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REPORT NO. MDC-94K9000

MD-90 

AIRWORTHINESS LIMITATIONS 

INSTRUCTIONS (ALI) 

REVISION 6

September 2011 
Report No. MDC-94K9000

 INITIAL RELEASE 

 November 1994 

 REVISION 6 

 September 2011 

 

MD-90 

AIRWORTHINESS LIMITATIONS 

INSTRUCTIONS (ALI) 

 Vinh Bui 

Principal Specialist 

Structural Mechanics 

Design and Technology 

 J. Tom 

Principal Specialist 

Structural Mechanics 

Design and Technology 

The Airworthiness Limitations Instructions (ALI) is Federal Aviation Authority (FAA) 

approved and specifies maintenance required under Sections 43.16 and 91.403 of 

the Federal Aviation Regulations unless an alternative program has been FAA 

approved. The release of this ALI was approved by the Manager, Los Angeles 

Aircraft Certification Office, Transport Airplane Directorate, on June 8, 2012. 

MCDONNELL DOUGLAS CORPORATION PROPTIETARY RIGHTS ARE INCLUDED IN THE INFORMATION DISCLOSED HEREIN. RECIPENT BY ACCEPTING 

THIS DOCUMENT AGREES THAT NEITHER THIS DOCUMENT NOR THE INFORMATION DISCLOSED HEREIN NOR ANY PART THEREOF SHALL BE 

REPRODUCED OR TRANSFERRED TO OTHER DOCUMENTS OR USED OR DISCLOSED TO OTHERS FOR MANUFACTURING OR FOR ANY OTHER 

PURPOSE EXCEPT AS SPECIFICALLY AUTHOIRIZED IN WRITING BY MCDONNELL DOUGLAS CORPORATION. UNPUBLISHED – ALL RIGHTS RESERVED 

UNDER COPYRIGHT LAWS. 


 MDC-94K9000 

MD-90 

AIRWORTHINESS LIMITATIONS INSTRUCTIONS (ALI) 

RECORD OF REVISION

REV. NO ISSUE DATE DATE 

INSERTED 

BY REV. NO ISSUE DATE DATE 

INSERTED 

BY 

ORIG NOV. 94 NOV. 94 DAC 

1 JAN. 95 JAN. 95 DAC 

2 JUL. 96 JUL. 96 DAC 

3 NOV. 97 NOV. 97 BCAG 

4 OCT. 01 OCT. 01 BCAG 

5 SEPT 02 SEPT 02 BCAG 

6 SEPT 11 

 

RETAIN THIS RECORD IN THE FRONT OF THIS REPORT. UPON RECEIPT OF REVISIONS, 

INSERT REVISED PAGES IN THE DOCUMENT AND ENTER REVISION NUMBER, DATE 

INSERTED AND INITIAL. 

McDonnell Douglas Corporation Proprietary Information. Use or disclosure of 

THESE DATA SUBJECT TO RESTRICTIVE LEGEND ON TITLE PAGE OR FIRST PAGE.

September 2011 
 MD-90 MDC-94K9000 

AIRWORTHINESS LIMITATIONS INSTRUCTIONS (ALI) 

LIST OF EFFECTIVE PAGES

LIST OF EFFECTIVE PAGES

PAGE I

September 2011

SECTION PAGE ISSUE DATE

Title 6 SEPT 11 

 

Record of Revisions 6 SEPT 11 

List of Effective 

Pages 

I 6 SEPT 11 

II 6 SEPT 11 

 III 6 SEPT 11 

 

Revision Summary R-1 6 SEPT 11 

 R-2 6 SEPT 11 

 

Preface P-1 4 OCT 01 

SECTION 1 

Table of Contents TC-1 3 NOV 97 

Safe-Life Limits A1-1 3 NOV 97 

 A1-2 3 NOV 97 

 A1-3 3 NOV 97 

 A1-4 3 NOV 97 

 A1-5 3 NOV 97 

 A1-6 3 NOV 97 

 A1-7 3 NOV 97 

 A1-8 3 NOV 97 

 A1-9 3 NOV 97 

 

List of PSE’s B1-1 4 OCT 01 

 B1-2 4 OCT 01 

 B1-3 6 SEPT 11 

 

PSE Inspection 

Requirements 

B2-1 6 SEPT 11 

B2-2 4 OCT 01 

 B2-3 0 NOV 94 

 B2-4 0 NOV 94 

B2-5 0 NOV 94 

B2-6 4 OCT 01 

B2-7 0 NOV 94 

B2-8 0 NOV 94 

 B2-9 0 NOV 94 

 B2-10 0 NOV 94 

 B2-11 0 NOV 94 

 B2-12 0 NOV 94 

 B2-13 0 NOV 94 

 B2-14 4 OCT 01 

 B2-15 0 NOV 94 

SECTION PAGE ISSUE DATE

PSE Inspection B2-16 0 NOV 94 

Requirements B2-17 0 NOV 94 

 B2-18 0 NOV 94 

 B2-19 0 NOV 94 

 B2-20 0 NOV 94 

 B2-21 0 NOV 94 

 B2-22 0 NOV 94 

 B2-23 0 NOV 94 

 B2-24 0 NOV 94 

 B2-25 0 NOV 94 

 B2-26 0 NOV 94 

 B2-27 0 NOV 94 

 B2-28 0 NOV 94 

 B2-29 0 NOV 94 

 B2-30 0 NOV 94 

 B2-31 0 NOV 94 

 B2-32 4 OCT 01 

 B2-33 4 OCT 01 

 B2-34 4 OCT 01 

 B2-35 1 JAN 95 

 B2-36 1 JAN 95 

 B2-37 1 JAN 95 

 B2-38 4 OCT 01 

 B2-39 1 JAN 95 

 B2-40 1 JAN 95 

 B2-41 1 JAN 95 

 B2-42 1 JAN 95 

 B2-43 1 JAN 95 

 B2-44 6 SEPT 11 

 B2-45 1 JAN 95 

 B2-46 1 JAN 95 

 B2-47 1 JAN 95 

 B2-48 4 OCT 01 

B2-49 4 OCT 01 

B2-50 6 SEPT 11 

B2-51 6 SEPT 11 

B2-52 6 SEPT 11 

B2-53 6 SEPT 11 

B2-54 6 SEPT 11 

 B2-55 6 SEPT 11 

 B2-56 6 SEPT 11 

 B2-57 6 SEPT 11 

 B2-58 6 SEPT 11 

 B2-59 6 SEPT 11 

 B2-60 6 SEPT 11 

 B2-61 6 SEPT 11 
 MD-90 MDC-94K9000 

AIRWORTHINESS LIMITATIONS INSTRUCTIONS (ALI) 

LIST OF EFFECTIVE PAGES

LIST OF EFFECTIVE PAGES 

PAGE II 

September 2011 

SECTION PAGE ISSUE DATE

B2-62 6 SEPT 11

B2-63 6 SEPT 11

PSE Inspection 

Requirements 

(Continued) B2-64 6 SEPT 11

 B2-65 6 SEPT 11 

 B2-66 6 SEPT 11 

 B2-67 6 SEPT 11 

 B2-68 6 SEPT 11 

 B2-69 6 SEPT 11 

 B2-70 6 SEPT 11 

 B2-71 6 SEPT 11 

 B2-72 6 SEPT 11 

 B2-73 6 SEPT 11 

 B2-74 6 SEPT 11 

 B2-75 6 SEPT 11 

 B2-76 6 SEPT 11 

 B2-77 6 SEPT 11 

 B2-78 6 SEPT 11 

 B2-79 6 SEPT 11 

 B2-80 6 SEPT 11 

 B2-81 6 SEPT 11 

 B2-82 6 SEPT 11 

 B2-83 6 SEPT 11 

 B2-84 6 SEPT 11 

 B2-85 6 SEPT 11 

 B2-86 6 SEPT 11 

 B2-87 6 SEPT 11 

 

Reporting of C1-1 4 OCT 01

Inspection Results C1-2 0 NOV 94

 

SECTION 2 

Introduction P2-1 0 NOV 94 

Table of Contents TC-2 6 SEPT 11 

 TC-3 6 SEPT 11 

 

References RF-1 4 OCT 01 

20-00-00 1 4 OCT 01 

NDI Techniques and Procedures 

53.12.09.1 1 6 SEPT 11 

 2 6 SEPT 11 

 3 6 SEPT 11 

SECTION PAGE ISSUE DATE

53.12.09.1 4 6 SEPT 11 

(Continued) 5 6 SEPT 11 

 6 6 SEPT 11 

 7 6 SEPT 11 

 8 6 SEPT 11 

 9 6 SEPT 11 

 10 6 SEPT 11 

 11 6 SEPT 11 

 

54.10.04.1 1 4 OCT 01 

 2 6 SEPT 11 

 3 4 OCT 01 

4 6 SEPT 11

5 4 OCT 01

6 4 OCT 01 

7 4 OCT 01 

8 4 OCT 01 

9 4 OCT 01 

10 4 OCT 01 

11 4 OCT 01 

 

54.40.01.2 1 4 OCT 01 

 2 4 OCT 01 

 

54.40.03.1 1 6 SEPT 11 

 2 4 OCT 01 

 

54.40.03.2 1 4 OCT 01 

 2 4 OCT 01 

 

54.40.04.1 1 5 SEP 02 

 2 4 OCT 01 

 

55.11.01.1 1 6 SEPT 11 

 2 6 SEPT 11 

 3 6 SEPT 11 

 4 6 SEPT 11 

 5 6 SEPT 11 

 6 6 SEPT 11 

 7 6 SEPT 11 

 8 6 SEPT 11 

 
 MD-90 MDC-94K9000 

AIRWORTHINESS LIMITATIONS INSTRUCTIONS (ALI) 

LIST OF EFFECTIVE PAGES

LIST OF EFFECTIVE PAGES

PAGE III

September 2011

SECTION PAGE ISSUE DATE

SECTION 2 SUPPLEMENT

 

Table of Contents TC-4 6 SEPT 11 

 

Equipment 

Utilization 2-0

1 6 SEPT 11 

 

Reference 

Standards 2-1

1 

2 

3 

6 

6 

6 

SEPT 

SEPT 

SEPT 

11

11 

11 

 

 

High Frequency 

Eddy Current 

Probes 2-2

1 6 SEPT 11 

 

 

Low Frequency 

Eddy Current 

Probes 2-3

1 6 SEPT 11 

 

Inspection 

Fixtures 2-4

1 6 SEPT 11 

 

Ultrasonic 

Transducers 2-5

1 6 SEPT 11 
MDC-94K9000 

MD-90 

AIRWORTHINESS LIMITATIONS INSTRUCTIONS (ALI) 

REVISION NO. 6 SUMMARY 

McDonnell Douglas Corporation Proprietary Information. Use of disclosure of R1 Revision Date: September 2011

THESE DATA SUBJECT TO RESTRICTIVE LEGEND ON TITLE PAGE OR FIRST PAGE

PAGE NO. CHANGE 

Section 1 

PSE Inspection 

Requirements 

B1-3 New PSE title added 

B2-1 Typographical correction 

B2-44 Replaced “MTF” with “PTF” 

B2-50-51 Added new PSE description and illustration 

B2-59 Revised art 

B2-52-87 Repaginate due to new PSE 

Section 2 

NDI Techniques 

and Procedures 

Table of Contents 

TC-2 

TC-3 

Added PSE numbers and titles for the added procedures 

New table of contents for Section 2 Supplement 

 

53.12.09.1 

Pages 1-11 

Added new procedure 

54.10.04.1 

Pages. 2, 4 

Corrected Header information. 

54.40.03.1 

Page. 1 

Number changes on Goodrich documents. 

55.11.01.1 

Pages. 1-8 

Added new procedure. 

 
MDC-94K9000 

MD-90 

AIRWORTHINESS LIMITATIONS INSTRUCTIONS (ALI) 

REVISION NO. 6 SUMMARY 

McDonnell Douglas Corporation Proprietary Information. Use of disclosure of R-2 Revision Date: September 2011

THESE DATA SUBJECT TO RESTRICTIVE LEGEND ON TITLE PAGE OR FIRST PAGE

PAGE NO. CHANGE

 

Section 2 

Supplement 

Added 

Page TC-4 Added equipment for new procedures 

Section 2-0 

Equipment Utilization 

Page 1 Added for new procedures 

Section 2-1 

Reference Standards 

Fig. 1.1 

Pages. 1-3 

Added reference standard 

Section 2-2 

High Frequency Eddy Current Probes 

Page 1 Added for new procedures 

Section 2-3

Low Frequency Eddy Current Probes 

Fig. 3.1 Added probe 

Page. 1 

Section 2-4

Inspection Fixtures 

Page 1 Added for new procedures 

Section 2-5

Ultrasonic Transducers 

Page 1 Added for new procedures
MD-90 MDC-94Kg000

AIRWORTHINESS LIMITATIONS INSTRUCTIONS (ALl)

PREFACE

This ALl document contains information that defines mandatory replacement imes for SafeLife Structure, the inspection requirements for Principal Structural Elements (PSE) and also

provides specific Non-Destructive Inspection (NDI) techniques and procedures for each PSE.

NDI is a technology that is used to detect defects in materials utilizing techniques that do not

damage or destroy the items being tested.

A Safe-Life Structure is defined as structure that has been shown to withstand repeated loads

of variable magnitude expected during its service life without detectable cracks.

Principal Structural Elements (PSE’s) are those elements of structure which contribute

significantly to carrying flight, ground, and pressurization loads, and whose failure could result

in catastrophic failure of the airplane.

Continued Airworthiness requires the continued update of the inspection procedures as

experience, data, and technology are increased. The ALl document is, therefore, prepared in

an incremental fashion. The procedures must be sufficiently defined to provide instructions

necessary to cover high time/cycle "fleet leader" aircraft, and are considered complete at the

time of issue, and until subsequent additions are issued.

The content of the ALl document is divided into two Sections: Section 1 and Section 2, each

with its own Table of Contents.

Section 1 Lists Safe-Life parts and mandatory replacement times as well as

Principal Structural Element Inspection requirements. The Illustrations in this section

are to be used for basic identification of the PSE only.

Section 2 - Provides tbe~etailed NDI techniques, tests, procedures and !nspection

areas for each specific PSE inspection requirements.

NOTE: Detailed NDI instructions and procedures for the specific PSE’s are to be

incorporated in this report and distributed to the operators a minimum ofone (1) year prior 

a PSE inspection coming due on the high time/cycle aircraft in the fleet.

The results of the analysis for Environmental Deterioration (ED) (i.e. corrosion) 

Accidental Damage (AD) required by type design (25.571 - Damage Tolerance and Fatigue

Evaluation and 25.1529, Appendix H - Instructions for Continued Airworthiness) are located

in the FAA Maintenance Review Board (MRB) Report, and identified as ED & AD tasks.

P-1

McDonnell Douglas Corporation Proprietary Information. Use or disclosure of

THESE DATA SUBJECT TO RESTRICTIVE LEGEND ON TITLE PAGE OR FIRST PAGE.

Revision Date: OCT 2001
MD-90 MDC-94K9000

AIRWORTHINESS LIMITATIONS INSTRUCTIONS (ALl)

SECTION 1

TABLE OF CONTENTS

SAFE-LIFE LIMITS ................................................................................................... A1-1

MD-90-30 (156,000 IbMTOGW) .......................................................................... A1-2

MD-90-30 EXR (168,000 Ib MTOGW), ER (166,000 Ib MTOGW

and HGW (160,000 IbMTOGW) ...................................................................... A1-6

INTRODUCTION TO PSE INSPECTION REQUIREMENTS ....................................... B1-1

PSE INSPECTION REQUIREMENTS ......................................................................... B2-1

REPORTING OF INSPECTION RESULTS ................................................................. C1-1

McDonnell Dou~ltlm Corporllttofl Proprietary Iflforn~ltion. Use or dilclolure or

THESE DATA SUBJECT TO RESTRICTIVE LEGEND ON TITLE PAGE OR FIRST PAGE. TC-1 Revision Date: November 1997
MD-90

SAFE-LIFE LIMITS

NOSE LANDING GEAR

COMPONENTS

MAIN LANDING GEAR

COMPONENTS
MD-90

AIRWORTHINESS LIMITATIONS INSTRUCTIONS (ALl) MDC-94K9000

SAFE-LIFE LIMITS

This section contains the list of landing gear parts that have been categorized as

safe-life. Parts which have limited life are shown with their respective life-limits

specified in landings (cycles). Those parts which were considered safe-life, but have

unlimited life are listed also. Unlimited life is equivalent to at least 300,000 landings

(cycles), or 100 years of service.

NOTE

1. Parts which are used by the airlines only on the MD-90-30 airplane will have

safe-life limits established for the MD-90 airplane.

.

A safe-life part which is being used interchangeably between two or more models

of the DC-9, MD-80, MD-90 or MD-95 series has the lowest safe-life shown for any

of the models on which it has been used, regardless of the time it has been used

on each model.

.

Any part listed in this report that is reworked beyond component maintenance

manual limits or is modified due to discrepancies, must have its safe-life reestablished according to the loads and methods contained in report MDC-K5717

(MD-90-30 Landing Gear Safe-Life Limits).

It is the responsibility of the airlines to keep proper records to ensure compliance

with the above.

McDonnell Dougl~l Corporation Proprietary Information. Use or dilclosure of

THESE DATA SUBJECT TO RESTRICTIVE LEGEND ON TITLE PAGE OR FIRST PAGE. A 1-1 Revision Date: November 1997
MD-90

AIRWORTHINESS LIMITATIONS INSTRUCTIONS (ALl) MDC-94K9000

SAFE-LIFE LIMITS

MD-90-30 (156,000 Ib MTOGW)

Main Landing Gear parts which are considered safe-life and have limited life are

listed below with the associated mandatory replacement times.

PART NO. ITEM

(A) 5935349-503

(B) 5937032-1

(C) 5935848-501

Link Assembly - Upper Lock

Bracket Assembly - Bungee

Fixed Side Link Assembly

MANDATORY REPLACEMENT TIME

FAA

48,000 Ldgs.

48,000 Ldgs.

199,000 Ldgs.

A c \

\

B

McDonnell Douglas Corporation Proprietary Informalion. Use or disclosure of

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MD-90

AIRWORTHINESS LIMITATIONS INSTRUCTIONS (ALl) MDC-94K9000

SAFE-LIFE LIMITS

MD-90-30 (156,000 Ib MTOGW)

Main Landing Gear parts which are considered

are listed below.

PART NO. ITEM

5935347-509,-511

5935348-503

3935358-1

5935352-1

3935368-501

5935374-1

5935353-1

5935351-501

5935346-503

5935350-501

.Piston

Cylinder

Restrictor

Restrictor Support Tube

Metering Pin Base

Upper Torque Arm

Lower Torque Arm

Lower Side Brace Link

Upper Side Brace Link

Lower Lock Link

safe-life, but have unlimited life

MANDATORY REPLACEMENT TIME

FAA

Unlimited

Unlimited

Unlimited

Unlimited

Unlimited

Unlimited

Unlimited

Unlimited

Unlimited

Unlimited

McDonnell Douglm; Corporation Proprietary Information. Use or dilclosuro of

THESE DATA SUBJECT TO RESTRICTIVE LEGEND ON TIILE PAGE OR FIRST PAGE A I-3 Revision Date: November 1997
MD-90

AIRWORTHINESS LIMITATIONS INSTRUCTIONS (ALl) MDC-94K9000

SAFE-LIFE LIMITS

MD-90-30 (156,000 Ib MTOGW)

Nose Landing Gear parts which are considered safe-life and have limited life are

listed below with associated mandatory replacement times.

PART NO. ITEM MANDATORY REPLACEMENT TIME

FAA

(A) 3914464-503, -507

(B) 3913968-513

(C) 5927079-509,-511

Link Assembly - Upper Lock

Link Assembly - Lower Lock

Housing Assembly

46,500 Ldgs.

59,333 Ldgs.

76,000 Ldgs.

A

B

/

C

M DII0-AI.-2

CAG~IGDS)

McDonnell Douglas Corporetion Proprietary Informalion. Use or disclosure of

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MD-90

AIRWORTHINESS LIMITATIONS INSTRUCTIONS (ALl) MDC-94Kg000

SAFE-LIFE LIMITS

MD-90-30 (156,000 Ib MTOGW)

Nose Landing Gear parts which are considered safe-life but have unlimited life are

listed below.

