

F. Special Tooling Necessary to do this Service Bulletin

To get the tools shown below, refer to Paragraph 2.E., Special Tooling - Price and Availability.

Maintenance and overhaul tools in the manuals shown in Paragraph 1.J., References, can also be

necessary. Examine operator tool supply to make sure all necessary tools are available.

NOTE: Designate instrument model used when ordering probe.

Equipment /material substitutions producing results equivalent to those defined may also be

used. Refer to Part 01, NDTSPM 01-00-03 and Part 06, NDTSPM 06-00-03 for

equipment/material information.

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BOEING SERVICE BULLETIN DC9-57-223
Tool Number Name Notes

DAC GSET AL.01 Eddy Current Reference Standard May be fabricated by the operator.

Refer to Part 06, NDTSPM 06-00-04.

NDT24 Eddy Current Flaw Detector (a)

or

Equivalent

MP901-50B Eddy Current, High Frequency Probe (b)

or operating at 50-500 kHz

Equivalent

(a) Can be purchased from: Staveley Instruments CAGE

1329 East Kemper Road 0M421

Cincinnati, Ohio 45246

(b) Can be purchased from: NDT Engineering Corporation 61100

19620 Russell Road

Kent, Washington 98032

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BOEING SERVICE BULLETIN DC9-57-223
3. ACCOMPLISHMENT INSTRUCTIONS

A. GENERAL INFORMATION

WARNING: IF ELECTRICAL POWER IS APPLIED TO THE AIRPLANE, MAKE SURE YOU OBEY

ALL PRECAUTIONS WHILE YOU DO WORK. IF YOU DO NOT OBEY THE

PRECAUTIONS, DEATH OR INJURY TO PERSONS, AND DAMAGE TO THE AIRPLANE

CAN OCCUR.

CAUTION: ELECTRICALLY GROUND THE AIRPLANE. THIS WILL HELP TO PREVENT DAMAGE

TO THE AIRPLANE OR EQUIPMENT.

CAUTION: KEEP THE WORK AREA, WIRES AND ELECTRICAL BUNDLES CLEAN OF METAL

PARTICLES OR CONTAMINATION WHEN YOU USE TOOLS. UNWANTED MATERIAL,

METAL PARTICLES OR CONTAMINATION CAUGHT IN WIRE BUNDLES CAN CAUSE

DAMAGE TO THE BUNDLES. DAMAGED WIRE BUNDLES CAN CAUSE SPARKS OR

OTHER ELECTRICAL DAMAGE.

NOTE: 1. The instructions identified in Paragraph 3.B., Work Instructions and the Figure(s)

give the recommended sequence of steps. The sequence of steps to do this service

bulletin can be changed.

2. Manual titles are referred to by acronyms. Refer to Paragraph 1.J., References, for

definition of the acronyms.

3. Unless shown differently, these dimensions and tolerances are used:

– Linear dimensions are in inches

– Tolerance on linear dimensions, other than rivet and bolt edge margins, is plus

or minus 0.03 inch.

– Tolerance on rivet and bolt edge margin is plus or minus 0.06 inch

– Angular tolerance is plus or minus 30 minutes

– Hole dimensions for standard solid rivets are given in DC-9 SRM, Chapter 51

– Torque limits to tighten nuts and bolts are given in DC-9 SRM, Chapter 51.

4. Obey all of the warnings and cautions given in the specified manual sections.

5. A Detailed Inspection is defined as: An intensive examination of a specific item,

installation, or assembly to detect damage, failure, or irregularity. Available lighting

is normally supplemented with a direct source of good lighting at an intensity deemed

appropriate. Inspection aids such as mirrors, magnifying lenses, etc. may be

necessary. Surface cleaning and elaborate procedures may be required.

6. These work instructions refer to procedures included in other Boeing documents.

When the words "refer to" are used and the operator has an accepted alternative

procedure, the accepted alternative procedure can be used. When the words "in

accordance with" are included in the instruction, the procedure in the Boeing document

must be used.

