### Commercial **Airplanes** 

# DC8 Service Bulletin **ALERT Number: DC8-57A103**  Original Issue: May 05, 2010 ATA System: 5710 **SUBJECT:**WINGS - Wing Structure - Inspect/Repair Left and Right Wing Center Spar Lower Spar Cap at Stations Xrs=168.00, Xrs=251.00 and Xrs=358.00 Export of this technology is controlled under the United States Export Administration Regulations (EAR) (15 CFR 730-774). An export license may be required before it is used for development, production or use by foreign persons from specific countries. The controller of this data has the individual responsibility to abide by all export laws.9E991 ECCN: 

## BOEING PROPRIETARY, CONFIDENTIAL, AND/OR TRADE SECRET Copyright © 2010 The Boeing Company Unpublished Work - All Rights Reserved Boeing claims copyright in each page of this document only to the extent that the page contains copyrightable subject matter. Boeing also claims copyright in this document as a compilation and/or collective work. This document includes proprietary information owned by The Boeing Company and/or one or more third parties. Treatment of the document and the information it contains is governed by contract with Boeing. For more information, contact The Boeing Company, P.O. Box 3707, Seattle, Washington 98124. Boeing, the Boeing signature, the Boeing symbol, 707, 717, 727, 737, 747, 757, 767, 777, 787, Dreamliner, BBJ, DC-8, DC-9, DC-10, KC-10, KDC-10, MD-10, MD-11, MD-80, MD-88, MD-90, P-8A, Poseidon and the Boeing livery are all trademarks owned by The Boeing Company; and no trademark license is granted in connection with this document unless provided in writing by Boeing.

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: May 05, 2010 DC8-57A103 1 of 62 2.0BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: May 05, 2010 DC8-57A103 2 of 62 **BOEING SERVICE BULLETIN DC8-57A103 ALERT**  **ALERT**

BLANK PAGE**Table of Contents** Summary...................................................... 5 1. PLANNING INFORMATION........................................ 9 A. Effectivity................................................ 9 1. Airplanes............................................. 9 2. Spares Affected. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 B. Concurrent Requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 C. Reason. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 D. Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 E. Compliance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 F. Approval. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 G. Manpower. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 H. Weight and Balance Changes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 I. Electrical Load Data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 J. References. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 1. Existing Data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 2. Data supplied with this Service Bulletin. . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 3. Installation Drawings Used in the Preparation of this Service Bulletin. . . . . . . . . . . . 34 K. Publications Affected. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 L. Interchangeability and Intermixability of Parts. . . . . . . . . . . . . . . . . . . . . . . . . . . 35 2. MATERIAL INFORMATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 A. Material - Price and Availability. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 B. Industry Support Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 C. Parts Necessary For Each Airplane. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 1. Kits/Parts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 2. Parts and Materials Supplied by the Operator. . . . . . . . . . . . . . . . . . . . . . . . 37 3. Parts Modified and Reidentified. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48 4. Parts Removed and Not Replaced. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49 D. Parts Necessary to Change Spares. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49 E. Special Tooling - Price and Availability. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49 F. Special Tooling Necessary to do this Service Bulletin. . . . . . . . . . . . . . . . . . . . . . . 49 3. ACCOMPLISHMENT INSTRUCTIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51 A. GENERAL INFORMATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51 B. WORK INSTRUCTIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52 FIGURE 1: INSPECT THE LEFT AND RIGHT WING CENTER SPAR - EDDY CURRENT, HIGH FREQUENCY INSPECTION METHOD. . . . . . . . . . . . . . . . . . . . . . . . . . . . 56 FIGURE 2:INSPECT THE LEFT AND RIGHT WING CENTER SPAR -EDDY CURRENT, LOW FREQUENCY INSPECTION METHOD. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: May 05, 2010 DC8-57A103 3 of 62 **BOEING SERVICE BULLETIN DC8-57A103 ALERT**  **ALERT**BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: May 05, 2010 DC8-57A103 4 of 62 **BOEING SERVICE BULLETIN DC8-57A103 ALERT**  **ALERT**