PART NO.

5920603-511

5920602-511

5920210-503

5920209-503

5920209-504

2912726-1

5958412-511

5958412-513

3963295-1

3D0026-10

5920605-503

4958424-503

3928233-501

5963256-1

ITEM

Piston

Cylinder

Lower Drag Brace

Upper Drag Brace

Upper Drag Brace

Knee Hinge Nut

Torque Arm

Torque Arm

Torque Arm Apex Bolt

Torque Arm Apex Nut

Steering Lever

Nut Restrictor Support

Head Restrictor Support

Metering Pin Base

MANDATORY REPLACEMENT TIME

FAA

Unlimited

~o

Unlimited

Unlimited

Unlimited

Unlimited

Unlimited

Unlimited

Unlimited

Unlimited

Unlimited

Unlimited

Unlimited

Unlimited

Unlimited

McDonnell Douglas Corporwtion Proprietary Information. Use or disclotlure of

THESE DATA SUBJECT TO RESTRICTIVE LEGEND ON TITLE PAGE OR FIRST PAGE. A 1-5 Revision Date: November 1997
MD-90

AIRWORTHINESS LIMITATIONS INSTRUCTIONS (ALl) MDC-94K9000

SAFE-LIFE LIMITS

MD-90-30 EXR (168,000 Ib MTOGW), ER (166,000 Ib MTOGW)

and HGW (160,000 Ib MTOGW)

Main Landing Gear parts which are considered safe-life and have limited life are

listed below with the associated mandatory replacement times.

PART NO. ITEM MANDATORY REPLACEMENT TIME

FAA

(A) 5935349-503

(B) 5937032-1

(C) 5935848-501

(D) 5935348-503

Link Assembly - Upper Lock

Bracket Assembly - Bungee

Fixed Side Link Assembly

Cylinder Assembly

48,000 Ldgs.

48,000 Ldgs.

194,000 Ldgs.

195,000 Ldgs.

\

D

C

A

\

\

MDg~AI-,1

CAEdIGOS)

McDonnell Ooughm Corporation Proprietary Information. Use or disclosure of

THESE DATA SUBJECT TO RESTRICTIVE LEGEND ON TITLE PAGE OR FIRST PAGE. A1-6

B

Revision Date: November lgg7
MD-90

AIRWORTHINESS LIMITATIONS INSTRUCTIONS (ALl) MDC-94K9000

SAFE-LIFE LIMITS

MD-90-30 EXR (168,000 Ib MTOGW), ER (166,000 Ib MTOGW)

and HGW (160,000 Ib MTOGW)

Main Landing Gear parts which

are listed below.

are considered safe-life, but have unlimited life

PART NO. ITEM

Piston

Restrictor

Restrictor Support Tube

Metering Pin Base

Upper Torque Arm

Lower Torque Arm

Lower Side Brace Link

Upper Side Brace Link

Lower Lock Link

5935347-513

3935358-1

5935352-I

3935368-501

5935374-1

5935353-I

5935351-501

5935346-503

5935350-50i

MANDATORY REPLACEMENT TIME

FAA

Unlimited

Unlimited

Unlimited

Unlimited

Unlimited

Unlimited

Unlimited

Unlimited

Unlimited

McDonnell Douglas Corporation Proprietary tnform~ion. Use or disclosure of

THESE DATA SUBJECT TO RESTRICTIVE LEGEND ON TITLE PAGE OR FIRST PAGE. A 1-7 Revision Date: November 1997
MD-90

AIRWORTHINESS LIMITATIONS INSTRUCTIONS (ALl) MDC-94K9000

SAFE-LIFE LIMITS

MD-90-30 EXR (168,000 Ib MTOGW), ER (166,000 Ib MTOWG)

and HGW (160,000 Ib MTOGW)

Nose Landing Gear parts which are considered safe-life and have limited life are

listed below with associated mandatory replacement times.

PART NO. ITEM

(A) 3914464-503, -507

(B) 3913968-513

(C) 5927079-511

Link Assembly - Upper Lock

Link Assembly - Lower Lock

Housing Assembly

I

MANDATORY REPLACEMENT TIME

FAA

46,500 Ldgs.

59,333 Ldgs.

46,000 Ldgs.

A

B

/

C

McDonnell Oougtas Corporation Proprietary Informalion, Use or disclosure or

THESE DATA SUBJECT TO RESTRICTIVE LEGEND ON TITLE PAGE OR FIRST PAGE. A 1-8 Revision Date: November 1997
MD-90

AIRWORTHINESS LIMITATIONS INSTRUCTIONS (ALl) MDC-94Kg000

SAFE-LIFE LIMITS

MD-90-30 EXR (168,000 Ib MTOGW), ER (166,000 Ib MTOGW)

and HGW (160,000 Ib MTOGW)

Nose Landing Gear parts which are considered safe-life but have unlimited life are

listed below.

PART NO.

5920603-511

5920602-511

5920210-503

5920209-503

5920209-504

2912726-1

5958412-511

5958412-513

3963295-1

3D0026-10

5920605-503

4958424-503

3928233-501

5963256-1

ITEM

Piston

Cylinder

Lower Drag Brace

Upper Drag Brace

Upper Drag Brace

Knee Hinge Nut

Torque Arm

Torque Arm

Torque Anro. Apex,Bolt

Torque Arm Apex Nut

Steering Lever

Nut Restrictor Support

Head Restrictor Support

Metering Pin Base

MANDATORY REPLACEMENT TIME

FAA

Unlimited

Unlimited

Unlimited

Unlimited

Unlimited

Unlimited

Unlimited

Unlimited

Unlimited

Unlimited

Unlimited

Unlimited

Unlimited

Unlimited

McDonnell Douglas Corporation Proprietary Information. Use or disclosure of

THESE DATA SUBJECT TO RESTRICTIVE LEGEND ON TITLE PAGE OR FIRST PAGE. A 1-9 Revision Date: November 1997
MD-90 MDC-94K9000

AIRWORTHINESS LIMITATIONS INSTRUCTIONS (ALl)

INTRODUCTION TO PSE INSPECTION REQUIREMENTS

This section contains the MD-90 Principal Structural Element (PSE) inspection requirements. Any

deviations from these requirements (other than more frequent inspections than required), or any

structural alterations/modifications to the PSE’s shall be coordinated with DAC and requires

approval from the FAA Los Angeles Aircraft Certification Office.

The MD-90 PSE’s were selected based on the following critieria:

ANALYSIS & TEST

 ̄ operating stress level

static/fatigue margins of safety

 ̄ severity of consequence of damage

 ̄ operational experience of the DC-9/MD-80

 ̄ DC-9/MD-80/MD-90 test data

OPERATIONAL SUSCEPTIBILITY TO

 ̄ fatigue

 ̄ corrosion

 ̄ accidental damage

 ̄ stress corrosion

 ̄ manufacturing defects

Normal airplane operations are assumed for damage tolerance assessment of the MD-90

structure. Typical variations of flight range and gross weight were taken into account. The

damage tolerance assessment were based on the principles of Linear Elastic Fracture Mechanics

(LEFM). The resulting inspection requirements included in this document apply to all MD-90

airplane types.

Following is the list of MD-90 PSE’s:

1. 53.12.09.1

2. 53.12.09.2

3. 53.12.15.1

4. 53.12.15.2

53.12.15.3

CHAPTER 53

Fuselage Skin and Frames from Longeron 16 to Longeron 19, at all Frames in

area above Wing and MLG

Fuselage Frame to Floor Beam Joints, at all frames above MLG Wheel Well

Bulkhead Skin & Stiffener at STA Z = 63.500, Left Side Only (Area of Firex

Wye)

Bulkhead Skin & Stiffener at STA Z = 14.000, Between Finger Doublers &

Blanket Attach Angles

Bulkhead Skin & Doublers at STA Z = -18.000

B1-1

McDonnell Douglas Corporation Proprietary Information. Use or disclosure of

THESE DATA SUBJECT TO RESTRICTIVE LEGEND ON TITLE PAGE OR FIRST PAGE.

Revision Date: OCT 2001
~6. 53.12.15.4

7. 53.30.02.1

8. 53.30.02.2

9. 53.30.02.3

10. 53.30.02.4

11. 53.30.02.5

12. 53.30.02.6

13. 53.30.02.7

1. 54.10.01.1

2. 54.10.04.1

3. 54.10.08.1

4. 54.40.01.1

5. 54.40.01.2

6. 54.40.02.1

7. 54.40.03.1

8. 54.40.03.2

~9. 54.40.04.1

MD-90 MDC-94K9000

AIRWORTHINESS LMITATIONS INSTRUCTIONS (ALl)

INTRODUCTION TO PSE INSPECTION REQUIREMENTS

Bulkhead - Fuselage Attachment Tee Radius between Longeron 6 & F.R.P.

Overwing Frame Splices above Wing & MLG Wheel Well, Longeron 8 to

Longeron 12

Skin & Frame at STA 864.000 from Longeron 16 to Longeron 21

Fuselage Skin in Constant Section from Longeron 3 Left to Longeron 3 Right

Fuselage Hoop Skin Splice in Constant Section from Longeron 5 Left to

Longeron 5 Right

Upper & Lower Window Belt Splices along entire length of Window Belt

Fuselage Skin around all Window Cutouts

Fuselage Skin Splice at Aft Pressure Bulkhead, Longeron 14 Left to Longeron

14 Right

CHAPTER 54

Pylon Front spar Upper Cap, from Fuselage Intersection to 10 inches

Inboard of Fuselage

Rear Spar and Engine Thrust support fitting (Upper & Lower)

Shear Pin Plate, Shear Pin Holes (both Upper & Lower Holes)

Engine Yoke Flanges in vicinity of Support Fitting Attach Points

Pylon, Forward Upper & Lower Isolators and Cone Bolts

Yoke Support Frame Upper Lug

Pylon, Thrust Struts

Pylon, Thrust Isolator

Pylon, Aft Isolator & Cone Bolt

B1-2

McDonnell Douglas Corporation Proprietary Information. Use or disclosure of

THESE DATA SUBJECT O RESTRICTIVE LEGEND ON TITLE PAGE OR FIRST PAGE.

Revision Date: OCT 2001
 MD-90 MDC-94K9000 

AIRWORTHINESS LIMITATIONS INSTRUCTIONS (ALI) 

INTRODUCTION TO PSE INSPECTION REQUIREMENTS

B1-3 

McDonnell Douglas Corporation Proprietary Information. Use or disclosure of Revision Date: September 2011

THESE DATA SUBJECT TO RESTRICTIVE LEGEND ON TITLE PAGE OR FIRST PAGE. 

CHAPTER 55 

1. 55.11.01.1 Rear Spar Upper Cap – between STA Xe = 5.000 and Xe = 14.000 

2. 55.11.02.1 Rear Spar Upper Cap & Skin from STA Xh 7.234 to Xh 26.859 

3. 55.11.03.1 Bushed Holes in Horizontal Stabilizer Jack Screw Attach Lug at STA Xh 6.625 

4. 55.13.01.1 Upper Aft Skin Plank with Integral Stringers from STA Xh 7.234 to Xh 26.859 

5. 55.53.01.1 Dorsal Fin Attach Angle & adjoining Fuselage Skin 

CHAPTER 57 

1. 57.11.01.1 Lower Front Spar Splice at STA Xcw 94.500, from STA Xcw 79.688 to 

 Xcw 104.500 

2. 57.11.01.2 Lower Front Spar Stringer Runout at STA Xcw 115.000, from STA 

 Xcw 104.500 to Xcw 121.688 

3. 57.11.01.3 Lower Front Spar Stringer Runout at STA Xrs 115.000, from STA Xrs 91.000 

to Xrs 137.750 

4. 57.11.01.4 Lower Front Spar Stringer Runout at STA Xrs 164.000, from STA Xrs 137.750 

to Xrs 267.000 

5. 57.11.02.1 Lower Rear Spar Splice at STA Xrs 111.500, from STA Xrs 85.000 to 

 Xrs 130.000 

6. 75.11.02.2 Lower Rear Spar Outboard from STA Xrs 130.000 to Xrs 180.000 

7. 57.12.02.1 Lower Rear Spar Splice from STA Xcw 8.000 to Xcw 24.000 

8. 57.12.02.2 Lower Rear Spar Inboard from STA Xcw 24.000 to Xcw 60.000 

9. 57.12.03.1 Lower Rear Spar Splice from STA Xcw 60.000 to Xcw 100.000 

10. 57.32.01.1 Center Wing Skin Splice at Stringer 17 from STA Xrs 121.688 to Xrs 214.000 

11. 57.32.02.1 Lower Surface Access Door Cutouts STA Xrs 189.000 to Xrs 324.000 

12. 57.34.01.1 Center Wing Skin Splice at Stringer 17 from STA Xcw 20.000 to Xcw 121.688 

13. 57.34.01.2 Stringer 14, 15, 16 & Skin from STA Xcw 42.000 to Xcw 79.688 

14. 57.34.01.3 Stringer 18, 19, 20 & Skin from STA Xcw 42.000 to Xcw 79.688
PSE INSPECTION

REQUIREMENTS
MD-90 AIRWORTHINESS LIMITATIONS INSTRUCTIONS 

McDonnell Douglas Corporation Proprietary Information. Use or disclosure of NOTE: ALL INTERVALS IN LANDINGS (CTHESE DATA SUBJECT TO RESTRICTIVE LEGEND ON TITLE PAGE OR FIRST PAGE. B2-1 

PSE INSP

Number DESCRIPTION NDI PROCEDURE Init

54.10.01 

.1 

Front Spar Pylon – STA 1364 Pylon Front Spar, Upper Cap from Fuselage Intersection to 10 inches Inboard of Fuselage  Description of PSE  (NOTE: All PSE’s are symmetrical unless otherwise noted)  SSI Title and Number for purpose of  cross reference to the MRB report. 

54. 10. 01. 1

 Task Number  Sequence Number NDI Procedure Number is  ATA Sub-Chapter identical to PSE Number.  ATA Chapter  Abbreviation for  NDT Test(s) to be used at the 

 applicable inspection intervals. 

Refer to Section 2 

 ETHF  Refer to Section 2  of this document  for procedure. 

60,000 

Prepared by: DESIGN & TECHNOLOGY Revision 

Description Abbreviation Diffracto-SightEddy Current High FrequencyEddy Current Low FrequencyPenetrant – Color ContrastPenetrant – FluorescentMagnetic Particle – Color ContrastMagnetic Particle – FluorescentMagneto Optic Imaging Ultrasonic – “L” WaveUltrasonic – Shear WaveUltrasonic – Surface (90 Rayleigh)X-ray RadiographyGamma-ray RadiographyVisual AidedTorque Test 

DST 

ETHF 

ETLF 

PT 

PTF 

MT 

MTF 

MOI UTL 

UTS 

UTR 

RT 

RTG 

VT 

TT

INITIAaccomREPErepeatRepeathe timaccominspecThe Nselectthe nebe per

ZR(A
MD-90 AIRWORTHINESS LIMITATIONS INSTRUCTIONS 

McDonnell Douglas Corporation Proprietary Information. Use or disclosure of NOTE: ALL INTERVALS IN LANDINGS (CTHESE DATA SUBJECT TO RESTRICTIVE LEGEND ON TITLE PAGE OR FIRST PAGE. B2-2 

PSE INSPE

Number DESCRIPTION NDI PROCEDURE Initia

53.12.09 

.1 .2 

Floor Beam to Frame Intersection, Overwing, STA’s 924 – 1041 Fuselage Skin and Frames from Longeron 16 to Longeron 19, at all Frames in area above Wing and MLG Wheel Well Fuselage Frame to Floor Beam Joints, at all Frames above MLG Wheel Well 

Refer to Section 2 

60,000 60,000 

Prepared by: DESIGN & TECHNOLOGY Revision 
M D-90 .,.wo,,..,..ss .,M,...,o.s ,.s..uc.,o.s MDC-94K9000

INSPECT FUSELAGE FRAME INNER FLANGE AND FRAME

ATTACHMENTS COMMON TO FRAME AND SKIN BETWEEN

LONGERON 16 AND 19 FROM STA 883.000 TO STA 1060.000

IN SHADED AREA, LEFT SIDE SHOWN

(RIGHT SIDE OPPOSITE)

M D90-63-12-011-01

CAGpGDS)

LONGERON 16

LONGERON 19

STA

883.000

I:! i:i

..,

!ip Ill !i!

FRAME ,~,,,,~

I

SECTION A-A

FUSELAGE

SKIN

STA

1060.000

F RAM En~,,,,,~r~ IA

II II I I

It II I I

.l:::l I:l r:::l

. LONGERON lS

i’:::~ ~:: ’1

- LONGERON 20

~ FUSELAGE

SKIN

PSE 53.12._n9.t [ Fuselage SUn and Frames from Longeron 16 to Longeron 19, at all Frames In area above Wing and MLG Revision Date: Original

McOomwll Do~llm COrllOlltion Pml~leta~y l~on. ~ or d~ of

THE ILLUSTRATION SHOWN ON THIS PAGE IS FOR GENERAL IDENTIFICATION ONLY,

THESE DATA SUBJECT TO RESTRICTIVE LEGEND ON TITLE PAGE OR FIRST PAGE. B2-3 SEE SECTION I FOR THE DETAILED NDI PROCEDURE AND ILLUSTRATION(I).
THIS PAGE INTENTIONALLY LEFT BLANK

McDonnoll DolNlll Corp~on Proprtltll~/In(orig. UI¢ m" dlsclmlufe Of

B2-4 Revision Date: ~  ̄  ̄ 8

THESE DATA SUBJECT O RESTRICTIVE LEGEND ON TITLE PAGE OR RRST PAGE, urlglnal
M D-90 MDC-94K9000

FRP FRAME

SPLICE

STA

1041.000

STA /

STA 1022.000 ,,~

I~OUTBD

~FWD

INSPECT FUSELAGE FRAME,

FLOORBEAM AND FASTENER HOLES

IN SHADED AREA. RIGHT SIDE SHOWN

(LEFT SIDE OPPOSITE)

FLOORBEAM

MDDO-.E3-124g-~2

CAG(IGOS)

VIEW A

LOOKING FORWARD

STATION 1003.000

SIMILAR FOR STATION 1022.000

AND I041.000

PSE 53.12.09.2 I Fuselage Frame to Floor Beam Joints, at all frames above MLG Wheel Well Revision Date: Original

McDonnell Dot,~Ms C, orporstt0n Prl)prletlry Info~on, Ulm or dhl¢loll,l~ of THE ILLUSTRATION SHOWN ON THIS PAGE IS FOR GENERAL IDENTIFICATION ONLY,

THESE DATA SUBJECT TO RESTRICTIVE LEGEND ON TITLE PAGE OR FIRST PAGE. B2-5 SEE SECTION 2 FOR THE DETAILED NDI PROCEDURE AND ILLUSTRATfON(=).
MD-90 AIRWORTHINESS LIMITATIONS INSTRUCTIONS MDC-94Kg000

PSE NDI INSPECTION INTERVAL

Number DESCRIPTION PROCEDURE Zone(s) Initial Repeat

53.12.15 Pressure Bulkhead, Aft Fuselage, STA 1395 (Aft Face) Refer to Section 2

.1 Bulkhead Skin & Stiffener at STA Z = 63,500, Left Side Only (Area of 89,000 28,000 223

Firex Wye)

.2 Bulkhead Skin & Stiffener at STA Z = 14.000, Between Finger Doublers 89,000 15,500 223

& Blanket Attach Angles

.3 Bulkhead Skin & Stiffener at STA Z = -18.000 89,000 10,000 181

.4 Bulkhead - Fuselage Attachment Tee Radius Between Longeron 6 & 89,000 21,000 311

F.R.P.

Prepared by:. DESIGN & TECHNOLOGY Revision Date: OCT 2001

McDonnell Douglas Coq~ration Propdetanj Information. Use or disclosure of

THESE DATA SUBJECT TO RESTRICTIVE LEGEND ON TITLE PAGE OR FIRST PAGE. B2-6

NOTE: ALL INTERVALS IN LANDINGS (CYCLES) UNLESS OTHERWISE NOTED
M D-90 MDC-94K9000

STA

1396.000

DOOR

JAMB

STA

Z =63.500

F.R.P.