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BOEING SERVICE BULLETIN DC9-57-223
B. WORK INSTRUCTIONS

Group 1, Configuration 1, 3; Group 2, Configuration 1, 3:

Airplanes that have Accomplished the Initial Release of this Service Bulletin and no Crack(s)

Found or Airplanes that have not Accomplished the Initial Release of this Service Bulletin

1. Fabricate DAC GSET AL.01 reference standard. Refer to Part 06, NDTSPM 06-20-01.

2. Defuel and purge left, right, and center main fuel tanks. Refer to DC9 AMM 28-00-00 and DC9

AMM 28-10-01 as an accepted procedure.

3. Remove and keep the doors and attaching parts as follows:

Group 1, Configuration 1, 3:

Door Location Notes

Number

1307 Left Wing Main Tank Refer to DC9 AMM 06-11-01 for door locations.

1410 Right Wing Main Tank

2301 Center Wing Tank (left side) Refer to DC9 AMM 06-11-02 for door locations.

2302 Center Wing Tank (right side)

Group 2, Configuration 1, 3:

Door Location Notes

Number

1307A Left Wing Main Tank Refer to DC9 AMM 06-11-01 for door locations.

1410A Right Wing Main Tank

2301A Center Wing Tank (left side) Refer to DC9 AMM 06-11-02 for door locations.

2302A Center Wing Tank (right side)

4. Do Eddy Current, High Frequency (ETHF) inspection of the left and right rear spar upper cap

vertical leg and horizontal flange on the inboard and outboard sides of station Xcw=58.500 bulkhead

for crack(s) in accordance with Figure 1 using the procedures that follow:

Procedure 1

a. Use calibration scan method "M" and calibrate on the N8 notch using DAC GSET AL.01 in

accordance with NDTSPM 06-10-01.001, Procedure 1.

b. Scan center wing rear spar upper cap vertical leg with Method 66 in accordance with Figure

1.

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BOEING SERVICE BULLETIN DC9-57-223
Procedure 2

a. Use scan method "C" or "G" and calibrate on the N2 or N8 notch using DAC GSET AL.01 in

accordance with NDTSPM 06-10-01.001, Procedure 1.

b. Scan center wing rear spar upper cap vertical leg with Methods 62 and 69, as applicable in

accordance with Figure 1.

Procedure 3

a. Use scan method "K" and calibrate on the N3 notch using DAC GSET AL.01 in accordance

with NDTSPM 06-10-01.001, Procedure 1.

b. Scan center wing rear spar upper cap horizontal flange with Method 44 in accordance with

Figure 2.

5. Based on ETHF test results do as follows:

Condition 1 (No Crack)

a. Do repeat inspection of the rear spar upper cap vertical leg and horizontal flange for crack(s).

Condition 2 (Crack)

a. Contact Boeing for repair instructions and do the repair.

Direct inquires to:

Email dse.boecom@boeing.com

ATA CODE: 5710

OR

Long Beach Service Engineering

FAX: (206) 766-5683

ATA CODE: 5710

OR

Boeing Company

P.O. Box 1771

Long Beach, California 90801-9939

Attn: Senior Manager:

Technical Customer Support - Airframe Engineering

ATA CODE: 5710

Service Engineering D800-0032

(Service Bulletin DC9-57-223)

6. Reinstall all removed items using kept attaching parts.

7. Put the airplane back to a serviceable condition.

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BOEING SERVICE BULLETIN DC9-57-223
Group 1-2, Configuration 2:

Airplanes that have Accomplished the Initial Release of this Service Bulletin and did Crack

Repair.

1. Fabricate DAC GSET AL.01 reference standard. Refer to Part 06, NDTSPM 06-20-01.

2. Defuel and purge left, right, and center main fuel tanks. Refer to DC9 AMM 28-00-00 and DC9

AMM 28-10-01 as an accepted procedure.