BLANK PAGE

### Commercial **Airplanes** 

# DC8 Service Bulletin **ALERT Summary**  **Number: DC8-57A103** Original Issue: May 05, 2010 ATA System: 5710 **SUBJECT:**WINGS - Wing Structure - Inspect/Repair Left and Right Wing Center Spar Lower Spar Cap at Stations Xrs=168.00, Xrs=251.00 and Xrs=358.00 THIS BULLETIN IS SENT TO THE OPERATORS OF RECORD OF THE AIRPLANES SHOWN IN PARAGRAPH 1.A., EFFECTIVITY. IF AN AIRPLANE HAS BEEN LEASED OR SOLD, SEND THIS SERVICE BULLETIN TO THE NEW OPERATOR. IF APPLICABLE SPARES HAVE BEEN SOLD, SEND THIS SERVICE BULLETIN TO THE NEW OWNER. **CONCURRENT REQUIREMENTS** None. **BACKGROUND** Boeing has been advised that cracks in the center spar lower cap and in some cases, the web of the spar, have been found at stations Xrs=168.00, Xrs=251.00 and Xrs=358.00. These cracks originate in the most inboard fastener hole of the access opening doublers. A total of 12 cracks have been found in airplanes with between 26,121 and 50,136 landings, and appear to be consistent with fatigue cracks. This service bulletin provides instructions to inspect these areas to determine if these cracks are present, and accomplish a repair, if required. If not corrected, these cracks can compromise the structural integrity of the wing structure. **ACTION OPTION 1**  1. This service bulletin provides instructions to conduct an Eddy Current, High Frequency Inspection in the area of the inboard fastener of the access opening doubler on the left and right wing center spar lower cap in three specfic areas to locate any cracks, and do as follows:
**CONDITION 1 (No Crack Found)** a. Repetitively inspect for cracks at specific intervals. **CONDITION 2 (Crack Found at Station Xrs=168.00, Left and/or Right Wing)** a. Repairs the crack. b. Inspects the repair at specific intervals. c. Repetitively inspects the non-repaired locations at specific intervals.

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: May 05, 2010 DC8-57A103 5 of 62**CONDITION 3 (Crack Found at Station Xrs=251.00, Left and/or Right Wing)** a. Repairs the crack. b. Inspects the repair at specific intervals. c. Repetitively inspects the non-repaired locations at specific intervals. **CONDITION 4 (Crack Found at Station Xrs=358.00, Left and/or Right Wing)** a. Repairs the crack. b. Inspects the repair at specific intervals. c. Repetitively inspects the non-repaired locations at specific intervals. **OPTION 2** 1. This service bulletin provides instructions to conduct an Eddy Current, Low Frequency Inspection of the center spar lower cap in three specific areas of the left and right wing center spar to locate any cracks, and do as follows:
**CONDITION 1 (No Crack Found)** a. Repetitively inspect for cracks at specific intervals. **CONDITION 2 (Crack Found at Station Xrs=168.00, Left and/or Right Wing)** a. Repairs the crack. b. Inspects the repair at specific intervals. c. Repetitively inspects the non-repaired locations at specific intervals. **CONDITION 3 (Crack Found at Station Xrs=251.00, Left and/or Right Wing)** a. Repairs the crack. b. Inspects the repair at specific intervals. c. Repetitively inspects the non-repaired locations at specific intervals. **CONDITION 4 (Crack Found at Station Xrs=358.00, Left and/or Right Wing)** a. Repairs the crack. b. Inspects the repair at specific intervals. c. Repetitively inspects the non-repaired locations at specific intervals.

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: May 05, 2010 DC8-57A103 6 of 62 **BOEING SERVICE BULLETIN DC8-57A103 ALERT**  **ALERT EFFECTIVITY**  All DC-8-11, DC-8-12, DC-8-21, DC-8-31, DC-8-32, DC-8-33, DC-8-41, DC-8-42, DC-8-43, DC-8-51, DC-8-52, DC-8-53, DC-8-55, DC-8-61, DC-8-61F, DC-8-62, DC-8-62F, DC-8-63, DC-8-63F, DC-8-71, DC-8-71F, DC-8-72, DC-8-72F, DC-8-73, DC-8-73F, DC-8F-54, DC-8F-55 Airplanes. Refer to Paragraph 1.A.1., Airplanes, for the list of affected airplanes. **COMPLIANCE** Refer to Paragraph 1.E., Compliance. Federal Aviation Administration (FAA) Airworthiness Directive 2008-25-05 is related to this service bulletin. **INDUSTRY SUPPORT INFORMATION** Boeing warranty remedies are not available for the inspection and/or repair procedures given in this service bulletin. **MANPOWER** Refer to Paragraph 1.G., Manpower. **MATERIAL INFORMATION** Operator Supplied Parts/Materials. Refer to Paragraph 2.A., Material - Price and Availability