INSPECT BULKHEAD SKIN AND STIFFENER

IN SHADED AREA. LEFT SIDE ONLY

ATTACH

TEE

BULKHEAD STIFFENER /

~/~ ~i!!}!}!!!!:!!~!!!~!!!!i:!!~!!!!!i:!!!~:!i:!~:!!!~:!i:!

!!’ ij--i i~’~~ z=S~’~

WYE SUPPORT

VIEW A

MDgO--53-12-15-01

CAG(IGDS)

I

AFT PRESSURE BULKHEAD

LOOKING AFT

I

PSE53.12.15.1I Bulkhead Skin & Stiffener at STA Z = 63.500, Left Side Only (Area of Fimx Wye) I Revision Date: Original

B

McDonnell Doqllas Corpotle~ion Pmprl~ Informa~on. UN or dim of THE ILLUSTRATION SHOWN ON THIS PAGE IS FOR GENERAL IDENTIRCATION ONLY.

THESE DATA SUBJECT TO RESTRICTIVE LEGEND ON TITLE PAGE OR RRST PAGE. 92-7 SEE SECTION 2 FOR THE DETAILED NDI PROCEDURE AND ILLUSTRATION(s).
THIS PAGE INTENTIONALLY LEFT BLANK

Mr.JDon~ell Douglas Cocporwtion Pmpr~ In~,r’~r~Jon. Uie or disclosure of

THESE DATA SUBJECT TO RESTRICTIVE LJEGEHD ON TITLE PAGE OR FIRST PAGE. B2-8 Revision Date: Original ~ m m m
M D-90 .,.,...,o.s MDC-94K9000

STA

1395.000

INSPECT BULKHEAD SKIN AND STIFFENER

IN SHADED AREA. LEFT SIDE SHOWN

(RIGHT SIDE OPPOSITE)

ATTACH

TEE

BULKHEAD ATTACH

/

SKIN ANGLE

DOOR

JAMB ~,~

STA

STIFFENER STA

Z=14.000 FINGER

DOUBLERS F.R.P. VIEW A

MDII0-63-12-16-1D2

CAG{mDS)

I

AFT PRESSURE BULKHEAD

LOOKING AFT

PSE 53.12.15.2 L Bulkhead Sldn & Stiffener at STA Z = 14.000, Between Finger Doublers & Blanket Attach Angles " L Revision Date:Original

McDeemell Do~glm Corporodon Proprletlfy information. Ule or d~ of THE ILLUSTRATION SHOWN ON THIS PAGE IS FOR GENERAL IDENTIFICATION ONLY.

THESE DATA SUBJECT TO RESTRICTIVE LEGEND ON TITLE PAGE OR FIRST PAGE. B2-9 SEE SECTION IE FOR THE DETAILED NOI PROCEDURE AND ILLUSTRATION(s).
THIS PAGE INTENTIONALLY LEFT BLANK

McDcmnoi! DO4JgIN CorporaUon Pmprtatary Information. Use or disclosure of

THESE DATA SUSUEC~ TO RESTRIc’rr~ UEG~O O. ~rU~ P~E OR ~RST P~E. B2-10 Revision Date: Original
M D-90 LIMITATIONS INSTRUCTIONS MDC-94K9000

STA

1395.000

INSPECT BULKHEAD SKIN AND DOUBLERS

IN SHADED AREA. LEFT SIDE SHOWN

(RIGHT SIDE OPPOSITE)

MOg0-S3-12-$1;-03

CAGIIGOS)

F.R.P.

STA

Z = -18.000

I

AFT PRESSURE BULKHEAD

LOOKING AFT

- /,7 F RP

--.--. .... O ,

//V-l\\ ~ :---’,,’:: u ( ) o c~,’I/

II W 11 : :’~ ," ’ r~ ",.-../ r~ ~-J, //

t ~ "./ II , , ’ , tJ t I s II , o ,, , ,o ,.-

v ,

t J ) .:- =:. ........ :~ -.:.+~....:.... -..V/ -ST,

, -- ......... -. ~ ,.. ~. +. . "~ // Z =-18 oo0 -- ’ .’:": ~ :$i..~i i~ ~ ’~::’,~.i:~::" , "//

~. . .:::;.:: ~.:.’:’::~: .~ ~ ~, :~.:~.:::  ̄ / .- ~- ::::::,¢::;;:: ~.,.¢.~.::::~:~::: ~ ~..,...~.~..

(. / 

~,,~ ~::.~-~.’..:::.:’ ......:~ ......... ~::."~:: 0 ,-//  ̄ <. ~::" ’, < ~!i~!i~:. .."/,7 -: :: "::i::W::~::;S: ,

\ 

~

"ATTACH TEE

,’"-.. ..

.

i} i: "BU~.EAD

:° \’, ,.

, , ,,, .... .:.:.:.:

., , ......................................).~.............::~:

;J , ..::::~:~:~@i:i~i:~}~."4:~:.~:::~:~:..(~i:~:. ’

I

.......~.~....,:..o,..’~.:~.:~’.’.:.:.:.:.~.:~.:.:

’ ," ".’,’.’~.’.’,’,’"" "" " .............. ,~" ~" "4~’" d ~.,.~: .......~’\:::"~ .........~::~:~:!~ 4 ~!::" \ \ ’:iS~::¢:,~:::.  ̄ .  ̄ ::~i~,ii~.;~,~:

 ̄

::.~:~i :~i :..

I

VIEW A

PSE 53.12.15.3 i

McDonnell Dougb-, Cor~n Propdmry Infomun~n. Utm or dlllclc~u~ Of

THESE DATA SUBJECT TO RESTRICTIVE LEGEND ON TITLE PAGE OR RRST PAGE.

Bulkhead Skin & Doublers at STA Z = .18.000

B2-11

I Revision Date: Original

THE ILLUSTRATION SHOWN ON THIS PAGE IS FOR GENERAL IDENTIFICATION ONLY.

SEE SECTION 2 FOR THE DETAILED NDI PROCEDURE AND ILLUSTt~.TION(s).
THIS PAGE INTENTIONALLY LEFT BLANK

McDonnell Dougllm Corpomth)fl Proprilltlry Inf~mllUon. Uim or dllclolum of

THESE DATA SUBJECT TO RESTRICTIVE LEGEND ON TITLE PAGE OR FIRST PAGE. B2-12 Revision Date: Original
M D’g0.,RwoRT.,. ss .,.,T.T,o.s ,.STRUCT,O.S MDC-94K9000

STA

1395.000

INSPECT BULKHEAD.FUSELAGE ATTACHMENT TEE

BETWEEN LONGERON 6 AND F.R.P.

IN SHADED AREA. LEFT SIDE SHOWN

(RIGHT SIDE OPPOSITE)

LONGERON 6

A

F.R.P.

BULKHEAD

SKIN

ATTACH

TEE

MDIm-S3-12-15-04

CAGIIGDS)

I

AFT PRESSURE BULKHEAD

LOOKING AFT

SECTION A-A

~SE 53.12.15.4 I Bulkhead - Fuselage Atlachment Tee Radius between Longeron 6 & F.R.P. Revision Date: Original

MoDerato41 I)~#lllll ~on Propdellary I~n. UIt ~" dkmlolmri of THE ILLUSTRATION SHOWN ON THIS PAGE IS FOR GENERAL IDENTIRCATION ONLY.

THESE DATA SUBJECT TO RESTR/CT/VE LEGEND ON TITLE PAGE OR FIRST PAGE. B2-13 SEE SECTION 2 FOR THE DETAILED NDI PROCEDURE AND ILLUSTRATION(s).
M D-90 AIRWORTHINESS LIMITATIONS INSTRUCTIONS MDC-94Kg000

PSE NDI INSPECTION INTERVAL Zone(s)

Number DESCRIPTION PROCEDURE Initial Repeat

53.30.02 Skin Panels, STA 237 to 1395 Refer to Section 2

.1 Overwing Frame Splices above Wing & MLG Wheel Well, Longeron 8 to 60,000 30,000 220,222

Longeron 12

.2 Skin & Frame at STA 864.000 from Longeron 16 to Longeron 21 60,000 30,000 123,151,

152,220,

222

.3 Fuselage Skin in Constant Section from Longeron 3Left to Longeron 3 60,000 11,000 22O

Right

.4 Fuselage Hoop Skin Splice in Constant Section from Longeron 5Left to 60,000 30,000 220

Longeron 5 Right

.5 Upper & Lower Window Belt Splices along entire length of Window Belt 60,000 30,000 220

.6 Fuselage Skin around all Window Cutouts 60,000 5,600 220

.7 Fuselage Skin Splice at Aft Pressure Bulkhead, Longeron 14 Left to 60,000 30,000 220,310

Longeron 14 Right

.8 Fuselage Skin & Frame at STA’s 1231.000, 1269.000, 1288.000, Longeron 60,000 30,000 220,223

16 to Longeron 18 (RH Side Only)

.9 Fuselage Skin & Frame at STA’s 1098.000 to 1155.000, Longeron 15 to 60,000 30,000 220,222

Longeron 18

Prepared by:. DESIGN & TECHNOLOGY Revision Date: OCT 2001

McDonnell Douglas Corporation Proprietary Information. Use or disclosure of

THESE DATA SUBJECT TO RESTRICTIVE LEGEND ON TITLE PAGE OR FIRST PAGE. B2-14

NOTE: ALL INTERVALS IN LANDINGS (CYCLES) UNLESS OTHERWISE NOTED
M D-90 .,.,.A.,O.S ,.S..UC.,O.S MDC-94K9000

STA

883,000

STA

1041.000

UPPER

FRAME

\\

\\

\\

\ 

\%

\\

\\

\\

LONGERON

FORMER

\ \

\ \

\\ \

\

\\

\\ \

\\ \

\\

FUSELAGE

SKIN

INSPECT FUSELAGE SKIN, FRAMES SPLICES

AND FORMERS AT ATTACHMENTS

IN SHADED AREA. LEFT SIDE SHOWN

(RIGHT SIDE OPPOSITE}

LONGERON

TYPICAL FRAME SPLICE

LOOKING FORWARD

(SPLICE LOCATION VARIES

BETWEEN LONGERON 8 AND 12)

FORMER

MDg~S3-30.-O2.-Ol

CAGOGDS)

LOWER

FRA~

LONGERON

PSE 53,30.02.1 I Overwing Frame Splices above Wing & MLG Wheel Well, Longeron 8to Longeron 12 [ Revision Date:Original

McDonnell DOullllm Corporltion Proprietary Information. ~ or diKIosum of THE ILLUSTRATION SHOWN ON THIS PAGE IS FOR GENERAL IDENTIFICATION ONLY.

THESE DATA SUBJECT TO RE$TRICT/VE LEGEND ON TITLE PAGE OR FIRST PAGE. B2-15 SEE SECTION 2 FOR THE DETAILED NDI PROCEDURE AND ILLUSTRATION(s).
THIS PAGE INTENTIONALLY LEFT BLANK

McDonnell Doughm Cm’l~o. Pml~’h~w In/ormetkm. U~ or di~"l~ure of

B2-16 Revision Date:  ̄ ’%.’! I

THESE OATA SUBJECT TO RESTRICTIVE LEGEND ON TITLE PAGE OR RRST PAGE. urlg real
M D-90 MDC-94K9000

STA

864.000

INSPECT FRAME AND SKIN FROM LONGERON 16 TO 21 AND

FRAME INNER FLANGE FROM I.ONGERON 18 TO 18 AT STA 864.000

IN SHADED AREA. LEFT SIDE SHOWN

(RIGHT SIDE OPPOSITE)

,:,:,:.;,,:,:;:,:;:+,:;;,:;:,.,;,;,.

I

SECTION A-A

FUSELAGE

SKIN

MD90-§3-30-O2--02

CAG|IGDS|

UP

~1 FWD

LONGERON 16

LONGERON 17

FUSELAGE,~

SKIN

LONGERON 18

LONGERON 19

LONGERON 20

LONGERON 21

STA

855.000

I

STA

864.000

I

~RAME

-’1"

I

I

I

I

-T

~ - _ _

L!:i:i:l

~!~ _ _ _

i!::i~)

~! ;~il

f.i!!:!:l

~::~ - _ _ ~i~ - - -

lii;:i:l

~’:’::::i

I I

i PSE 53.30.02.2 i Skin & Frame at STA 864.000 from Longeron 16 to Longeron 21 Revision Date: Original

McDofmell Doughm C~r~on Propel m Iffformlt~ Use or dllclwum of THE ILLUSTRATION SHOWN ON THIS PAGE IS FOR GENERAL IDENTIFICATION ONLY.

THESE DATA SUBJECT TO RESTRICTIVE LEGEND ON TITLE PAGE OR FIRST PAGE. B2-17 SEE SECTION 2 FOR THE DETAILED ND1 PROCEDURE AND ILLUSTRATION(s).
THIS PAGE INTENTIONALLY LEFT BLANK

McDom~,ll Do~im Corporation Pmprlma~, Informs~on. U~ or dlllchmtmb of

THESE DATA SUBJECT O RESTRICTIVE LEGEND ON TITLE PAGE OR FIRST PAGE. B2-18 Revision Date: original ~ L ~ A
M D-90 .,.,...,o.s MDC-94K9000

STA

1211.500

STA

STA 796.000

674~

STA

1288.000

INSPECT FUSELAGE SKIN IN CONSTANT SECTION

FROM LONGERON 3 LEFT AND 3 RIGHT FROM

STATIONS 674.000 TO 796.000 AND STATIONS 1211.500 TO 1288.000

IN SHADED AREA. LEFT SIDE SHOWN (RIGHT SIDE OPPOSITE)

LONGERON 1

LONGERON 2L

LONGERON 3L

LONGERON 4L

FUSELAGE

SKIN

-....,

C

STA STA STA STA STA

1211.500 1231.000 1250.000 1269.000 1288.000

[ I I I I

- -~w:%::;~i:~::~!:~::~w~:~:~x4::~a:~:~:~:~!~i~:~:~:~:~::~:!~:!:~:i~:~:~:~::~.W~- -

.’ "".: "":’ ’ "’:.~.’""..~:.’" ~::"" ":’ L: ’." "’::’.’ "".~.’""" ’" ’.’::" ’/:’.’ "::’/’" .~. ....... :": "’: ;" " .~." "~::.".:::. ":~’"

l::. ti~ |

~_-~.~.:,-:.:~.:.~:~:~ ....... ~:.~.:~i!w.:-:: ....... :,-~:...-....:.-:.:~...-.-x-.:.~::..-.:.:.:....--...:.~ - -~_ ~::.~:::~.~.~::..~:~::~.~W.:::::~::~:~:~:~:.~::~.:::~::...-..::~:.~x~:....~:~:~.~:;~:~:~:c.‘:~:~ -

 ̄ . . ., .| :: ’::i :! "’!t :: _ _ ~.. ..........~ ............... ~:~ .......-. ........~ ........-~ ~!~ -

_ _ ::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::: _

I

I

I

I

I

I

I

I

I

I

_ _~1 ..... ~L .... JJ L~ _,L _

-,~- _ n ;; .... -,~

STA STA STA STA STA STA

FUSELAGE 674.000 693°000 712.000 731.000 780.000 769.000

LONGERON 1 i

LONGERON 2L

LONGERON 3L~

LONGERON 4L~ C

STA

796.000

STA

788.000

I

~’-~’~ ..................... . ........... . ,..;,...-;,~-T~: .-..-....,.:.-...:.,.:.;.;.:.; ........- ....-..........v ..-.. -,... ̄|.~ .’.’,’.’.’.’.."

- - ~.: .~.:~: :.~..:~: ..~..: V,:: :..~.: ~ :.~..: :~ :~: :~ :.~..: :~:~::~::~’:~’.’; "~:~’:’~:’~:~:’:~’:~:’:~:~:’:~: -.’..:::~:~i:~:i~!:~’:..-"~’:’....~.’:.. ..:::. .~-::~::- .~-’:-  ̄ ..,.. . ..~.,, .:. ,: :.. : .~...: , :,. ;, ...~,.......,;..:..,; ,..,..~.’...:. ~.:. ,:..... .~r. ;..:. :.. : .... .v ":’. ":v. ’;’.’. ),-’~."-’.’.’. ":’.

~:! I:.~ (:.. I t:. ~::. .t:.:

 ̄ -- ~’...~. -,.~:..’:~.,.~., .~.,.’~.-’..’~..’..’~.",,~’:"~.".-’~:.’~. ’..~:’:’ ."~’. ’.’~..’:.~..-,.---.....~,-..,.’C.,..--~.....’--.-..-.~’." ..~’.-:."~.".’~. .......’C....’~...-.’~..-.,~.::,,--.: .--’~..:. :~:~...’~..: ...... :...,.,"~..:..’~.,-:..~" "~

- ~ ~’.: :...,.. ............ .,.-..v,....-..,.....:...., :.~,;.:;,~:. ,~.:. ~,;::,’.’.’. :,’. ’.:-:;,~. :~;:.::~~ ..... w(.;(,.,,.. :,.~..:.g, ..~:. ,..~. ..,;,;..v...:,.~. ,;,;,t .L~.:.:~," ".~.; ’.:.’,’,v,’: ,:.v.’..~.w...,,.=..: ;Zv ~-. ~.,.., ~ ,. ~...,~ ....,=.....~, -. w..,." .~.-.’--

. _ ~:..:..:;~:~:~:~:.:.:.~:~x.~:.:.:~:~:.i~‘;:;~:~..~...~’~: ~ ~:’~:~:‘~:~;‘;~:":::~::~:#~;::~:~:~:::~:~:k:~:~::~:~::~:~.~:~;~’L~:~‘;-

I

I II I

I II II I

I II

JJ ..... d .... J)- J J, bl 1,! ..... ].)_ _ 

~- -,," ,~ ;] - -- ~I .~ - - -~ ,’; -,T ....

M DgO-53-30--OZ-03

CAGIIGDS)

I

I PSE 53.30.02.3 Fuselage Sldn In Constant Section from Longeron 3 Left to Longemn 3 Right I Revision Date: Original

I

McOormell Dou0hm Corporl~on Proprletlry I~. U~ or dllclmmm of THE ILLUSTRATION SHOWN ON THIS PAGE IS FOR GENERAL IDENTIFICATION ONLY.

THESE DATA SUBJECT TO RESTRICTIVE LEGEND ON TITLE PAGE OR RRST PAGE. B2-19 SEE SECTION 2 FOR THE DETAILED NDI PROCEDURE AND ILLUSTRATION(s).
THIS PAGE INTENTIONALLY LEFT BLANK

McDm1~el! Douglm Corl~on Proprim Information. Use or dlw:losm of

THESE DATA SUBJECT TO RESTRICTIVE LEGEND ON TITLE PAGE OR FIRST PAGE. B2-20 Revision Date: Original
M D-90 A,.wo...,.ESS .,M,.A.,O.S ,.ST.UC.,O.S MDC-94K9000

STA

STA 1145.600

STA 81eooo I /~

L

~,,,~ [ "~y~ ~ ~ TOP CENTERLINE

ERON1

I FwD

LONGERON 2L

INSPECT FUSELAGE SKIN, SPUCE STRAPS

AND FINGER DOUBLERS FROM LONGERON BL

TO LONGERON 5R AT STA 229.000, 588.000,

816o000, AND STA 1141.500

IN SHADED AREA LEFT SIDE SHOWN

(RIGHT SIDE OPPOSITE)

LONGERON 6L

VIEW LOOKING DOWN

AT UPPER SURFACE

OF FUSELAGE

t::i:::i:~:~. :::::::::::~

I

I

I

!

I

STA

229.000

tI

STA

588.000

816.000

._ ~ii:!~i!ili!=======================li’~’:’!’i’i’!’~’i’li’i’i~i~i __

I

STA

1145.500

I

PSE53.30.02.4I Fuselage Hoop Skin Splice In Constant Section from Longeron 5 Left to Longeron 5 Right I Revision Date: Original

i

McOonmll Dou0hm Corpor~ion Prolprk~ Inllm’mstlan. ~ of dicl~mm of THE ILLUSTRATION SHOWN ON THIS PAGE IS FOR GENERAL IDENTIFICATION ONLY.