3. Remove and keep the doors and attaching parts as follows:

Group 1, Configuration 2:

Door Location Notes

Number

1307 Left Wing Main Tank Refer to DC9 AMM 06-11-01 for door locations.

1410 Right Wing Main Tank

2301 Center Wing Tank (left side) Refer to DC9 AMM 06-11-02 for door locations.

2302 Center Wing Tank (right side)

Group 2, Configuration 2:

Door Location Notes

Number

1307A Left Wing Main Tank Refer to DC9 AMM 06-11-01 for door locations.

1410A Right Wing Main Tank

2301A Center Wing Tank (left side) Refer to DC9 AMM 06-11-02 for door locations.

2302A Center Wing Tank (right side)

4. Do Eddy Current, High Frequency inspection (ETHF) of the horizontal flange on the inboard and

outboard sides of station Xcw=58.500 bulkhead for crack(s) using the procedures that follow:

a. Use scan method "K" and calibrate on the N3 notch using DAC GSET AL.01 in accordance

with NDTSPM 06-10-01.001, Procedure 1.

b. Scan center wing rear spar upper cap horizontal flange with Method 44 in accordance with

Figure 2.

5. Based on ETHF test do as follows:

Condition 1 (No Crack)

a. Do repeat inspection of the horizontal flange on the inboard and outboard sides of station

Xcw=58.500 bulkhead.

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BOEING SERVICE BULLETIN DC9-57-223
Condition 2 (Crack)

a. Contact Boeing for repair instructions and do the repair.

Direct inquires to:

Email dse.boecom@boeing.com

ATA CODE: 5710

OR

Long Beach Service Engineering

FAX: (206) 766-5683

ATA CODE: 5710

OR

Boeing Company

P.O. Box 1771

Long Beach, California 90801-9939

Attn: Senior Manager:

Technical Customer Support - Airframe Engineering

ATA CODE: 5710

Service Engineering D800-0032

(Service Bulletin DC9-57-223)

6. Reinstall all removed items using kept attaching parts.

7. Put the airplane back to a serviceable condition.

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BOEING SERVICE BULLETIN DC9-57-223
FIGURE 1: LEFT AND RIGHT WING CENTER REAR SPAR CAP - VERTICAL LEG INSPECTION

(SHEET 1 OF 6)

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BOEING SERVICE BULLETIN DC9-57-223
FIGURE 1: LEFT AND RIGHT WING CENTER REAR SPAR CAP - VERTICAL LEG INSPECTION

(SHEET 2 OF 6)

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BOEING SERVICE BULLETIN DC9-57-223
FIGURE 1: LEFT AND RIGHT WING CENTER REAR SPAR CAP - VERTICAL LEG INSPECTION

(SHEET 3 OF 6)

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BOEING SERVICE BULLETIN DC9-57-223
FIGURE 1: LEFT AND RIGHT WING CENTER REAR SPAR CAP - VERTICAL LEG INSPECTION

(SHEET 4 OF 6)

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FIGURE 1: LEFT AND RIGHT WING CENTER REAR SPAR CAP - VERTICAL LEG INSPECTION

(SHEET 5 OF 6)

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FIGURE 1: LEFT AND RIGHT WING CENTER REAR SPAR CAP - VERTICAL LEG INSPECTION

(SHEET 6 OF 6)

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FIGURE 2: LEFT AND RIGHT WING CENTER REAR SPAR CAP - UPPER FLANGE INSPECTION

(SHEET 1 OF 4)

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FIGURE 2: LEFT AND RIGHT WING CENTER REAR SPAR CAP - UPPER FLANGE INSPECTION

(SHEET 2 OF 4)

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BOEING SERVICE BULLETIN DC9-57-223
FIGURE 2: LEFT AND RIGHT WING CENTER REAR SPAR CAP - UPPER FLANGE INSPECTION

(SHEET 3 OF 4)

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BOEING SERVICE BULLETIN DC9-57-223
FIGURE 2: LEFT AND RIGHT WING CENTER REAR SPAR CAP - UPPER FLANGE INSPECTION

(SHEET 4 OF 4)

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BOEING SERVICE BULLETIN DC9-57-223