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: May 05, 2010 DC8-57A103 7 of 62 **BOEING SERVICE BULLETIN DC8-57A103 ALERT**  **ALERT**BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: May 05, 2010 DC8-57A103 8 of 62 **BOEING SERVICE BULLETIN DC8-57A103 ALERT**  **ALERT**

### Commercial **Airplanes** 

# DC8 Service Bulletin **ALERT Number: DC8-57A103**  Original Issue: May 05, 2010 ATA System: 5710 **SUBJECT:**WINGS - Wing Structure - Inspect/Repair Left and Right Wing Center Spar Lower Spar Cap at Stations Xrs=168.00, Xrs=251.00 and Xrs=358.00 THIS BULLETIN IS SENT TO THE OPERATORS OF RECORD OF THE AIRPLANES SHOWN IN PARAGRAPH 1.A., EFFECTIVITY. IF AN AIRPLANE HAS BEEN LEASED OR SOLD, SEND THIS SERVICE BULLETIN TO THE NEW OPERATOR. IF APPLICABLE SPARES HAVE BEEN SOLD, SEND THIS SERVICE BULLETIN TO THE NEW OWNER. **1. PLANNING INFORMATION A. Effectivity**  1. Airplanes This service bulletin is for the airplanes shown below.
**DESCRIPTION CONFIGURATION**  **GROUP** DC-8 airplanes in PSE population 'D'

- 1 DC-8 airplanes in PSE population 'E'

- 2

Airplane Models: DC-8-11, DC-8-12, DC-8-21, DC-8-31, DC-8-32, DC-8-33, DC-8-41, DC-8-42, DC-8-43, DC-8-51, DC-8-52, DC-8-53, DC-8-55, DC-8-61, DC-8-61F, DC-8-62, DC-8-62F, DC-8-63, DC-8-63F, DC-8-71, DC-8-71F, DC-8-72, DC-8-72F, DC-8-73, DC-8-73F, DC-8F-54, DC-8F-55 **Group Fuselage Num-**  **ber** 1 1 1 10 1 100 - 109 1 11 1 110 - 119

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: May 05, 2010 DC8-57A103 9 of 62**Group Fuselage Num-**  **ber** 1 12 1 120 - 129 1 13 1 130 - 139 1 14 1 140 - 149 1 15 1 150 - 159 1 16 1 160 - 169 1 17 1 170 - 179 1 18 1 180 - 189 1 19 1 190 - 199 1 2 1 20 1 200 - 209 1 21 1 210 - 219 1 22 1 220 - 229 1 23 1 230 - 239 1 24 1 240 - 249 1 25 1 250 - 259 1 26 1 260 - 269 1 27

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: May 05, 2010 DC8-57A103 10 of 62 **BOEING SERVICE BULLETIN DC8-57A103 ALERT**  **ALERT Group**  **Fuselage Num- ber**  1 270 - 279 1 28 1 280 - 289 1 29 1 290 - 297 2 298 1 299 1 3 1 30 1 300 - 306 2 307 1 308 2 309 1 31 1 310 - 318 2 319 1 32 1 320 - 321 2 322 - 323 1 324 - 329 1 33 1 330 - 332 2 333 1 334 2 335 1 336 - 339 1 34 1 340 - 346 2 347 - 348 1 349 1 35 1 350 - 359

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: May 05, 2010 DC8-57A103 11 of 62 **BOEING SERVICE BULLETIN DC8-57A103 ALERT**  **ALERT Group**  **Fuselage Num- ber**  1 36 1 360 2 361 1 362 - 369 1 37 1 370 - 375 2 376 - 377 1 378 2 379 1 38 1 380 - 389 1 39 1 390 - 399 1 4 1 40 1 400 - 406 2 407 1 408 - 409 1 41 1 410 - 416 2 417 1 418 - 419 1 42 1 420 - 426 2 427 - 428 1 429 1 43 1 430 - 436 2 437 - 438 1 439 1 44 1 440 - 442