THESE DATA SUBJECT TO RESTRICTIVE LEGEND ON TITLE PAGE OR FIRST PAGE. B2-21 SEE SECTION 2 FOR THE DETAILED NDI PROCEDURE AND ILLUSTRATION(s).
THIS PAGE INTENTIONALLY LEFT BLANK
M D-90 A,RWO.T.,..SS ",.,TA.,O.S ,.S..UCT,O.S MDC-94K9000

SKIN

INNER FINGER

DOUBLER

STA

218.000

STA

1328.000

INSPECT UPPER AND LOWER WINDOW BELT

SPLICES ALONG ENTIRE LENGTH OF SPLICE

AT FIRST TWO ATTACHMENT ROWS COMMON

TO THE FUSELAGE SKIN AND INNER FINGER

DOUBLERS, AND ALSO AT LAST ATTACHMENT

ROW COMMON TO THE WINDOW BELT PANEL

AND EXTERNAL DOUBLER IN SHADED AREA.

LEFT SIDE SHOWN (RIGHT SIDE OPPOSITE)

INSPECT ALONG

NOTED ROWS

LONGERON 11

LONGERON 15

..:.:: ~,!i:,:,!i! !!!!!!i!!!!!i!!!!!!!!!ij!!i!!!!!i!!!!!!!i!!!!!i!!!!!!!!!~ii~: ..... -.~ A

::::::::::::::::::::::::::::::::::::::::::::::::::::: ...........~!~i!~i:!~i~:~!~i~i~!~i~i~{.{i~i!~:.i~i:.~i~.~:.:.

J

WINDOW BELT

PANEL

DOUBLER OUTBD

VIEW A-A

MD90--53-3O-O2-O5

CAG(IGDS|

LOOKING INBOARD

UPPER AND LOWER

WINDOW BELT SPLICE

UP

~1 FWD

I Upper & Lower Window Belt Splices along entire length of Window Belt I Revision Date: Original PSE 53,30,02,5

|

McDonnell Dowtls Cor~n Proprtetw~/I~n. Um or dleda~um of THE ILLUSTRATION SHOWN ON THIS PAGE IS FOR GENERAL IDENTIFICATION LY.

THESE DATA SUBJECT TO RESTRICTIVE LEGEND ON TITLE PAGE OR FIRST PAGE. B2-23 SEE SECTION :~ FOR THE DETAILED NDI PROCEDURE AND ILLUSTRATION(s).
THIS PAGE INTENTIONALLY LEFT BLANK

McOonnsll Dougllm Corporation Propl, letm~ Informi~on. Use o¢ dillciosm~ of

THESE DATA SUBJECT TO RESTRICTIVE LEGEND ON TITLE PAGE OR FIRST PAGE. B2-24 Revision Date: Original
M D-90 .,,,wo,.-.,..ss LIMITATIONS INSTRUCTIONS MDC-94K9000

INSPECT FUSELAGE SKIN AROUND ALL CABIN WINDOWS

IN SHADED AREA. LEFT SIDE SHOWN

(RIGHT SIDE OPPOSITE)

UP

CABIN WINDOW

(TYPICAL)

.08 INCH

1. k~-~ .70 INCH -

OUTSIDE WINDOW

.1B INCH

L

I_

t

SECTION A-A

TYPICAL WINDOW CUTOUT

SKIN SHOWN ONLY

M Dg0-.53-30-02-08

CAG(IGDS)

PSE 53.30.02.6 i Fuselage Skin around all Window Cutouts Revision Date: Original

McOmm~l Drachm Corlmmtion Proprietary Ioft)fmatt~m. Ule or dim:toeum of THE ILLUSTRATION SHOWN ON THIS PAGE IS FOR GENERAL IDENTIFICATION LY,

THESE DATA SUBJECT TO RESTRICTIVE LEGEND ON TITLE PAGE OR FIRST PAGE. B2-25 SEE SECTION 2 FOR THE DETAILED NDI PROCEDURE AND ILLUSTRATION(=).
THIS PAGE INTENTIONALLY LEFT BLANK

McDonnell Douglse Col’~on Proprietary Information. Use or dlllckmum of

THESE DATA SUBJECT TO RESTRICTIVE LEGEND ON TITLE PAGE OR FIRST PAGE. B2-26 Revision Date: Original
M D-90 UMITATIONS INSTRUCTIONS MDC-94K9000

STA

1395.000

STA

1395.000

INSPECT FUSELAGE SKIN AND AFT

PRESSURE BULKHEAD FRAME

FROM LONGERON 14 LEFT TO 14 RIGHT

IN SHADED AREA. LEFT SIDE SHOWN

{RIGHT SIDE OPPOSITE)

I _ _ ~-~;il t~iii~

L ’, / ~ ~~-::il |~-:~. ..... ~~~.:;j i;~~ \

TOP CENTERLINE I=:=~ = = = = =1 ~Tr~:i" "’:-::::-::::~:: ::.::::::.-.-.-.::~

"-~ --- ~---J- :J :-1-

I I ~:i’.:::l ~~-~ ,

LONGERON 1F FUSELAGE I I ’ ~iil] ~~i i::::::::::::::::::::::::::::::::::::::::::::: :::::::::::::::::::::::::::::::::::::::i )

~^ ,~ / ~ ::]J::::::::::::::::::::;I I~::)::::::::::::::~.::::::::::: /

~. ; ~.._._.__ ._,...~::::~:~::~:~ ~::;~::~:::~:~::L _ _ _ --I

..... ~ ~ .,.-.~-~-. ,...~.’q~:,.’~..,:-?~: ..~-J I~. ;-~, ..:,."~, ..:~-:,.~...: "~.  ̄ __ ..... -1

] ~.iiiiiiii;~ii~!i;~:~i;ililil [iil;i!i;ii~iii~i~ii~i;iiiii~i;iii~i~i /

FUSELAGE | ::::::::::::::::::::::::::::;:::::::::::::::: :::::::::::::::::::::::::::::::::::::::" =

s KIN _ / ::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::

[i::i:: ::::::::::::::::::::::::::::: /

!i :: ii ::!. ::~ i!i!.ii ! :: ~::~ii ! : : !:::: :::::::::::::::::::::::::::::::::::::::::

/

::::::::::::::::::::::::::::::::::::::::::::::: :::::::::::::::::::::::::::::::::::::::::::

LONGERON 14L

:::::::::::::::::::::::::: i:i i:i:::~ .--~,.--’ ========================

::::::::::::::::::::::::::::::::::::::::::::::::::::::: i ~ i !;; il;::; i::;i!::;::;i;i!i~ii::;::~ii

(ii!iii!i!i ~iiiiiii i iiiiiiii i!iiiii I ::::::::::::::::::::::::::::::

I ..... =================================::iiii~i~ii~ i ~ i~iii~ \ = =-=: -_- ----~ Ji -~!:i~ii~iiiii ~!!~!i!i:..i E i:

/- - - - -r - ~ - ~i~ii::;i~:~::;i!i;i~i~i;~;~ !~i ::::::::::::::::::::::::::::::::::::::::::::

!

!

~. ~._-._~ .... -I~

I

I

!

I

LOOKING DOWN ~------~~

FUSELAGE UPPER SURFACE

I

I

I

J

PSE 53.30.02,7 I Fuselage Skin Splice at Aft Pressure Bulkhead, Longeron 14Left to Longeron 14Right Revision Date: Original

I~l~n~ll Oeulll~ Corpemtion Pmprimry Infomtmton, UN ¢~ dimdum of THE ILLUSTRATION SHOWN ON THIS PAGE IS FOR GENERAL IDENTIRCATION ONLY,

THESE DATA SUBJECT TO RESTRICTIVE LEGEND ON TITLE PAGE OR RRST PAGE. B2-27 SEE SECTION Z FOR THE DETAILED NDI PROCEDURE AND ILLUSTRATION(e).
THIS PAGE INTENTIONALLY LEFT BLANK

McDonnell DoWIIm Corl~r~tion Pmpriewry Inform~bon. UIm or discl~u~re of

B2-28 Revision Date: f’~., "._z I

THESE DATA SUBJECT 1’O RESTRICTIVE LEGEND ON TITLE PAGE OR RRST PAGE. ~Jr,g,na,
M D-90 A,.WO.T.,. ss.,.,.A.,O.S ,.S..UC.,O.S MDC-94K9000

STA

p 1288.000

INSPECT FUSELAGE SKIN, FRAME INNER FLANGE

AND SHEAR CLIPS BETWEEN LONGERON

16 AND 18 AT STATIONS 1231.000, 1269.000 AND 1288.000

IN SHADED AREA. RIGHT SIDE ONLY

SECTION A-A

STA STA STA STA STA

1288.000 1276.000 1269.000 FUSELAGE 1250,000 1231,000

REF REF SHEAR

I I I

SKIN

.

’ i -"~ii ~ .....

~ .... ~

I ~iiii!:i A f- iii~iiii:iii-~ A i:::!iiiiiiiiii

M D90-~3-30-02-08 ~ /

CAGOOOS)

LONGERON 16

LONGERON 17

LONGERON 18

"~

FUSELAGE

SKIN

PSE 53.30.02.8 ] Fuselage Sldn & Frame at STAs 1231.000, 1289.000, 1288.000, Longeron 16 to Longeron 18 (RH side only) J Revision Date: Original

McDonnell Dougllm Cm!~on Pro~ry Informm|oh. Use or dlactoslme or

THESE DATA SUBJECT TO RESTRICTIVE LEGEND ON TITLE PAGE OR FIRST PAGE. B2-29

THE ILLUSTRATION SHOWN ON THIS PAGE IS FOR GENERAL IDENTIFICATION ONLY.

SEE SECTION 2 FOR THE DETAILED NOI PROCEDURE AND ILLUSTRATION(l).
THIS PAGE INTENTIONALLY LEFT BLANK

McDonnell Douglm Co~n Pmpr~m Informat~o~ thin or disclosure of

THESE DATA SUBJECT TO RESTRiCTIVE LEGEND ON TITLE PAGE OR FIRST PAGE. B2-30 Revision Date: Original
M D-90 L,.,T.T,O.S MDC-94K9000

STA

1098.000

STA FUSELAGE 1155.000 SKIN

LONGERON 15 ~ C~

LONGERON 17

LONGERON 18 ~

1

LONGERON 17 ~ C~

LONGERON 18 ~ C

STA STA STA STA

1098.000 1117.000 1136.000 1155.000

w

INSPECT FUSELAGE SKIN AND FRAMES BETWEEN LONGERON

15 AND 18 AT STATIONS I098.000, 1117.000, 1136.000 AND 1155.000

IN SHADED AREA. LEFT SIDE SHOWN (RIGHT SIDE OPPOSITE)

J

INSPECT FUSELAGE SKIN AND FRAME FITTING,

FASTENERS AND FORMER BETWEEN AND

INCLUDING STATIONS 1098.000 AND 1165.000

IN SHADED AREA. LEFT SIDE SHOWN

IRIGHT SIDE OPPOSITE)

LONGERON 18 --

MDBO-S3-30-02-011

CAGgGDS|

~OUTBD

A

VIEW LOOKING FOPWARD

(TYPICAL FRAHE)

FUSELAGE

SKIN ¢~j FRAME

FITTING

SECTION A-A

PSE 53.30.02.9 I Fuselage Skin & Frame at STAs 1098.000 to 1155.000, Longeron 15 to Longeron 18 I Revision Date: Original

McD~II DoWIm Corporxtt~ Pmlerimmy Inf=rmatlon, UN ¢w dIMd~ of THE ILLUSTRATION SHOWN ON THIS PAGE IS FOR GENERAL IDENTIFICATION ONLY.

THESE DATA SUBJECT TO RESTRICTIVE LEGEND ON TITLE PAGE OR FIRST PAGE. B2-31 SEE SECTION 2 FOR THE DETAILED NDI PROCEDURE AND ILLUSTRATION(=).
PSE NDI INSPECTION INTERVAL Zone(s)

Number DESCRIPTION PROCEDURE Initial Repeat

54.10.01 Front Spar Pylon - STA 1364 Refer to Section 2

.1 Pylon Front Spar Upper Cap from Fuselage Intersection to 10 inches In- 60,000 10,200 223

board of Fuselage

Prepared by: DESIGN & TECHNOLOGY Revision Date: OCT 2001

McDonnell Douglas Corporation Proprietary Information. Use or disclosure of NOTE: ALL INTERVALS IN LANDINGS (CYCLES) UNLESS OTHERWISE NOTED

THESE DATA SUBJECT TO RESTRICTIVE LEGEND ON TITLE PAGE OR FIRST PAGE. 92-32
MD-90 MDC-94K9000

FUSELAGE

INTERSECTION

LONGERON 15

i

-- 10 INCHES

=i

UPPER SPAR

CAP

0

0

0

0

I o

Io

I o

0

0

0

0

0

0

INSPECT UPPER SPAR CAP

AND FASTENERSIN SHADED AREA.

LEFT SIDE SHOWN

(RIGHT SIDE OPPOSITE)

YOKE SUPPORT

FITTING

FRONT SPAR

MD90-54-I0~01-01

CAGIIGDS)

~ OUTBD

VIEW A-A

FRONT SPAR

LOOKING FORWARD

ANGLE A

A

FORWARD ENGINE

MOUNT YOKE

I PSE 54.10.01.1 I Pylon Front Spar Upper Cap, from Fuselage Intersection to 10 Inches Inboard of Fuselage I Revision Date: OCT 2001

McDonnell Douglas Corporation Proprietary Information. Use or disclosure of THE ILLUSTRATION SHOWN ON THIS PAGE IS FOR GENERAL IDENTIFICATION ONLY.

THESE DATA SUBJECT TO RESTRICTIVE LEGEND ON TITLE PAGE OR FIRST PAGE. B2-33 SEE SECTION 2 FOR DETAILED NDI PROCEDURE AND ILLUSTRATION(s).
M D-90 AIRWORTHINESS LIMITATIONS iNSTRUCTiONS MDC-94K9000

PSE NDI INSPECTION INTERVAL Zone(s) Number DESCRIPTION PROCEDURE Initial Repeat

54.10.04 Thrust Bulkhead, Pylon - STA Yn 170.5 Referto Section 2

Only aircraft fuselage numbers 2094, 2095, 2096, 2097, 2098, 2099, 2100,

2115, 2117, 2120 2122 and 2123.

.1 Rear Spar and Engine Thrust support fitting (Upper & Lower) ETHF 15,000 4,500 431,441

Accomplishment of modification per Service Bulletin MD90-54-001 terminates

ALl inspection requirements for PSE 54.10.04.1.

Prepared by:. DESIGN & TECHNOLOGY Revision Date: OCT 2001

McDonnell Douglas Corporation Proprietary Information. Use or disclosure of NOTE: ALL INTERVALS IN LANDINGS (CYCLES) UNLESS OTHERWISE NOTED

THESE DATA SUBJECT TO RESTRICTIVE LEGEND ON TITLE PAGE OR RRST PAGE. B2-34
M D-90 .,.WO.TH,.ESS L,.,T.T,ONS ,NST.UCT, O.S MDC-94K9000

REAR SPAR

INSPECT REAR SPAR AND ENGINE THRUST SUPPORT

FITTING (UPPER AND LOWER CAPS) IN SHADED AREA.

LEFT SIDE SHOWN (RIGHT SIDE OPPOSITE)

FUSELAGE

AUXILIARY SPAR

REAR SPAR

AFT ENGINE

MOUNT SUPPORT

PER CAP

LOWER CAP

VIEW A

ENGINE THRUST

SUPPORT FITTING

M DgO-S4-110-04-01

CAGilGDS)

CLOSING RIB

PSE 54.10.04.1 I Rear Spar and Engine Thrust support fitting (Upper & Lower Ii Revision Date: JAN 1995

McDonnell Dougl-,s Corporation Proprietary Information. Use or disclosure of THE ILLUSTRATION SHOWN ON THIS PAGE IS FOR GENERAL IDENTIFICATION ONLY.

THESE DATA SUBJECT TO RESTRICTIVE LEGEND ON TITLE PAGE OR FIRST PAGE. B2-35 SEE SECTION ;~ FOR THE DETAILED NDI PROCEDURE AND ILLUSTRATION(s). MIIOPSEBL
M D-90 MDC-94Kg000

PSE NDI INSPECTION INTERVAL Zone(s)

Number DESCRIPTION PROCEDURE Initial Repeat

54.10.08 Plate, Pylon Thrust Refer to Section 2

.1 Shear Pin Plate, Shear Pin Holes (both Upper & Lower Holes) 60,000 30,000 431,441

Prepared by: DESIGN & TECHNOLOGY Revision Date: JAN 1995

McDonnell Douglas Corporation Proprietary Information. Use or disClosure of NOTE: ALL INTERVALS IN LANDINGS (CYCLES) UNLESS OTHERWISE NOTED

THESE DATA SUBJECT TO RESTRICTIVE LEGEND ON TITLE PAGE OR FIRST PAGE. B2-36 MgOPSO.V
M D-90 A,.WOm,. ss ,.S .UCT, O.S MDC-94K9000

REAR SPAR

FUSELAGE

AUXILIARY SPAR

\

INSPECT SHEAR PIN HOLES

IN SHADED AREA.

LEFT SIDE SHOWN

(RIGHT SIDE OPPOSITE)

AFT ENGINE

MOUNT SUPPORT

UPPER AND LOWER

SHEAR PIN HOLES

UP

VIEW A

THRUST ISOLATOR PLATE

LOOKING INBOARD

CLOSING RIB

PSE 54.10.08.1 I Shear Pin Plate, Shear Pin Holes (both Upper & Lower Holes) I Revision Date:JAN 1995

McDmmell DOUl;Im C~ Peopr~ In]brm~lMm. Umo ar dil~lom~e of

THESE DATA SUBJECT TO RESTRICTIVE LEGEND ON TITLE PAGE OR RRST PAGE. B2-37

THE ILLUSTRATION E, HQNIN ON THIS PAGE I$ FOR GENERAL IDENTIFICATION ONLY

SEE SECTION ~ FOR THE DETAILED NOI PROCEDURE ANO ILLUSTRATION(t)
M D-90 AIRWORTHINESS LIMITATIONS INSTRUCTIONS MDC-94Kg000

PSE NDI INSPECTION INTERVAL Zone(s)

Number DESCRIPTION PROCEDURE Initial Repeat

54.40.01 Yoke - Forward Engine Mount, Pylon - STA 1364 Refer to Section 2

.1 Engine Yoke Flanges in vicinity of Support Fitting Attach Points 60,000 10,600 412, 422

.2 Pylon, Forward Upper & Lower Isolators and Cone Bolts (see note) MTF 15,000 15,000 412,422

NOTE: Accomplishment of the MD-90 ALl inspection procedure 54.40.01.2 at

intervals specified in the document listed below for these components, is an

acceptable means to satisfy the ALl requirements for PSE 54.40.01.2.

Maintenance Review Board Report McDonnell Douglas MD-90

Tasks (71-20-00/01 and 71-20-00/02)

Prepared by: DESIGN & TECHNOLOGY Revision Date: OCT 2001

McDonnell Douglas Corporation Proprietary Information. Use or disclosure of NOTE: ALL INTERVALS IN LANDINGS (CYCLES) UNLESS OTHERWISE NOTED

THESE DATA SUBJECT TO RESTRICTIVE LEGEND ON TITLE PAGE OR FIRST PAGE. B2-38
M D-90 UMFrATIONS INSTRUCTIONS MDC-94K9000

ORT

FITTING

FRONT SPAR

INSPECT INBOARD FLANGES BETWEEN ~

UPPER AND LOWER RIBS

INSPECT AREA AROUND SUPPORT .,4

FITTING ATTACHMENT HOLES

IN SHADED AREAS. ~ UPPERRIBS

LEFT SIDE SHOWN

(RIGHT SIDE OPPOSITE)

/~: UPPER SUPPORT FITTING TO

"~.(::’.-c~E

YOKE ATTACH POINT

LOWER

RIBS INBD

UPPER

RIBS

INSPECT OUTBOARD FLANGES BETWEEN

UPPER AND LOWER RIBS LOWER SUPPORT FITTING TO

INSPECT AREA AROUND SUPPORT YOKE ATTACH POINT

FITTING ATTACHMENT HOLES

IN SHADED AREAS.

LEFT SIDE SHOWN

~

:!i!

LO WER

(RIGHT SIDE OPPOSITE)

i~.

RIBS

VIEW A

FORWARD ENGINE MOUNT

LOOKING AFT

FORWARD ENGINE

MOUNT YOKE

PSE 54.40.01.t I Engine Yoke Flanges In vicinity of Support Flffin9 Attach Points J Revision Date: JAN 1095

McOomtefl Omalllm Corl~ ~ h~ UIII or II1~ air THE ILLUSTRATION SHOWN ON THIS PAGE IS FOR GENERAL IDENTIFICATION ONLY

THESE DATA SUBJECT TO RESTRICTIVE LEGEND ON TITLE PAGE OR FIRST PAGE. B2-39 SEE SECTION 1 FOR THE DETAILED NDI PROCEDURE AND ILLUSTRATION(sl
THIS PAGE INTENTIONALLY LEFT BLANK

I

McOonnoll Douglm| Corporation Proprietary InFormation, Un or dl|closum of

THESE DATA SUBJECT TO RESTRICTIVE LEGEND ON TITLE PAGE OR FIRST PAGE. B2-40 Revision Date: JAN 1995
M D-90 .,..A.O.S ,NSTRUC ONS MDC-94K9000

YOKE

CONE BOLT

UPPER COVER

VIBRATION PLATE

ISOLATOR

%

LOWER

VIBRATION

ISOLATOR

MDIO-E4-40-01-4)Z

CA6(1OOS)

INSPECT UPPER AND LOWER

ISOLATORS AND CONE BOLTS

IN SHADED AREAS.

LEFT SIDE SHOWN

{RIGHT SIDE OPPOSITE)

COVER

PLATE

CONE BOLT

PSE S4.40.01.2 1 Pylon, Forward Upper & Lower Isolators and Cone Bolts I Revision Date:JAN 1995

THE ILLUSTRATION SHOWN ON THIS PAGE ISFOR GENERAL IDENTIFICATION ONLY

THESE DATA SUBJECT TO NESTRICTWE LEGEND ON TITLE PAGE OR FIRST PAGE. B2-41 SEE SECTION = FOR THE OETAILEO NO, PROCEDURE AND ILLUSTRATIONIIJ.
M D-90 .,.wo.~.,.~ss .,.,~.~,o.~ ,.s~.oc~,o.s MDC-94K9000

PSE NDI INSPECTION INTERVAL

Repeat Zone(s)

Number DESCRIPTION PROCEDURE Initial

54.40.02 Fitting, Yoke Support Refer to Section 2

.1 Yoke Support Frame Upper Lug 60,000 30,000 412, 422

Prepared by: DESIGN & TECHNOLOGY Revision Date: JAN 1995

McDonnell Douglas Corporation Proprietary Information. Use or disclosure of

THESE DATA SUBJECT TO RESTRICTIVE LEGEND ON TITLE PAGE OR FIRST PAGE, B2-42

NOTE: ALL INTERVALS IN LANDINGS (CYCLES) UNLESS OTHERWISE NOTED

M00PSI~RV
MD-90 AIRWORTHINESS LIMITATIONS INSTRUCTIONS 

THE ILLUSTRATION SHOWN ON THIS PAGE IS SEE SECTION 2 FOR DETAILED NDI PROCED

B2-43 McDonnell Douglas Corporation Proprietary Information. Use or disclosure of THESE DATA SUBJECT TO RESTRICTIVE LEGEND ON TITLE PAGE OR FIRST PAGE.

YOKE SUPPORTFITTING

INBOARDFLANGE

LUG CONSECTION

FORWARD ENGINEMOUNT YOKE

FRONT SPAR

YOKE SUPPORT FITTING

LOOKING AFT

BB

VIEW A-A

A

A

INSPECT UPPER CAPIN SHADED AREAS.LEFT SIDE SHOWN(RIGHT SIDE OPPOSITE)

MD90-54-40-02-01CAG(IGDS)

PSE 54.40.02.1 Yoke Support Frame Upper Lug R
MD-90 AIRWORTHINESS LIMITATIONS INSTRUCTIONS 

McDonnell Douglas Corporation Proprietary Information. Use or disclosure of NOTE: ALL INTERVALS IN LANDINGS (CTHESE DATA SUBJECT TO RESTRICTIVE LEGEND ON TITLE PAGE OR FIRST PAGE. B2-44 

PSE INSPE

Number DESCRIPTION NDI PROCEDURE Initia

54.40.03 

.1 .2 

Links, Pylon Thrust Pylon, Thrust Struts Pylon, Thrust Isolator 

Refer to Section 2 

PTF 

MTF 

15,000 15,000 

Prepared by: DESIGN & TECHNOLOGY Revision 
M D-90 UMITATIONS INSTRUCTIONS MDC-94K9000

,ENGINE

INSPECT UPPER AND LOWER

THRUST STRUTS

IN SHADED AREA.

LEFT SIDE SHOWN

IRIGHT SIDE OPPOSITE)

MDt0-S4-40-0$-01

CAGllGDS|

THRUST STRUTS

FWD

THRUSTISOLATOR

I

PSE 54.40.03.1 [

McC.~-.-~:I Do~hm CmToretl~ Pr~rtotmy hdrm.mJeJ~, Ibm et dh~ltm~

THESE DATA SUBJECT TO RESTRICTIVE LEGEND ON TITLE PAGE OR RRflT PAGL

Pylon, Thrust Struts

B2-45

I Revision Date:JAN 1995

THE ILLUSTRATION SHOWN ON THIS PAGE IS FOR GENERAL IDENTIFICATION ONLY

SEE SECTION | FOR THE DETAJLED NI PROCEDURE AND ILLUSTFU~,TION{s)
THIS PAGE INTENTIONALLY LEFT BLANK

i

McDonnell DOuplN Corporation Proprietary Information. Ule or disclosure of ~

THESE DATA SUBJECT TO RESTRICTIVE LEGEND ON TITLE PAGE OR FIRST PAGE. B2-46 Revision Date: JAN 1995
M D-90 .,.n’..,o.s ,.s..oc.,o.s MDC-94K9000

%

SUPPORT

/"/FITTING

INSPECT THRUST ISOLATOR

IN SHADED AREA.

LEFT SIDE SHOWN

(RIGHT SIDE OPPOSITE)

.,..~.......~THRUSTISOLATOR

M D90-~,-40--03-02

CAGIIGDS|

I

PSE 54.40.03.2 I

McOommn OOBI)llm Coq~flltton Pml~ietmry toformtitk=n. Use or IP _ __tim Of ,.,.,,,.

THESE DATA SUBJECT TO RESTRICTIVE LEGEND ON TITLE PAGE OR FIRST PAGE,

Pylon, Thrust Isolator

B2-47

I Revision Date:JAN tgg5

THE IllUSTRATION SHOWN ON THIS PAGE I,~ FOR GENERAL IDENTIFICATION ONLY

SEE SECTION 2 FOR THE DE’TAILED NDI PROCEDURE AND IllUSTRATION(s)
M D-90

PSE NDI INSPECTION INTERVAL Zone(s)

Number DESCRIPTION PROCEDURE Initial Repeat

54.40.04 Pylon, Aft Isolator Refer to Section 2

.I Pylon, Aft Isolator & Cone Bolt MTF 15,000 15,000 413, 423

NOTE: Accomplishment of the MD-90 ALl inspection procedure 54.40.04.1 at

intervals specified in the document listed below for these components, i an

acceptable means to satisfy the ALl requirements for PSE 54.40.04.1.

Maintenance Review Board Report McDonnell Douglas MD-90

Tasks (71-20-00/01 and 71-20-00/02)

|

Prepared by: DESIGN & TECHNOLOGY Revision Date: OCT 2001

McDonnell Douglas Corporation Proprietary InformaUon. Use or disclosure of

THESE DATA SUBJECT TO RESTRICTIVE LEGEND ON TITLE PAGE OR FIRST PAGE B2-48

NOTE: ALL INTERVALS IN LANDINGS (CYCLES) UNLESS OTHERWISE NOTED
M D-90 .,.WORTH,. ss L,.,T.T,O.S,.ST. CT,O.S MDC-94K9000

AFT CONE BOLT

MD90-54-40-04-01

CAG(IGDS)

LM 442-S16

AFT CONE BOLT

AFT VIBRATION

ISOLATOR

INBD

INSPECT AFT ISOLATOR AND

AFT CONE BOLT

IN SHADED AREA.

LEFT SIDE SHOWN

(RIGHT SIDE OPPOSITE)

LM 442-SA6

PSE 54.40.04.1 I Pylon, Aft Isolator & Cone Bolt I RevisionDate: OCT 2001

McOonn~ Douglas Corpor~on Pmlxletl~ IrffOmllll~l. U~ or disclosure Of THE 111USTRATION SHOY~ ON THIS PAGE IS FOR GENERAL IDENTIFICATION ONLY. B2-49 SEE SECTION 2 FOR THE DETAILED NDI PROCEDURE AND ILLUSTRATION(s). THESE DATA SUBJECT O RESTRICTIVE LEGEND ON Ti’II.IE PAGE OR RRST PAGE
MD-90 AIRWORTHINESS LIMITATIONS INSTRUCTIONS 

McDonnell Douglas Corporation Proprietary Information. Use or disclosure of NOTE: ALL INTERVALS IN LANDINGS (CTHESE DATA SUBJECT TO RESTRICTIVE LEGEND ON TITLE PAGE OR FIRST PAGE. B2-50 

PSE INSPE

Number DESCRIPTION NDI PROCEDURE Initia

55.11.01 

.1 

Horizontal Stabilizer Rear Spar Caps Rear Spar Upper Cap - between STA Xe = 5.000 and Xe = 14.000 

Refer to Section 2 

51,000 

Prepared by: DESIGN & TECHNOLOGY Revision 
MD-90 AIRWORTHINESS LIMITATIONS INSTRUCTIONS 

THE ILLUSTRATION SHOWN ON THIS PAGE IS SEE SECTION 2 FOR DETAILED NDI PROCED

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PSE 55.11.01.1 Rear Spar Upper Cap - between STA Xe = 5.000 and Xe = 14.000 R
MD-90 AIRWORTHINESS LIMITATIONS INSTRUCTIONS 

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PSE INSPE

Number DESCRIPTION NDI PROCEDURE Initia

55.11.02 

.1 

Rear Spar – Center Box Caps, STA Xh 27 Left to Xh 27 Right Rear Spar Upper Cap & Skin from STA Xh 7.234 to Xh 26.859 

Refer to Section 2 

60,000 

Prepared by: DESIGN & TECHNOLOGY Revision 
MD-90 AIRWORTHINESS LIMITATIONS INSTRUCTIONS 

THE ILLUSTRATION SHOWN ON THIS PAGE IS SEE SECTION 2 FOR DETAILED NDI PROCED

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MD90-55-11-02-01CAG(IGDS)

INSPECT UPPER SPARCAP AND SKININ SHADED AREAS.LEFT SIDE SHOWN(RIGHT SIDE OPPOSITE)

HORIZONTAL OUTER CONSTANT SECTION

UPPER SKIN PLANK

REAR SPAR PLANE

STA

Xh=7.234

STA

Xh=26.859

PSE 55.11.02.1 Rear Spar Upper Cap & Skin from STA Xh 7.234 to Xh 26.859 R
MD-90 AIRWORTHINESS LIMITATIONS INSTRUCTIONS 

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PSE INSPE

Number DESCRIPTION NDI PROCEDURE Initia

55.11.03 

.1 

Joints, Center Box, STA Xh 7.0 and Xh 26.0 (Left & Right Sides) Bushed Holes in Horizontal Stabilizer Jack Screw Attach Lug at STA Xh 6.625 

Refer to Section 2 

60,000 

Prepared by: DESIGN & TECHNOLOGY Revision 
MD-90 AIRWORTHINESS LIMITATIONS INSTRUCTIONS 

THE ILLUSTRATION SHOWN ON THIS PAGE IS SEE SECTION 2 FOR DETAILED NDI PROCED

B2-55 McDonnell Douglas Corporation Proprietary Information. Use or disclosure of THESE DATA SUBJECT TO RESTRICTIVE LEGEND ON TITLE PAGE OR FIRST PAGE.

MD90-55-11-03-01CAG(IGDS)

INSPECT FOUR BUSHED HOLESIN SHADED AREAS.LEFT SIDE SHOWN(RIGHT SIDE OPPOSITE)

A

UP

VIEW A

LOOKING INBOAR

FWD

JACKSCREWATTACH LUG

STA

Xh=6.625

PSE 55.11.03.1 Bushed Holes in Horizontal Stabilizer Jack Screw Attach Lug at STA Xh 6.625 R
MD-90 AIRWORTHINESS LIMITATIONS INSTRUCTIONS 

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PSE INSPE

Number DESCRIPTION NDI PROCEDURE Initia

55.13.01 

.1 

Plates/Skin – Upper/Lower, STA Xh 27.2 Left to Xh 27.2 Right Upper Aft Skin Plank with Integral Stringers from Xh 7.234 to Xh 26.859 

Refer to Section 2 

60,000 

Prepared by: DESIGN & TECHNOLOGY Revision 
MD-90 AIRWORTHINESS LIMITATIONS INSTRUCTIONS 

THE ILLUSTRATION SHOWN ON THIS PAGE IS SEE SECTION 2 FOR DETAILED NDI PROCED

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MD90-55-13-01-01CAG(IGDS)

HORIZONTAL OUTER CONSTANT SECTION

REAR SPAR PLANE

STA

Xh=7.234

INSPECT UPPER SKIN PLANKIN SHADED AREAS.LEFT SIDE SHOWN(RIGHT SIDE OPPOSITE)

UPPER SKIN PLANK

STA

Xh=26.859

PSE 55.13.01.1 Upper Aft Skin Plank with Integral Stringers from STA Xh 7.234 to Xh 26.859 R
MD-90 AIRWORTHINESS LIMITATIONS INSTRUCTIONS 

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PSE INSPE

Number DESCRIPTION NDI PROCEDURE Initia

55.53.01 

.1 

Attach Angle, Top Fuselage to Vertical Stabilizer Joint, STA 1458 to 1531 Dorsal Fin Attach Angle & adjoining Fuselage Skin 

Refer to Section 2 

60,000 

Prepared by: DESIGN & TECHNOLOGY Revision 
MD-90 AIRWORTHINESS LIMITATIONS INSTRUCTIONS 

THE ILLUSTRATION SHOWN ON THIS PAGE IS SEE SECTION 2 FOR DETAILED NDI PROCED

B2-59 McDonnell Douglas Corporation Proprietary Information. Use or disclosure of THESE DATA SUBJECT TO RESTRICTIVE LEGEND ON TITLE PAGE OR FIRST PAGE.

PSE 55.53.01.1 Dorsal Fin Attach Angle & adjoining Fuselage Skin R
MD-90 AIRWORTHINESS LIMITATIONS INSTRUCTIONS 

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PSE INSPE

Number DESCRIPTION NDI PROCEDURE Initia

57.11.01 

.1 .2 .3 .4 

Front Spar, STA Xcw 58.6 to Xw 560.8 Lower Front Spar Splice at STA Xcw 94.500, from STA Xcw 79.688 to Xcw 104.500 Lower Front Spar Stringer Runout at STA Xcw 115.000, from STA Xcw 

104.500 to Xcw 121.688 Lower Front Spar Stringer Runout at STA Xrs 115.000, from STA Xrs 91.000 to Xrs 137.750 Lower Front Spar Stringer Runout at STA Xrs 164.000, from STA Xrs 137.750 to Xrs 267.000 

Refer to Section 2 

60,000 60,000 60,000 60,000 

Prepared by: DESIGN & TECHNOLOGY Revision 
MD-90 AIRWORTHINESS LIMITATIONS INSTRUCTIONS 

THE ILLUSTRATION SHOWN ON THIS PAGE IS SEE SECTION 2 FOR DETAILED NDI PROCED

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MD90-57-11-01-01CAG(IGDS)

FWD

OUTBD

FRONTSPAR

REARSPAR

LEFT SIDE SHOWN(RIGHT SIDE OPPOSITE)

IN SHADED AREA

ST

Xcw=7

STA

Xcw=79.6

A

FORWARDSKIN

STRINGER 26

INSPECT FRONT SPAR, SPLICE PLATE,SPLICE ANGLE, STRINGER 26AND LOWER FORWARD SKIN

STA

Xcw=104.500

STA

Xcw=94.500

SPLICEANGLE LOOKING UP

LOWER FORWARD SKIN

VIEW A

FRONTSPAR

PSE 57.11.01.1 Lower Front Spar Splice at STA Xcw 94.500, from STA Xcw 79.688 to Xcw 104.500 R
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MD90-57-11-01-02CAG(IGDS)

VIEW A

STRINGER 

FRONTSPAR

REARSPAR

LEFT SIDE SHOWN(RIGHT SIDE OPPOSITE)

A

LOOKING UP

LOWER FORWARD SKIN

FORWARDSKIN

FRONTSPAR

SPLICEPLATE

SPLICEPLATE

STRINGER 24

STA

Xcw=104.500

STA

Xcw=104.500

STA

Xcw=121.688

INSPECT FRONT SPAR, SPLICE PLATES,STRINGER 24, 25 AND LOWER FORWARD SKIN

IN SHADED AREA.

PSE 57.11.01.2 Lower Front Spar Stringer Runout at STA Xcw 115.000, from STA Xcw 104.500 to Xcw 121.688 R
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MD90-57-11-01-03CAG(IGDS)

FWD

OUTBD

VIEW A

FRONTSPAR

REARSPAR

LEFT SIDE SHOWN(RIGHT SIDE OPPOSITE)

IN SHADED AREA

STA

Xrs=91.00

A

LOOKING UP

LOWER FORWARD SKIN

FORWARDSKIN

FITTING

INSPECT FRONT SPAR, STRINGER 22,FITTING AND LOWER FORWARD SKIN

STA

Xrs=137.750

STA

Xrs=115.000 STA Xrs=137.750

MD90-57-11-01-03CAG(IGDS)

FWD

OUTBD

VIEW A

FRONTSPAR

REARSPAR

LEFT SIDE SHOWN(RIGHT SIDE OPPOSITE)

IN SHADED AREA

STA

Xrs=91.00

A

LOOKING UP

LOWER FORWARD SKIN

FORWARDSKIN

FITTING

INSPECT FRONT SPAR, STRINGER 22,FITTING AND LOWER FORWARD SKIN

STA

Xrs=137.750

STA

Xrs=115.000 STA Xrs=137.750

MD90-57-11-01-03CAG(IGDS)

PSE 57.11.01.3 Lower Front Spar Stringer Runout at STA Xrs 115.000, from STA Xrs 91.000 to Xrs 137.750 R
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MD90-57-11-01-04CAG(IGDS)

FWD

OUTBD VIEW A

FRONTSPAR

REARSPAR

LEFT SIDE SHOWN(RIGHT SIDE OPPOSITE)

A

LOOKING UP

LOWER FORWARD SKIN

FORWARDSKIN

FRONTSPAR

SPLICEFITTING

VOLTILON

STA

Xrs=164.000

STA

Xrs=267.000 STA Xrs=164.000 S

Xrs=1

INSPECT FRONT SPAR, STRINGER 20, 21,SPLICE FITTING AND LOWER FORWARD SKIN

IN SHADED AREA.

MD90-57-11-01-04CAG(IGDS)

FWD

OUTBD VIEW A

FRONTSPAR

REARSPAR

LEFT SIDE SHOWN(RIGHT SIDE OPPOSITE)

A

LOOKING UP

LOWER FORWARD SKIN

FORWARDSKIN

FRONTSPAR

SPLICEFITTING

VOLTILON

STA

Xrs=164.000

STA

Xrs=267.000 STA Xrs=164.000 S

Xrs=1

INSPECT FRONT SPAR, STRINGER 20, 21,SPLICE FITTING AND LOWER FORWARD SKIN

IN SHADED AREA.