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: May 05, 2010 DC8-57A103 12 of 62 **BOEING SERVICE BULLETIN DC8-57A103 ALERT**  **ALERT Group**  **Fuselage Num- ber**  2 443 1 444 - 449 1 45 1 450 - 457 2 458 1 459 1 46 1 460 - 462 2 463 1 464 2 465 1 466 2 467 1 468 2 469 1 47 1 470 - 479 1 48 1 480 - 486 2 487 1 488 - 489 1 49 1 490 2 491 1 492 - 499 1 5 1 50 1 500 - 508 2 509 1 51 1 510 - 515 2 516

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: May 05, 2010 DC8-57A103 13 of 62 **BOEING SERVICE BULLETIN DC8-57A103 ALERT**  **ALERT Group**  **Fuselage Num- ber**  1 517 - 519 1 52 1 520 - 522 2 523 1 524 - 529 1 53 1 530 - 534 2 535 1 536 - 538 2 539 1 54 1 540 - 541 2 542 1 543 - 545 2 546 1 547 - 549 1 55 1 550 2 551 1 552 - 553 2 554 - 555 1 556 1 56 - 59 1 6 1 60 - 69 1 7 1 70 - 79 1 8 1 80 - 89 1 9 1 90 - 99

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: May 05, 2010 DC8-57A103 14 of 62 **BOEING SERVICE BULLETIN DC8-57A103 ALERT**  **ALERT**2. Spares Affected None. **B. Concurrent Requirements** None. **C. Reason** Boeing has been advised that cracks in the center spar lower cap and in some cases, the web of the spar, have been found at stations Xrs=168.00, Xrs=251.00 and Xrs=358.00. These cracks originate in the most inboard fastener hole of the access opening doublers. A total of 12 cracks have been found in airplanes with between 26,121 and 50,136 landings, and appear to be consistent with fatigue cracks. This service bulletin provides instructions to inspect these areas to determine if these cracks are present, and accomplish a repair, if required. If not corrected, these cracks can compromise the structural integrity of the wing structure. **D. Description OPTION 1 (Eddy Current, High Frequency Inspection)**  1. This service bulletin provides instructions to conduct an Eddy Current, High Frequency Inspection in the area of the inboard fastener of the access opening doubler on the left and right wing center spar lower cap in three specfic areas to locate any cracks, and do as follows:
**CONDITION 1 (No Crack Found)** a. Repetitively inspect for cracks at specific intervals. **CONDITION 2 (Crack Found at Station Xrs=168.00, Left and/or Right Wing)** a. Repairs the crack. b. Inspects the repair at specific intervals. c. Repetitively inspects the non-repaired locations at specific intervals. **CONDITION 3 (Crack Found at Station Xrs=251.00, Left and/or Right Wing)** a. Repairs the crack. b. Inspects the repair at specific intervals. c. Repetitively inspects the non-repaired locations at specific intervals.

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: May 05, 2010 DC8-57A103 15 of 62 **BOEING SERVICE BULLETIN DC8-57A103 ALERT**  **ALERT CONDITION 4 (Crack Found at Station Xrs=358.00, Left and/or Right Wing)**  a. Repairs the crack. b. Inspects the repair at specific intervals. c. Repetitively inspects the non-repaired locations at specific intervals. **OPTION 2 (EDDY CURRENT, LOW FREQUENCY INSPECTION)** 1. This service bulletin provides instructions to conduct an Eddy Current, Low Frequency Inspection of the center spar lower cap in three specific areas of the left and right wing center spar to locate any cracks, and do as follows:
**CONDITION 1 (No Crack Found)** a. Repetitively inspect for cracks at specific intervals. **CONDITION 2 (Crack Found at Station Xrs=168.00, Left and/or Right Wing)** a. Repairs the crack. b. Inspects the repair at specific intervals. c. Repetitively inspects the non-repaired locations at specific intervals. **CONDITION 3 (Crack Found at Station Xrs=251.00, Left and/or Right Wing)** a. Repairs the crack. b. Inspects the repair at specific intervals. c. Repetitively inspects the non-repaired locations at specific intervals. **CONDITION 4 (Crack Found at Station Xrs=358.00, Left and/or Right Wing)** a. Repairs the crack. b. Inspects the repair at specific intervals. c. Repetitively inspects the non-repaired locations at specific intervals. The work in this service bulletin is done in the maintenance zone(s) given below.