MD90-57-11-01-04CAG(IGDS)

PSE 57.11.01.4 Lower Front Spar Stringer Runout at STA Xrs 164.000, from STA Xrs 137.750 to Xrs 267.000 R
MD-90 AIRWORTHINESS LIMITATIONS INSTRUCTIONS 

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PSE INSPE

Number DESCRIPTION NDI PROCEDURE Initia

57.11.02 

.1 .2 

Rear Spar, STA Xcw 121.6 to Xw 560.8 Lower Rear Spar Splice at STA Xrs 111.500, from STA Xrs 85.000 to Xrs 130.000 Lower Rear Spar Outboard from STA Xrs 130.000 to Xrs 180.000 

Refer to Section 2 

60,000 60,000 

Prepared by: DESIGN & TECHNOLOGY Revision 
MD-90 AIRWORTHINESS LIMITATIONS INSTRUCTIONS 

THE ILLUSTRATION SHOWN ON THIS PAGE IS SEE SECTION 2 FOR DETAILED NDI PROCED

B2-69 McDonnell Douglas Corporation Proprietary Information. Use or disclosure of THESE DATA SUBJECT TO RESTRICTIVE LEGEND ON TITLE PAGE OR FIRST PAGE.

MD90-57-11-02-01CAG(IGDS)

FWD

OUTBD

VIEW A

FRONTSPAR

REARSPAR

A

LOOKING UP

LOWER AFT SKIN

LEFT SIDE SHOWN(RIGHT SIDE OPPOSITE)

IN SHADED AREA

SPLICEPLATE

STA

Xrs=85.00

STA

Xrs=111.500

STA

Xrs=130.000

STA

Xrs=111.500

INSPECT REAR SPAR, SPLICE

PLATE AND LOWER AFT SKIN

PSE 57.11.02.1 Lower Rear Spar Splice at STA Xrs 111.500, from STA Xrs 85.000 to Xrs 130.000 R
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MD90-57-11-02-02CAG(IGDS)

FWD

OUTBD

VIEW A

FRONTSPAR

REARSPAR

LOOKING UP

LOWER AFT SKIN

LEFT SIDE SHOWN(RIGHT SIDE OPPOSITE)

IN SHADED AREA

A

VORTILON

STA

Xrs=164.000

STA

Xrs=130.000

STA

Xrs=164.000

STA

Xrs=180.000

INSPECT REAR SPARAND LOWER AFT SKIN

PSE 57.11.02.2 Lower Rear Spar Outboard from STA Xrs 130.000 to Xrs 180.000 R
MD-90 AIRWORTHINESS LIMITATIONS INSTRUCTIONS 

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PSE INSPE

Number DESCRIPTION NDI PROCEDURE Initia

57.12.02 

.1 .2 

Rear Spar, STA Xcw 58.6 Left to Xcw 58.6 Right Lower Rear Spar Splice from STA Xcw 8.000 to Xcw 24.000 Lower Rear Spar Inboard from STA Xcw 24.000 to Xcw 60.000 

Refer to Section 2 

60,000 60,000 

Prepared by: DESIGN & TECHNOLOGY Revision 
MD-90 AIRWORTHINESS LIMITATIONS INSTRUCTIONS 

THE ILLUSTRATION SHOWN ON THIS PAGE IS SEE SECTION 2 FOR DETAILED NDI PROCED

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MD90-57-12-02-01CAG(IGDS)

VIEW A

REARSPAR

SPLICEPLATE

STRINGER 11

AFTSKIN

FRONTSPAR

REARSPAR

STA

Xcw=0.0

LOOKING UP

LOWER AFT SKIN

LEFT SIDE SHOWN(RIGHT SIDE OPPOSITE)

IN SHADED AREA

Xcw

STA

Xcw=8.000

STA

Xcw=24.000

INSPECT REAR SPAR, SPLICEPLATE AND LOWER AFT SKIN

PSE 57.12.02.1 Lower Rear Spar Splice from STA Xcw 8.000 to Xcw 24.000 R
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MD90-57-12-02-02CAG(IGDS)

VIEW A

REARSPAR

STRINGER 11

AFTSKIN

FRONTSPAR

REARSPAR

A

LOOKING UP

LOWER AFT SKIN

LEFT SIDE SHOWN(RIGHT SIDE OPPOSITE)

IN SHADED AREA

STA

Xcw=42.0

STA

Xcw=24.000

STA

Xcw=42.000

STA

Xcw=60.000

INSPECT REAR SPARAND LOWER AFT SKIN

PSE 57.12.02.2 Lower Rear Spar Inboard from STA Xcw 24.000 to Xcw 60.000 R
MD-90 AIRWORTHINESS LIMITATIONS INSTRUCTIONS 

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PSE INSPE

Number DESCRIPTION NDI PROCEDURE Initia

57.12.03 

.1 

Rear Spar, STA Xcw 58.6 to Xcw 121.6 (Left & Right Sides) Lower Rear Spar Splice from STA Xcw 60.000 to Xcw 100.000 

Refer to Section 2 

60,000 

Prepared by: DESIGN & TECHNOLOGY Revision 
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THE ILLUSTRATION SHOWN ON THIS PAGE IS SEE SECTION 2 FOR DETAILED NDI PROCED

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MD90-57-12-03-01CAG(IGDS)

VIEW A

REARSPAR

STRINGER 11

AFTSKIN

FRONTSPAR

REARSPAR

A

LOOKING UP

LOWER AFT SKIN

LEFT SIDE SHOWN(RIGHT SIDE OPPOSITE)

IN SHADED AREA

STA

Xcw=79.688

STA

Xcw=79.688

SPLICEPLATE

STA

Xcw=100.000

STA

Xcw=60.000

INSPECT REAR SPAR, SPLICEPLATE AND LOWER AFT SKIN

PSE 57.12.03.1 Lower Rear Spar Splice from STA Xcw 60.000 to Xcw 100.000 R
MD-90 AIRWORTHINESS LIMITATIONS INSTRUCTIONS 

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PSE INSPE

Number DESCRIPTION NDI PROCEDURE Initia

57.32.01 

.1 

Panels, Lower Wing, STA Xcw 58.6 to Xcw 560.8 Center Wing Skin Splice at Stringer 17 from STA Xrs 121.688 to Xrs 214.000 

Refer to Section 2 

60,000 

Prepared by: DESIGN & TECHNOLOGY Revision 
MD-90 AIRWORTHINESS LIMITATIONS INSTRUCTIONS 

THE ILLUSTRATION SHOWN ON THIS PAGE IS SEE SECTION 2 FOR DETAILED NDI PROCED

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MD90-57-32-01-01CAG(IGDS)

VIEW A

STRINGER 17

STRINGER 17

FRONTSPAR

REARSPAR

A

LEFT SIDE SHOWN(RIGHT SIDE OPPOSITE)

LOOKING UP

CENTER WING SPLICE

FORWARDSKIN

AFTSKIN

VORTILON

STRINGER 18

STRINGER 16

STA

Xrs=214.000 STA

Xrs=111.500

Xr

STA

Xrs=121.688

STA

Xrs=164.000

STA

Xrs=214.000

INSPECT STRINGER 17,FORWARD AND AFT SKIN

IN SHADED AREA.

PSE 57.32.01.1 Center Wing Skin Splice at Stringer 17 from STA Xrs 121.688 to Xrs 214.000 R
MD-90 AIRWORTHINESS LIMITATIONS INSTRUCTIONS 

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PSE INSPE

Number DESCRIPTION NDI PROCEDURE Initia

57.32.02 

.1 

Cutouts, Lower Wing Door, STA Xcw 58.6 to Xcw 560.8 Lower Surface Access Door Cutouts between STA Xrs 189.000 to Xrs 324.000 

Refer to Section 2 

60,000 

Prepared by: DESIGN & TECHNOLOGY Revision 
MD-90 AIRWORTHINESS LIMITATIONS INSTRUCTIONS 

THE ILLUSTRATION SHOWN ON THIS PAGE IS SEE SECTION 2 FOR DETAILED NDI PROCED

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MD90-57-32-02-01CAG(IGDS)

FWD

OUTBD

VIEW A

FRONTSPAR

REARSPAR

LEFT SIDE SHOWN(RIGHT SIDE OPPOSITE)

A

STA

Xrs=189.00

AFTSKIN

STA

Xrs=324.000

X

STA

Xrs=324.000

IN SHADED AREA.

ACCESS DOORCUTOUT

INSPECT ACCESS DOOR CUTOUT,STRINGER 12, 15 AND LOWER AFT SKIN

LOOKING UP

LOWER AFT SKIN

PSE 57.32.02.1 Lower Surface Access Door Cutouts STA Xrs 189.000 to Xrs 324.000 R
MD-90 AIRWORTHINESS LIMITATIONS INSTRUCTIONS 

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PSE INSPE

Number DESCRIPTION NDI PROCEDURE Initia

57.34.01 

.1 .2 .3 

Panel, Lower Wing Skin, STA Xcw 58.6 Left to Xcw 58.6 Right Center Wing Skin Splice at Stringer 17 from STA Xcw 20.000 to Xcw 121.688 Stringer 14, 15, 16 & Skin from STA Xcw 42.000 to Xcw 79.688 Stringer 18, 19, 20 & Skin from STA Xcw 42.000 to Xcw 79.688 

Refer to Section 2 

60,000 60,000 60,000 

Prepared by: DESIGN & TECHNOLOGY Revision 
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THE ILLUSTRATION SHOWN ON THIS PAGE IS SEE SECTION 2 FOR DETAILED NDI PROCED

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MD90-57-34-01-01CAG(IGDS)

FWD

VIEW A OUTBD

FRONTSPAR

REARSPAR

LEFT SIDE SHOWN(RIGHT SIDE OPPOSITE)

IN SHADED AREA

STA

Xcw=20

A

LOOKING UP

CENTER WING SPLICE

INSPECT STRINGER 17,LOWER FORWARD AND AFT SKIN

AFTSKIN

FORWARDSKIN

STA

Xcw=20.000 

X

STA

Xcw=121.688

STA

Xcw=121.688

PSE 57.34.01.1 Center Wing Skin Splice at Stringer 17 from STA Xcw 20.000 to Xcw 121.688 R
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MD90-57-34-01-02CAG(IGDS)

FWD

OUTBD

VIEW A

FRONTSPAR

REARSPAR

LEFT SIDE SHOWN(RIGHT SIDE OPPOSITE)

STA

Xcw=58.688

A

STRINGER 

STRINGER 

LOOKING UP

LOWER AFT SKIN

AFTSKIN

STA

Xcw=79.688

STRINGER 

STA

Xcw=58.688

STA

Xcw=42.000

INSPECT STRINGER 14, 15, 16AND LOWER AFT SKIN

IN SHADED AREA.

PSE 57.34.01.2 Stringer 14, 15, 16 & Skin from STA Xcw 42.000 to Xcw 79.688 R
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MD90-57-34-01-03CAG(IGDS)

FWD

OUTBD

VIEW A

FRONTSPAR

REARSPAR

LEFT SIDE SHOWN(RIGHT SIDE OPPOSITE)

STA

Xcw=58.688

A

STRINGER 

STRINGER 

STA

Xcw=79.688

STRINGER 

STA

Xcw=58.688

STA

Xcw=42.000

LOOKING UP

LOWER FORWARD SKIN

FORWARDSKIN

INSPECT STRINGER 18, 19, 20AND LOWER FORWARD SKIN

IN SHADED AREA.

PSE 57.34.01.3 Stringer 18, 19, 20 & Skin from STA Xcw 42.000 to Xcw 79.688 R
REPORTING OF

INSPECTION RESULTS
MD-90 MDC-94Kg000

AIRWORTHINESS LIMITATIONS INSTRUCTIONS (ALl)

PSE REPORTING PROCEDURES

ReDortincj of Inspection Results

Whenever a PSE enters the inspection program phase, the form on page C1-2 shall be

for providing further details when an inspection results in a crack finding.

Results of findings must be reported to Boeing Commercial Airplane Group at the

following address;

Mail to: Senior Manager

Stress and Aging Airplanes

Technical and Fleet Support

Service Engineering

The Boeing Company

Boeing Commercial Airplane Group

Dept. L37 M/C D800-0037

P.O. Box 1771

Long Beach, California 90801-1771

McOonnell ~ Coqxxation Pro~rieta~ Information. Use of dsc~os~e of

THESE DATA SUBJECT TO RESTRICTIVE LEGEND ON TITLE PAGE OR FIRST PAGE C 1-1 Revision Date: OCT 2001
MD-90 PSE CRACK FINDINGS DETAIL FORM

Operator:. Reporting Date:

PSE SIDE SERIAL FUSELAGE DATE OF FLIGHT CYCLES/ TYPE OF

NUMBER LH / RH NUMBER NUMBER INSPECTION HOURS LANDINGS INSPECTION

COMMENTS I ILLUSTRATIONS:

THIS PAGE MAY BE REPRODUCED C1-2
MD-90

AIRWORTHINESS LIMITATIONS INSTRUCTIONS (ALl)

NDI TECHNIQUES AND PROCEDURES

MDC-94K9000

This section contains the MD-90 Principal Structural Element (PSE) Non-Destructive

Inspection (NDI) techniques, tests and procedures.

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THESE DATA SUBJECT TO RESTRICTIVE LEGEND ON TITLE PAGE OR FIRST PAGE. P2-1

Revision Date: Original
 MD-90 MDC-94K9000

AIRWORTHINESS LIMITATIONS INSTRUCTIONS (ALI) 

SECTION 2 

TABLE OF CONTENTS

TC-2 Revision Date: September 2011

Title: 

Chapter 

Sub-Chapter 

Sequence 

No. 

Task No.: 

Reference RF-1 

 

CHAPTER 20 – STANDARD PRACTICES – AIRFRAME 20.00.00 

CHAPTER 53 – FUSELAGE 

 

 Floor Beam to Frame Intersection, Overwing, STA’s 924 – 1041 

 Fuselage Skin and Frames from Longeron 16 to Longeron 

19, at all Frames in area above Wing and MLG Wheel Well 53.12.09.1 

 

 CHAPTER 54 – NACELLES 

 Thrust Bulkhead, Pylon – STA Yn 170.5

 Rear Spar and Engine Thrust Support Fitting (Upper & Lower) 54.10.04.1 

 Yoke – Forward Engine Mount, Pylon STA 1364 

 Pylon, Forward Upper & Lower Isolators and Cone Bolts 54.40.01.2 

Links, Pylon Thrust

 Pylon, Thrust Struts 54.40.03.1 

 Pylon, thrust Isolator 54.40.03.2 

Pylon, Aft Isolator 

 Pylon, Aft Isolator & Cone Bolt 54.40.04.1 

 

 CHAPTER 55 – STABILIZERS 

 

 Horizontal Stabilizer Rear Spar Caps 

 Rear Spar Upper Cap - between STA Xe = 5.000 and 

Xe = 14.000 

55.11.01.1 
 MD-90 MDC-94K9000

AIRWORTHINESS LIMITATIONS INSTRUCTIONS (ALI) 

SECTION 2 

TABLE OF CONTENTS

 TC-3 Revision Date: September 2011

Title: Chapter 

Sub-Chapter 

SECTION 2 SUPPLEMENT 

TABLE OF CONTENTS ................................................................................................ TC-4 

 EQUIPMENT UTILIZATION 2-0 

 REFERENCE STANDARDS 2-1 

 HIGH FREQUENCY EDDY CURRENT PROBES 2-2 

 LOW FREQUENCY EDDY CURRENT PROBES 2-3 

 INSPECTION FIXTURES 2-4 

 ULTRASONIC TRANSDUCERS 2-5 
MD-90 MDC-94K9000

AIRWORTHINESS LIMITATIONS INSTRUCTIONS (ALl)

SECTION 2

REFERENCES

=

.

Douglas Publication Entitled

"Nondestructive Testing Standard Practice Manual" (NDTSPM)

Document No. MDC 93K0393

Douglas Publication Entitled

"MD-90 Aircraft Maintenance Manual" (AMM)

3, IAE/Goodrich Publication Entitled

" IAE Component Maintenance Manual" (CMM)

for V2500/MD90 PYLON APRON ASSEMBLY

4. Lord Publication Entitled

"Component Maintenance Manual" (CMM)

RF-1 Revision Date: OCT 2001
MD-90 MDC-94K9000

AIRWORTHINESS LIMITATIONS INSTRUCTIONS (ALl)

SECTION 2

STANDARD PRACTICES - AIRFRAME

° General

A. The Nondestructive Testing information previously documented in Chapter 20 has

been updated and portions are now located in the Douglas Aircraft Company (DAC)

Nondestructive Testing Standard Practice Manual (NDTSPM). Although the first

release of the NDTSPM is in support of the Section 2 NDI Procedure requirements

found within this document, the NDTSPM contains general NDT information and

procedures applicable to all DAC aircraft.

B. Please refer to the NDTSPM as noted below for the following subjects:

Introduction

Part 01 General Information

Part 02 X-Ray

Part 03 Gamma-Ray

Part 04 Ultrasonic

Part 05 Sonic/Resonance

Part 06 Eddy Current

Part 07 Magnetic Particle

Part 08 Penetrant

Part 09 Visual/Optical

Part 10 Physical/Mechanical

Part 11 Chemical

Part 12 Leak Testing

Part 13 Thermal

Part 14 Laser or Light Energy

(Proposed)

(Proposed)

(Proposed)

(Proposed)

(Proposed)

Nondestructive Testing Methods - General

McDonnell Douglas Corporation Proprietary Information. Use or disclosure of

THESE DATA SUBJECT TO RESTRICTIVE LEGEND ON TITLE OR FIRST PAGE.

20-00-00

Page 1

OCT 2001
NDI TECHNIQUES

AND PROCEDURES
 MD-90 MDC-94K9000 

AIRWORTHINESS LIMITATIONS INSTRUCTIONS (ALI) 

 SECTION 2 

 NDI PROCEDURES

53.12.09.1 

McDonnell Douglas Corporation Proprietary Information. Use or disclosure of Page 1

THESE SUBJECT TO RESTRICTIVE LEGEND ON TITLE PAGE OR FIRST PAGE. September 2011

Title: Floor Beam to Frame Intersection, Overwing, STA’s 924 – 1041, 

Fuselage Skin and Frames from Longeron 16 to Longeron 19, at all 

Frames in area above Wing and MLG Wheel Well 

Inspection Item: PSE 53.12.09.1 

Model Affected: MD-90 

Ships Affected: All 

Service Bulletin: MD90-53A031 

Drawing Reference: 9936483, 9936482, 9923410, 9923411, 9923412, 9923413, 9923414, 

9936508, 9923435, 9919649 

Requirement: TO COMPLETE THE REQUIREMENTS OF THIS PSE, THE PRIMARY 

INSPECTION (01), OF EACH INSPECTION SEQUENCE, OR ITS 

ALTERNATE SUBSTITUTE(S) MUST BE ACCOMPLISHED. 

NOTES: (1) ALTERNATE INSPECTIONS WILL BE IDENTIFIED BY 

NUMERALS OTHER THAN 01. 

 (2) MULTIPLE ALTERNATE INSPECTIONS WHICH MUST 

BE PERFORMED TO ADEQUATELY REPLACE A PRIMARY 

INSPECTION WILL BE IDENTIFIED BY AN ALPHA 

CHARACTER FOLLOWING THE ALTERNATE 

DESIGNATOR, i.e., 02a and 02b, ETC. 

Inspection Sequence 1: (Outer Fuselage Skin) 

 01. Eddy Current, High Frequency 

Inspection Sequence 2: (Inner Fuselage Skin) 

 01. Eddy Current, High Frequency 

Inspection Sequence 3: (Frame Outer Flange) 

 01. Eddy Current, High Frequency 

Inspection Sequence 4: (Frame Inner Flange) 

01. Eddy Current, High Frequency 
 MD-90 MDC-94K9000 

AIRWORTHINESS LIMITATIONS INSTRUCTIONS (ALI) 

 SECTION 2 

 NDI PROCEDURES

53.12.09.1 

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Description: 

Inspection Sequence 1 is a high frequency eddy current inspection of the fuselage skin at the 

fastener holes common to the frame. Inspect the skin from Longerons 16 to 19 at each of the 

ten frame locations where accessible. The purpose of these inspections is to detect fatigue 

cracks initiating at the fastener holes as shown on Figures 1, 2, and 3. The fatigue cracks will 

emanate in the forward and aft directions. Both sides of the fastener holes will be inspected. 

Inspection Sequence 2 is a high frequency eddy current inspection of the fuselage skin from 

inside the cabin adjacent to the frames. Inspect the skin from Longerons 16 to 19 at each of the 

ten frame locations where accessible. The purpose of these inspections is to detect fatigue 

cracks initiating from beneath the frame and propagating beyond the frames. The fatigue 

cracks will emanate in the forward and aft directions. Both forward and aft sides of the frames 

will be inspected. See Figures 4 and 5. 

Inspection Sequence 3 is a high frequency eddy current inspection of the frames at the 

outboard flange inboard face around the fasteners common with the fuselage skin. Inspect the 

frame from Longerons 16 to 19 at each of the ten frame locations where accessible. The 

purpose of these inspections is to detect fatigue cracks initiating at the fastener holes as shown 

on Figure 4 and 5. The fatigue cracks will emanate in the forward and aft directions. 

Inspection Sequence 4 is a high frequency eddy current inspection of the frames at the inboard 

flange, inboard face at the leading and trailing edges of the “I beam” type configuration frames 

or the open side of the “C” channel type frames. Inspect the frame from Longerons 16 to 19 at 

each of the ten frame locations where accessible. The purpose of these inspections is to detect 

fatigue cracks initiating at the edge of the flange as shown on Figure 4 and 5. The fatigue 

cracks will emanate in the forward and aft directions. 
 MD-90 MDC-94K9000 

AIRWORTHINESS LIMITATIONS INSTRUCTIONS (ALI) 

 SECTION 2 

 NDI PROCEDURES

53.12.09.1 

McDonnell Douglas Corporation Proprietary Information. Use or disclosure of Page 3

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Access:

FOLLOW APPLICABLE SAFETY INSTRUCTIONS AND PRECAUTIONS PER THE 

NONDESTRUCTIVE TESTING STANDARD PRACTICE MANUAL (NDTSPM) PART 

01-00-01 AS WELL AS ALL LOCAL AND COMPANY REQUIREMENTS. 

A. Major Zone 100, Submajor Zone 150, remove panels 150CL, 150FL, 150ML, and 150RL. 

B. Major Zone 100, Submajor Zone 160, remove panels 160CR, 160FR, 160MR, and 160RR. 

C. Remove seats, wall paneling, insulation, and floor panels per Chapter 25 of the MD-90 

Maintenance Manual between fuselage stations Y=883.000 to Y=1060.000. 

D. For access to aft side of Sta. 1060.000 frame below Longeron 18 on aft side, remove wall 

paneling, ceiling panels, and insulation per Chapter 25 of the MD-90 Maintenance Manual 

at fuselage station Y=1060.000 in the cargo bay area. 

Preparation for Inspection: 

A. Remove all dirt, grease, and loose paint from the inspection area. 

B. Thoroughly clean the inspection area with an approved cleaning agent. 

General Visual Inspection: 

A. Perform a preliminary check of the general PSE area for cleanliness, presence of foreign 

objects, distortion, damage, cracks, corrosion, security of parts and evidence of loose 

attachments. 

B. After completion of general area check, perform the specific PSE inspection(s) to 

complete the requirement. 

NOTE: The presence of repairs and/or modifications in the inspection area may affect 

the inspectability of this PSE. Inspect non-discrepant areas of the PSE and report details 

of the discrepancy with inspection results to BCA-LBD. 

C. If additional information regarding visual inspection is desired, See Part 09 of the 

NDTSPM. 
 MD-90 MDC-94K9000 

AIRWORTHINESS LIMITATIONS INSTRUCTIONS (ALI) 

 SECTION 2 

 NDI PROCEDURES

53.12.09.1 

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Inspection Procedure: 

A. Inspection Sequence 1: 

1. Inspection Method 01 (Eddy Current, High Frequency) 

a. Utilizing the information supplied in Figures 1, 2, and 3, perform a surface eddy 

current inspection of the fuselage skin at the fastener holes common to the 

frame. Inspect the skin from Longerons 16 to 19 at each of the ten frame 

locations where accessible. The purpose of these inspections is to detect 

fatigue cracks initiating at the fastener holes and propagating in the forward and 

aft directions. Scan around the fasteners following the instructions found in the 

NDTSPM 06-10-01.001 (HFET - Procedure 1). Use Calibration Method “P” and 

Scan Method “47”. 

B. Inspection Sequence 2: 

1. Inspection Method 01 (Eddy Current, High Frequency) 

a. Utilizing the information supplied in Figures 1, 4, and 5, perform a surface eddy 

current inspection of the fuselage skin from inside the cabin adjacent to the 

frames. Inspect the skin from Longerons 16 to 19 at each of the ten frame 

locations where accessible. The purpose of these inspections is to detect 

fatigue cracks initiating from beneath the frame and propagating in the forward 

and aft directions. Scan the forward and aft sides of the inner skin adjacent to 

the frame following the instructions found in the NDTSPM 06-10-01.001 (HFET - 

Procedure 1). Use Calibration Method “R” and Scan Method “63”. 

C. Inspection Sequence 3: 

1. Inspection Method 01 (Eddy Current, High Frequency) 

a. Utilizing the information supplied in Figures 1, 4, and 5, perform a surface eddy 

current inspection of the frames at the outboard flange inboard face around the 

fasteners common with the fuselage skin. Inspect the frame from Longerons 16 

to 19 at each of the ten frame locations where accessible. The purpose of these 

inspections is to detect fatigue cracks initiating at the fastener holes and 

propagating in the forward and aft directions Scan around the fasteners 

following the instructions found in the NDTSPM 06-10-01.001 (HFET - 

Procedure 1). Use Calibration Method “K” and Scan Method “44”. 
 MD-90 MDC-94K9000 

AIRWORTHINESS LIMITATIONS INSTRUCTIONS (ALI) 

 SECTION 2 

 NDI PROCEDURES

53.12.09.1 

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D. Inspection Sequence 4: 

1. Inspection Method 01 (Eddy Current, High Frequency) 

a. Utilizing the information supplied in Figures 1, 4, and 5, perform a surface eddy 

current inspection of the frames at the inboard flange, inboard face at the 

leading and trailing edges of the “I beam” type configuration frames or the open 

side of the “C” channel type frames. Inspect the frame from Longerons 16 to 19 

at each of the ten frame locations where accessible. The purpose of these 

inspections is to detect fatigue cracks initiating at the edge of the flange and 

propagating in the forward and aft directions. Perform a surface eddy current 

inspection of the frame following the instructions found in the NDTSPM 06-10-

01.001 (HFET - Procedure 1). Use Calibration Method “A” and Scan Method 

“79”. 

Inspection Results: 

A. Any indication is considered a crack which exhibits the same relative phase angle and an 

amplitude of 50 percent or greater than the indication obtained from the calibration notch 

in the reference standard. 

B. Report all inspection results, Positive, Negative, or Discrepant. 

 1. Positive - Cracks found 

 2. Negative - Cracks not found 

 3. Discrepant - PSE inspection could not be completed or performed due to obstruction 

or other physical anomalies. 
 MD-90 MDC-94K9000 

AIRWORTHINESS LIMITATIONS INSTRUCTIONS (ALI) 

 SECTION 2 

 NDI PROCEDURES

53.12.09.1 

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Post Inspection Procedure: 

A. Remove and secure all test equipment and materials from the area. 

B. Install seats, wall paneling, insulation, and floor panels per Chapter 25 of the MD-90 

Maintenance Manual between fuselage stations Y=883.000 to Y=1060.000. 

C. Major Zone 100, Submajor Zone 150, install panels 150CL, 150FL, 150ML, and 150RL. 

D. Major Zone 100, Submajor Zone 160, install panels 160CR, 160FR, 160MR, and 160RR. 

E. Install wall paneling, ceiling panels, and insulation per Chapter 25 of the MD-90 

Maintenance Manual at fuselage station Y=1060.000 in the cargo bay area. 
 MD-90 MDC-94K9000 

AIRWORTHINESS LIMITATIONS INSTRUCTIONS (ALI) 

 SECTION 2 

 NDI PROCEDURES

53.12.09.1 

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 SECTION 2 

 NDI PROCEDURES

53.12.09.1 

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AIRWORTHINESS LIMITATIONS INSTRUCTIONS (ALI) 

 SECTION 2 

 NDI PROCEDURES

53.12.09.1 

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AIRWORTHINESS LIMITATIONS INSTRUCTIONS (ALI) 

 SECTION 2 

 NDI PROCEDURES

53.12.09.1 

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 SECTION 2 

 NDI PROCEDURES

53.12.09.1 

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MD-90 MDC-94K9000

AIRWORTHINESS LIMITATIONS INSTRUCTIONS (ALl)

SECTION 2

NDI PROCEDURES

Title: Rear Spar and Engine Thrust Support Fitting (Upper and Lower)

Inspection Item: PSE 54.10.04.1

Model Affected: MD-90

Ships Affected: 2094, 2095, 2096, 2097, 2098, 2099, 2100, 2115, 2117, 2120, 2122, 2123

Service Bulletin: MD-90-54-001

Drawing Reference: 5965128, 5965673

Requirement: TO COMPLETE THE REQUIREMENTS OF THIS PSE, THE PRIMARY

INSPECTION (01), OF EACH INSPECTION SEQUENCE, OR ITS

ALTERNATE SUBSTITUTE(S) MUST BE ACCOMPLISHED.

NOTES: (1) ALTERNATE INSPECTIONS WILL BE IDENTIFIED 

NUMERALS OTHER THAN 01.

(2) MULTIPLE ALTERNATE INSPECTIONS WHICH MUST

BE PERFORMED TO ADEQUATELY REPLACE A PRIMARY

INSPECTION WILL BE IDENTIFIED BY AN ALPHA

CHARACTER FOLLOWING THE ALTERNATE

DESIGNATOR, i.e., 02a and 02b, ETC.

Inspection Sequence 1: (Upper and Lower Thrust Plates)

01. Eddy Current, High Frequency

Inspection Sequence 2: (Rear Spar and Thrust Support Fitting Caps)

01. Eddy Current, High Frequency

Inspection Sequence 3: (Radius of Thrust Plates)

01. Eddy Current, High Frequency

Inspection Sequence 4: (Rear Spar and Thrust Support Fitting Web)

01. Eddy Current, High Frequency

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AIRWORTHINESS LIMITATIONS INSTRUCTIONS (ALI) 

 SECTION 2 

 NDI PROCEDURES

54.10.04.1 

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Inspection Sequence 5: (Thrust Plates at Heat Shield Mount Plates) 

 01. Eddy Current, High Frequency 

Description: 

Inspection Sequence 1 is a high frequency eddy current inspection of the upper and lower thrust 

plates at the fastener holes common to the rear spar and thrust support fitting upper and lower 

caps. This sequence also inspects the thrust plates at fastener holes common to the –5 angle 

on the upper side and the –7 angle on the lower side. The purpose of these inspections is to 

detect fatigue cracks initiating at the fastener holes as shown on Figures 2, 3, and 4. The 

fatigue cracks will emanate in the forward and aft directions. Both sides of the fastener holes 

will be inspected. See Figures 2, 3, and 4. 

Inspection Sequence 2 is a high frequency eddy current inspection of the rear spar and thrust 

support fitting upper and lower caps at the fastener holes common to the upper and lower thrust 

plates. The purpose of these inspections is to detect fatigue cracks initiating at the fastener 

holes as shown on Figures 2 and 3. The fatigue cracks will emanate in the forward and aft 

directions. Both sides of the fastener holes will be inspected. See Figures 2 and 3. 

Inspection Sequence 3 is a high frequency eddy current inspection of the upper and lower thrust 

plates at the radius of the angle on the forward and aft sides (top side) of the upper plate and 

similarly for the bottom side of the lower plate. The purpose of these inspections is to detect 

fatigue cracks initiating at the forward and aft edges of the plates as shown on Figure 4 and 5. 

The fatigue cracks will emanate in the forward and aft directions. See Figures 4 and 5. 

Inspection Sequence 4 is a high frequency eddy current inspection of the rear spar web and the 

thrust support fitting web adjacent to the upper and lower thrust plates at Zn=6.000 and 

 Zn= -6.000. The purpose of these inspections is to detect fatigue cracks initiating at the top or 

bottom of the rear spar web and the thrust support fitting web adjacent to the thrust plates as 

shown on Figure 6. The fatigue cracks will emanate in the up or down direction. See Figure 6. 

Inspection Sequence 5 is a high frequency eddy current inspection of the upper and lower thrust 

plates around and adjacent to the heat shield mount plates. The purpose of these inspections 

is to detect fatigue cracks initiating at the fastener holes in common with the thrust plates and 

the heat shield mount plates. The fatigue cracks will emanate in the forward and aft directions. 

See Figures 2 and 3. 
MD-90 MDC-94K9000

AIRWORTHINESS UMITATIONS INSTRUCTIONS (AU)

SECTION 2

NDI pROCEDURES

Access:

FOLLOW APPLICABLE SAFETY INSTRUCTIONS AND PRECAUTIONS PER THE

NONDESTRUCTIVE TESTING STANDARD PRACTICE MANUAL (NDTSPM) PART

01-00-01 AS WELL AS ALL LOCAL AND COMPANY REQUIREMENTS.

A. Remove engine nacelles.

Preparation for Inspection:

A. Remove all dirt, grease, and loose paint from the inspection area.

B. Thoroughly clean the inspection area with an approved cleaning agent.

General Visual Inspection:

A. Perform a preliminary check of the general PSE area for cleanliness, presence of foreign

objects, distortion, damage, cracks, corrosion, security of parts and evidence of loose

attachments.

B. After completion of general area check, perform the specific PSE inspection(s) 

complete the requirement.

NOTE: The presence of repairs and/or modifications in the inspection area may affect

the inspectability of this PSE. Inspect non-discrepant areas of the PSE and report details

of the discrepancy with inspection results to BCA-LBD.

C. If additional information regarding visual inspection is desired, See Part 09 of the

NDTSPM.

Inspection Procedure:

A. Inspection Sequence 1:

I. Inspection Method 01 (Eddy Current, High Frequency)

ao Utilizing the information supplied in Figures 2, 3, and 4, perform a surface eddy

current inspection of the upper and lower thrust plates from outside the torque

box. Scan the forward and aft sides of the fasteners following the instructions

found in the NDTSPM 06-10-01.001 (HFET - Procedure 1). Use Calibration

Method =L~ and Scan Method =42".

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54.10.04.1

Page 3

October 2001
 MD-90 MDC-94K9000 

AIRWORTHINESS LIMITATIONS INSTRUCTIONS (ALI) 

 SECTION 2 

 NDI PROCEDURES

54.10.04.1 

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B. Inspection Sequence 2: 

1. Inspection Method 01 (Eddy Current, High Frequency) 

a. Utilizing the information supplied in Figures 2 and 3, perform a surface eddy 

current inspection of the rear spar cap and thrust support fitting from inside the 

torque box. Scan around the forward and aft sides of the fasteners. Scan the 

fastener hole areas following the instructions found in the NDTSPM 06-10-

01.001 (HFET - Procedure 1). Use Calibration Method “L” and Scan Method 

“41”. 

C. Inspection Sequence 3: 

1. Inspection Method 01 (Eddy Current, High Frequency) 

a. Utilizing the information supplied in Figures 4 and 5, perform a surface eddy 

current inspection of the upper and lower thrust plates from outside the torque 

box. Scan the forward and aft sides of the thrust plates at the radii of the angle 

following the instructions found in the NDTSPM 06-10-01.001 (HFET - 

Procedure 1). Use Calibration Method “G” and Scan Method “69”. 

D. Inspection Sequence 4: 

1. Inspection Method 01 (Eddy Current, High Frequency) 

a. Utilizing the information supplied in Figure 6, perform a surface eddy current 

inspection of the forward side of the rear spar adjacent to the upper thrust plate 

on the upper side and adjacent to the lower thrust plate on the lower side. 

Perform a surface eddy current inspection of the aft side of the thrust support 

fitting adjacent to the upper thrust plate on the upper side and adjacent to the 

lower thrust plate on the lower side. Scan following the instructions found in the 

NDTSPM 06-10-01.001 (HFET - Procedure 1). Use Calibration Method “R” and 

Scan Method “63”. 
MD-90 MDC-94K9000

AIRWORTHINESS LIMITATIONS INSTRUCTIONS (ALl)

SECTION 2

NDI PROCEDURES

E. Inspection Sequence 5:

1. Inspection Method 01 (Eddy Current, High Frequency)

ao Utilizing the information supplied in Figures 2 and 3, perform a surface eddy

current inspection of the upper and lower thrust plates adjacent to the upper and

lower heat shield mount plates. Scan the thrust plates on the forward, aft, and

inboard sides of the heat shield mount plates as shown. Scan following the

instructions found in the NDTSPM 06-10-01.001 (HFET - Procedure 1). Use

Calibration Method "R" and Scan Method =45".

Inspection Results:

Ao Any indication is considered a crack which exhibits the same relative phase angle and an

amplitude of 50 percent or greater than the indication obtained from the calibration notch

in the reference standard.

B. Report all inspection results, Positive, Negative, or Discrepant.

1. Positive - Cracks found

2. Negative - Cracks not found

3. Discrepant - PSE inspection could not be completed or performed due to obstruction

or other physical anomalies.

Post Inspection Procedure:

A. Remove and secure all test equipment and materials from the area.

B. Install engine nacelles as required.

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54.10.04.1

Page 5

October 2001
MD-90

AIRWORTHINESS LIMITATIONS INSTRUCTIONS (ALl)

SECTION 2

NDI PROCEDURES

MDC-94K9000

FUSELAGE

AUXILIARY SPAR

PLATE

~~/~-~ ~/

THRUST SUPPORT

:::::"’i...:~. ~ ’~::-<::~:"

REAR SPAR ~

":" 0 ~ g) 

~,~C (FIG 3)

INSPECT REAR SPAR AND ENGINE THRUST SUPPORT

VIEW A FITTING (UPPER AND LOWER CAPS) IN SHADED AREA.

LEFT SIDE SHOWN (RIGHT SIDE OPPOSITE)

ENGINE THRUST

SUPPORT FITTING

MI~O-54.10.O4.1F1

54.10.04.1

Page 6

October 2001

INSPECTION AREA

Figure 1

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MD.90

AIRWORTHINESS LIMITATIONS INSTRUCTIONS (ALl)

SECTION 2

NDI PROCEDURES

MDC-94K9000

CRACKS

(T’YPICAL)

-5 ANGLE

,|

0 O O 0 0, II

,

EDDY CURRENT

PROBE (TYPICAL)

SCAN DIRECTION (D ~\ .

(TYPICAL) "" ........

O REAR SPAR ’~’ O

II UPPER CAP ~ I

© ©

IST SUPPORT

FI’I-I’ING UPPER CAP

=../(~,~501)

SCAN UPPER THRUST PLATE

ADJACENT TO HEAT SHIELD

UPPER MOUNT PLATE

P °PPE" .osT o ’;3..-- o

.~TA

0 YN=170.500

HEAT SHIELD /

UPPER MOUNT

PLATE

OANDID

WEIGHT SAVINGS DESIGN

(P/N 5965673)

PRE-WEIGHT SAVINGS DESIGN ........

(P/N 5965128)

~IFWD ~e’, ,, ©

O T~D ’

,

’~qD ~’ ’~ ql)

VIEW B-B (FIG I) ’~ (D ’, ! (D VIEW LOOKING DOWN, LEFT SIDE,

FRAME STATION YN=170.500 ~ (D i! (D t (RIGHT S,DE oPPosi~ I

~, o ’,, . ...~-- \,>’, .......... --,,,: ~

I (101) SCAN UPPER THRUST PLATE ON FORWARI ~l ~.~-’"~"~.~" O

(~1~ AND AFT SLOES OF SHADED FASTENERS

(I ~01) SCAN FORWARD AND AFT SIDES OF SHADED FASTENERS

ON REAR SPAR UPPER CAP AND THRUST SUPPORT

FITTING UPPER CAP FROM INSIDE AFT TORQUE BOX

MDg0-B4.10,04.1F2

HIGH FREQUENCY EDDY CURRENT INSPECTION OF UPPER PLATE

Figure 2

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54.10.04.1

Page 7

October 2001
MD-90 MDC-94K9000

AIRWORTHINESS LIMITATIONS INSTRUCTIONS (ALl)

SECTION 2

NDIPROCEDURES

HEAT SHIELD

LOWER MOUNT ~._ ~

o i ’O"

REAR SPAR ~~~....._ / c~o,> scAR LDWER ~RUST.~

LOWER CAP ~_//"~"~"’’~t 4~_" ADJACENT TO HEAT SHIELD

~,,c~.> "~.//. ~. ; - 7 " ’ ~ ~il //(¢~.’ ,,’~ e_ll

// ~~ ’ I’~T~""~= TH RU ST SUPPORT

(TYPICAL) ~"..7~...~ PROBE(TYPICAL)

~ (D II

I1_~.,"~’-"; I@ "

II ~),’:’:".Z~  ̄  ̄  ̄  ̄  ̄ ’,: ~ //o

II " ,,’ ̄ W-’~ - - 1.1~.~ _ v r~

+,,.o~ y2 ~.<,’__ ~ o :’,;;," I

PRE-WEIGHT SAVINGS DESIGN i J _" ; - "" -- -’- L, - I

CP/N 5965128) OTBD # e ,, I -_’~ Is,’ !~

1’>,. ::

iD, ,iD v,Ew c-c <,,o,> !_’>,i i

VIEW LOOKING UP, LEFT SIDE, ~’ (D ; (D

FRAME STATION YN=170.500 ~’Ar~ ,’ ~.,G.’r SIDE OPPOS,m ~  ̄ t i ~.

,’0  ̄  ̄  ̄  ̄ -- _JL-" ---

WEIGHT SAVINGS DESIGN

 ̄ AND (D (1101) SCAN LOWER THRUST PLATE ON FORWARD (P/N 5965673)

~T~AND AFT SIDES OF SHADED FASTENERS

lr © | (201) SCAN FORWARD AND AFT SIDES OF SHADED FASTENERS ,41, ON REAR SPAR LOWER CAP AND THRUST SUPPORT C|~ Fn’nNG ,OWER CAP FROMINSIDEAFTTORQUEBOX

MDgO-54.10.O4.1F3

HIGH FREQUENCY EDDY CURRENT INSPECTION OF LOWER PLATE

Figure 3

54.10.04.1

Page 8

October 2001

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MD-90

AIRWORTHINESS LIMITATIONS INSTRUCTIONS (ALl)

SECTION 2

NDI PROCEDURES

MDC-94K9000

UPPER THRUST SCAN DIRECTION PLATE

J

!

,O O

E (FIG 6) o ooo ooo

t Ol, O  ̄  ̄  ̄  ̄  ̄

I STA

ZN=6.000

!

I

I

|

F (FIG 6)

CURRENT

= , PROBE (TYPICAL)

I

II ~ I (301) SCAN RADIUS PLATEANGLEON

UPPER AND LOWER THRUST PLATE

ON FORWARD AND AFT EDGEDS AS

SHOWN IN SHADED AREA (4 PLACES)

UP

~1 FWD

,.-THRUST SUPPORT

t FII-nNG |

STA o o o o o

J ,.x~,.~x\ WEIGHT SAVINGS DESIGN

I

ZN=’6’000

~

. . ..  ̄ . . . .

 ̄  ̄  ̄ "  ̄ "~

[

(P/N5965673)

~[~OlO 0 0 0 0 0 00uO

E’ .4~ o ’, ,, o o ~- iLol ,~

//

, F .ooo oo..

0, ,0 0 ’ ’

, , , ,, _ ,--JI , ,

.

’, ,!

PRE-WEIGHT SAVINGS DESIGN

(P/N 5965128) " ’ ! STA

i !

YN=170.500

VIEW D-D (FIG 1)

VIEW LOOKING INBOARD, LEFT SIDE,

FRAME STATION YN=170.500

(RIGHT SIDE OPPOSITE)

O I (101) SCAN UPPER AND LOWER THRUST PLATE ON FORWARD

(~T~

AND AFT SIDES OF SHADED FASTENERS

HIGH FREQUENCY EDDY CURRENT INSPECTION

OF UPPER AND LOWER PLATE

Figure 4

McDonnell Douglas Corporation Proprietary Information. Use or disclosure of

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M.DgO-54.tO.O,4.1F4

54.10.04.1

Page 9

October 2001
MD-90

AIRWORTHINESS LIMITATIONS INSTRUCTIONS (ALl)

SECTION 2

NDI PROCEDURES

MDC-94K9000

LOWER

INSPECTION

AREA

VIEW A (FIG 1)

VIEW LOOKING INBOARD AND AFT, LEFT SIDE,

FRAME STATION YN=170.500

(RIGHT SIDE OPPOSITE)

~h,~ 301) SCAN RADIUS OF PLATE ANGLE ON UPPER

AND LOWER THRUST PLATES ON FORWARD

AND AFT EDGES AS SHOWN IN SHADED AREA

UP

~FWD

MDgO-54.10.04.1F5

54.10.04.1

Page 10

October 2001

HIGH FREQUENCY EDDY CURRENT INSPECTION

OF UPPER AND LOWER PLATE

Figure 5

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MD-90

AIRWORTHINESS LIMITATIONS INSTRUCTIONS (ALl)

SECTION 2

NDI PROCEDURES

MDC-94K9000

0

0

0

0

0

0

0

I° \

UP

OTBD

PROBE (TYPICAL)

THRUST

SUPPORT

FITTING

/REAR SPAR

,e.-."

,.;>:..:.::;: ,,,,.~ STA

ZN=-6.000

LOWER THRUST

PLATE

UPPER THRUST

PLATE

\

0

0

0

0

0

0

0

0

0

0

/

LOWER THRUST

PLATE

\

CRACK

CrYPICAL)

UP

OTBD

H

VIEW E-E (FIG 4)

VIEW LOOKING AFT AT REAR SPAR,

LEFT SIDE (RIGHT SIDE OPPOSITE)

VIEW F-F (FIG 4)

V1EW LOOKING FORWARD

AT THRUST SUPPORT FII"rlNG,

LEFT SIDE (RIGHT SIDE OPPOSITE)

~=~401) SCAN ALONG FORWARD SIDE OF

REAR SPAR AND AFT SIDE OF

THRUST SUPPORT FR-rlNG AT

ZN-6.000 AND ZN=-6.000 IN

SHADED AREAS

HIGH FREQUENCY EDDY CURRENT INSPECTION

OF REAR SPAR AND THRUST SUPPORT FITTING

Figure 6

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MDgO~4.10.04.1F6

54.10.04.1

Page 11

October 2001
THIS PAGE INTENTIONALLY LEFT BLANK
MD-90 MDC-94K9000

AIRWORTHINESS LIMITATIONS INSTRUCTIONS (ALl)

SECTION 2

NDI PROCEDURES

Title:

Inspection Item:

Model Affected:

Ships Affected:

Service Bulletin:

Drawing Reference:

Inspection Requirements:

Pylon, Forward Upper and Lower Isolators and Cone Bolts

PSE 54.40.01.2

MD-90 All Series

All

None

5940573, LM-442-SA2, LM-442-SA20, LM-442-1

See Lord Component Maintenance Manual. Refer to Documents

71-20-27 and 71-20-24, pages 501 and subsequent pages and

Figure 1 of this document for specific inspection requirements.

For manual and updates contact

Lord Aerospace Products

Lord Corporation

1635 West 12th Street

Erie, PA 16514

Phone: (814) 456-8511

McDonnell Douglas Corporation Proprietary Information. Use or disclosure of

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54.40.01.2

Page 1

October 2001
MD-90

AIRWORTHINESS LIMITATIONS INSTRUCTIONS (ALl)

SECTION 2

NDI PROCEDURES

MDC-94K9000

 ̄

0

0

qo"

0 ~t~q~ 0

......~ ~

°o °

"--- ~

N~B

J \ UPPER COVER

t~ ~ ~B~ON PLATE

YOKE ~ ISOLATOR

LM-442-SA2 OR

LM-442.SA20

/

"~ LOWER

VIBRATION

ISOLATOR

LM-442-SA2

OR LM-442-SA20

~~

~’"~’--.~ COVER

PLATE

CONE BOLT

INSPECT- FORWARD UPPER AND LOWER ISOLATORS~~/

2-1"¢v~

/LM-44

AND CONE BOLTS PER LORD MAINTENANCE MANUAL

MD90-54.40,01.2F1

54.40.01.2

Page 2

October 2001

INSPECTION ZONE

Figure I

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AIRWORTHINESS LIMITATIONS INSTRUCTIONS (ALI) 

 SECTION 2 

 NDI PROCEDURES

54.40.03.1 

McDonnell Douglas Corporation Proprietary Information. Use or disclosure of Page 1

 THESE SUBJECT TO RESTRICTIVE LEGEND ON TITLE PAGE OR FIRST PAGE. September 2011

Title: Pylon, Thrust Struts

Inspection Item: PSE 54.40.03.1 

Model Affected: MD-90 All Series 

Ships Affected: All 

Service Bulletin: None 

Drawing Reference: ROHR 290-PL-2001 

Inspection Requirements: 

See International Aero Engines (IAE)/Goodrich Component 

Maintenance Manual. Refer to Document 71-14-00, pages 501 and 

subsequent pages, and Figure 1 of this document for specific inspection 

requirements. For manual and updates, contact: 

Goodrich Aerospace/Aerostructures Group 

850 Lagoon DR. 

Chula Vista, CA 91910 

Telephone (619) 691-2719 

techpubs@goodrich.com 
MD-90

AIRWORTHINESS LIMITATIONS INSTRUCTIONS (ALl)

SECTION 2

NDI PROCEDURES

MDC-94K9000

THRUST

ISOLATOR

THRUST STRUTS

P/N 290-2001

INSPECT - UPPER AND LOWER THRUST STRUTS PER IAE MAINTENANCE MANUAL

MDgO-54.40.03.1F I

54.40.03.1

Page 2

October 2001

INSPECTION ZONE

Figure 1

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MD-90 MDC-94K9000

AIRWORTHINESS LIMITATIONS INSTRUCTIONS (ALl)

SECTION 2

NDI PROCEDURES

Title:

Inspection Item:

Model Affected:

Ships Affected:

Service Bulletin:

Drawing Reference:

Inspection Requirements:

Pylon, Thrust Isolator

PSE 54.40.03.2

MD-90 All Series

All

None

5940573, LM-442-SA5, LM-442-SA15

See Lord Component Maintenance Manual. Refer to Document

71-20-25, pages 501 and subsequent pages and Figure 1 of this

document for specific inspection requirements. For manual and

updates contact

Lord Aerospace Products

Lord Corporation

1635 West 12th Street

Erie, PA 16514

Phone: (814) 456-8511

McDonnell Douglas Corporation Proprietary Information. Use or disclosure of

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54.40.03.2

Page 1

October 2001
MD-90

AIRWORTHINESS LIMITATIONS INSTRUCTIONS (ALl)

SECTION 2

NDI PROCEDURES

MDC-94K9000

SUPPORT

] w,.....-./ FFFTING

.d,./THRUST ISOLATOR REF LORD P/N LM-442-SA5

OR LM-442-SA15

INSPECT ° THRUST ISOLATOR PER LORD MAINTENANCE MANUAL

MDg0-~.40.03.2F 1

54.40.03.2

Page 2

October 2001

INSPECTION ZONE

Figure I

McDonnell Douglas Corporation Proprietary Information, Use or disclosure of

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MD-90 MDC-94K9000

AIRWORTHINESS LIMITATIONS INSTRUCTIONS (ALl)

SECTION 2

NDI PROCEDURES

Title:

Inspection Item:

Model Affected:

Ships Affected:

Service Bulletin:

Drawing Reference:

Inspection Requirements:

Pylon, Aft Isolator and Cone Bolts

PSE 54.40.04.1

MD-90 All Series

All

None

5940573, LM-442-SA6, LM-442-SA16, LM-442-13

See Lord Component Maintenance Manuals. Refer to Documents

71-20-26, 71-20-27 and 71-20-32 as applicable, pages 501 and

subsequent pages and Figure 1 of this document for specific

inspection requirements. For manual and updates contact:

Lord Aerospace Products

Lord Corporation

1635 West 12th Street

Ene, PA 16514

Phone: (814) 456-8511

McDonnell Douglas Corporation Proprietary Infon, n,Ydon. Use or disclosure of

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54.40.04.1

Page 1

September 2002
MD~0

AIRWOTHINESSLIMITATIONSINSTRUCTIONS(ALI)

SECTION2

NDIPROCEDURES

MDC-94K9000

AFT CONE BOLT

LM J. ~.2-13

AFT VIBRATION

ISOLATOR

LM-442-SA8

OR LM-442-SA-16

J~INBD

INSPECT - AFT ISOLATOR AND CONE BOLT PER LORD MAINTENANCE MANUAL

MDgO-84.40,04.1 F1

INSPECTION ZONE

Figure I

54.40.04.1

Page 2

October 2001

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AIRWORTHINESS LIMITATIONS INSTRUCTIONS (ALI) 

 SECTION 2 

 NDI PROCEDURES

55.11.01.1 

McDonnell Douglas Corporation Proprietary Information. Use or disclosure of Page 1

 THESE SUBJECT TO RESTRICTIVE LEGEND ON TITLE PAGE OR FIRST PAGE. September 2011

Title: Rear Spar Upper Cap - between STA Xe = 5.000 and Xe = 14.000 

Inspection Item: PSE 55.11.01.1 

Model Affected: MD-90 

Ships Affected: All 

Service Bulletin: MD-90 55A-012 

Drawing Reference: 5964815, 5940483, 5918000 

Requirement: TO COMPLETE THE REQUIREMENTS OF THIS PSE, THE PRIMARY 

INSPECTION (01), OF EACH INSPECTION SEQUENCE, OR ITS 

ALTERNATE SUBSTITUTE(S) MUST BE ACCOMPLISHED. 

NOTES: (1) ALTERNATE INSPECTIONS WILL BE IDENTIFIED BY 

NUMERALS OTHER THAN 01. 

 (2) MULTIPLE ALTERNATE INSPECTIONS WHICH MUST 

BE PERFORMED TO ADEQUATELY REPLACE A PRIMARY 

INSPECTION WILL BE IDENTIFIED BY AN ALPHA 

CHARACTER FOLLOWING THE ALTERNATE 

DESIGNATOR, i.e., 02a and 02b, ETC. 

Inspection Sequence 1: 

 01. Eddy Current, Low Frequency 

Description: 

The inspection area consists of the horizontal stabilizer rear spar upper cap at the area between 

the aft two fastener rows common with the upper skin plank. The purpose of the inspection is to 

detect fatigue cracks in the horizontal flange of the upper cap between Stations Xe = 5.000 and 

Xe = 14.000. The fatigue cracks will emanate in the forward/aft direction in the inspection area. 

See Figures 1, 3, and 4. 
 MD-90 MDC-94K9000 

AIRWORTHINESS LIMITATIONS INSTRUCTIONS (ALI) 

 SECTION 2 

 NDI PROCEDURES

55.11.01.1 

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Access:

FOLLOW APPLICABLE SAFETY INSTRUCTIONS AND PRECAUTIONS PER THE 

NONDESTRUCTIVE TESTING STANDARD PRACTICE MANUAL (NDTSPM) PART 

01-00-01 AS WELL AS ALL LOCAL AND COMPANY REQUIREMENTS. 

A. Access to upper surface of horizontal stabilizer at the aft spar. 

Preparation for Inspection: 

A. Remove all dirt, grease, and loose paint from the inspection area. 

B. Thoroughly clean the inspection area with an approved cleaning agent. 

General Visual Inspection: 

A. Perform a preliminary check of the general PSE area for cleanliness, presence of foreign 

objects, distortion, damage, cracks, corrosion, security of parts and evidence of loose 

attachments. 

B. After completion of general area check, perform the specific PSE inspection(s) to 

complete the requirement. 

NOTE: The presence of repairs and/or modifications in the inspection area may affect 

the inspectability of this PSE. Inspect non-discrepant areas of the PSE and report details 

of the discrepancy with inspection results to BCA-LBD. 

C. If additional information regarding visual inspection is desired, See Part 09 of the 

NDTSPM. 
 MD-90 MDC-94K9000 

AIRWORTHINESS LIMITATIONS INSTRUCTIONS (ALI) 

 SECTION 2 

 NDI PROCEDURES

55.11.01.1 

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Equipment/Materials 

DESCRIPTION METHOD 

APPLICABILITY

A. EDDY CURRENT 

1. Flaw Detector (Impedance Plane Display). 

 •NDT 24 Staveley Instruments Inc. 

101 

2. Low Frequency Spot Probe operating at 1 KHz. See Figure 2 and 

Section 2-3, Figure 3.1 

 •SPO-5496 Staveley Technologies Inc.

101 

3. Low Frequency Reference Standard. See Figure 2 and Section 2-

1, Figure 1.1 

 •MD90-01 Source optional

101 

B. SURFACE PREPARATION 

1. Cleaning Agent in conformance with environmental regulations 

and harmless to surfaces contacted. 

• Source optional 

ALL 

NOTES: (1) The equipment/materials listed above were used to develop this procedure. See 

NDTSPM Part 06-00-04 for supplier/ vendor information. 

 (2) Equipment/material substitutions producing results equivalent to those defined by 

this document may also be used. See NDTSPM Parts 01- and 06- 00-03 for 

equipment/material information. 
 MD-90 MDC-94K9000 

AIRWORTHINESS LIMITATIONS INSTRUCTIONS (ALI) 

 SECTION 2 

 NDI PROCEDURES

55.11.01.1 

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Inspection Procedure 

A. Inspection Sequence 1: 

1. Inspection Method 01 (Eddy Current, Low Frequency) 

a. Attach probe to eddy current instrument and set operating frequency to 

 1 KHz. 

b. Place the eddy current probe on the reference standard as shown in Figure 2. 

Null/balance the instrument with the probe centered between fasteners to 

minimize fastener affect from forward fastener row. 

c. Scan across the reference EDM notch area in the -5 detail and adjust the 

instrument display settings to obtain a display pattern similar to that shown in 

Figure 2. 

d. Gain access to the inspection area at the horizontal stabilizer aft spar upper cap 

between Stations Xe = 5.000 and Xe = 14.000. Null/balance probe between 

fasteners at the inspection area in a manner similar to that which was done for 

the calibration process. Scan along inspection area in the shaded area as 

shown on Figure 3 and 4 looking for cracks in the upper spar cap (cracks in the 

forward and aft direction.) 

Inspection Results: 

A. Any indication is considered a crack which exhibits the same relative phase angle and an 

amplitude of 50 percent or greater than the indication obtained from the calibration notch 

in the reference standard. 

B. Report all inspection results, Positive, Negative, or Discrepant. 

 1. Positive - Cracks found 

 2. Negative - Cracks not found 

 3. Discrepant - PSE inspection could not be completed or performed due to obstruction 

or other physical anomalies. 

Post Inspection Procedure: 

A. Remove and secure all test equipment and materials from the area. 
 MD-90 MDC-94K9000 

AIRWORTHINESS LIMITATIONS INSTRUCTIONS (ALI) 

 SECTION 2 

 NDI PROCEDURES

55.11.01.1 

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55.11.01.1 

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55.11.01.1 

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--I
 MD-90 MDC-94K9000 

AIRWORTHINESS LIMITATIONS INSTRUCTIONS (ALI) 

SECTION 2 SUPPLEMENT 

TABLE OF CONTENTS

TC-4 Revision Date: September 2011 

SECTION 2-0 EQUIPMENT UTILIZATION 

TBD 

SECTION 2-1 REFERENCE STANDARDS 

Figure 1.1 MD90-01 Horizontal Stabilizer at Station Xe=7.0 

SECTION 2-2 HIGH FREQUENCY EDDY CURRENY PROBES 

TBD 

SECTION 2-3 LOW FREQUENCY EDDY CURRENT PROBES 

Figure 3.1 SPO-5496 Probe 

SECTION 2-4 INSPECTION FIXTURES 

TBD 

SECTION 2-5 ULTRASONIC TRANSDUCERS 

TBD 
SECTION 2 SUPPLEMENT 

EQUIPMENT UTILIZATION 
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SECTION 2 SUPPLEMENT 

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SECTION 2 SUPPLEMENT 

HIGH FREQUENCY EDDY CURRENT PROBES 
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HIGH FREQUENCY EDDY CURRENT PROBES

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INSPECTION FIXTURES 
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