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: May 05, 2010 DC8-57A103 16 of 62 **BOEING SERVICE BULLETIN DC8-57A103 ALERT**  **ALERT Group 1:** 
**Affected Maintenance Zones Zone**  **Model** 117, 123 DC-8-11, DC-8-12, DC-8-21, DC-8-31, DC-8-32, DC-8-33, DC-8-41, DC-8-42, DC-8-43, DC-8-51, DC-8-52, DC-8-53, DC-8-55, DC-8-61, DC-8-61F, DC-8-62, DC-8-62F, DC-8-63, DC-8-63F, DC-8-71, DC-8-71F, DC-8-72, DC-8-73, DC-8-73F, DC-8F-54, DC-8F-55 **Group 2:**
**Affected Maintenance Zones Zone**  **Model** 117, 123 DC-8-62, DC-8-62F, DC-8-63, DC-8-72, DC-8-72F **E. Compliance TABLE 1, GROUP 1, OPTION 1 (EDDY CURRENT, HIGH FREQUENCY INSPECTION (ETHF) - IN**  **SPECT CENTER SPAR CAP Repeat Interval**  **(Not to Exceed) Compliance Time** **(Whichever Oc curs Later)**  **Action Condition** 

20,000 total landings Inspect the area of the inboard fastener of the access opening doubler on the left and right wing center spar lower cap at stations Xrs=168.00, Xrs=251.00 and Xrs=358.00 for cracks using Eddy Current, High Frequency Inspection inaccordance with Work Instructions, Paragraph 3.B. All Airplanes

or 3,000 landingsfrom the original issue date of this service bulletin

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: May 05, 2010 DC8-57A103 17 of 62 **BOEING SERVICE BULLETIN DC8-57A103 ALERT**  **ALERT TABLE 1, GROUP 1, OPTION 1 (EDDY CURRENT, HIGH FREQUENCY INSPECTION (ETHF) - IN**  **SPECT CENTER SPAR CAP Repeat Interval**  **(Not to Exceed) Compliance Time** **(Whichever Oc curs Later)**  **Action Condition** 

6,000 landings Inspect the area of the inboard fastener of the access opening doubler on the left and right wing center spar lower cap at stations Xrs=168.00, Xrs=251.00 and Xrs=358.00 for cracks using Eddy Current, High Frequency Inspection inaccordance with Work Instructions, Paragraph 3.B. Condition 1 No Crack(s) Found

Before further flight Repair crack(s) in accor-dance with Work Instructions, Paragraph 3.B. Option 1(ETHF) Condition 2 Crack Found at Station Xrs = 168.00, Left and/or Right Wing AND 6,000 landings Inspect the non-repairedarea of the inboard fastener of the access opening doubler on the left and right wing center spar lower cap at stations Xrs=168.00, Xrs=251.00 and Xrs=358.00 forcracks using Eddy Current, High Frequency Inspection in accordance with Work Instructions, Paragraph 3.B. AND 2,100 landings Within 15,200landings after repairInspect the repair at station Xrs =168.00 left and/or right wing using the inspection defined in DC-8 SID, Volume II, Chapter 57-10-06, Method 101 for the length of the repair.

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: May 05, 2010 DC8-57A103 18 of 62 **BOEING SERVICE BULLETIN DC8-57A103 ALERT**  **ALERT TABLE 1, GROUP 1, OPTION 1 (EDDY CURRENT, HIGH FREQUENCY INSPECTION (ETHF) - IN**  **SPECT CENTER SPAR CAP Repeat Interval**  **(Not to Exceed) Compliance Time** **(Whichever Oc curs Later)**  **Action Condition** 

Before further flight.Repair crack(s) in accordance with Work Instructions, Paragraph 3.B. Condition 3 Crack Found at Station Xrs = 251.00, Left and/or Right Wing AND 6,000 landings Inspect the non-repairedarea of the inboard fastener of the access opening doubler on the left and right wing center spar lower cap at stations Xrs=168.00, Xrs=251.00 and Xrs=358.00 forcracks using Eddy Current, High Frequency Inspection in accordance with Work Instructions, Paragraph 3.B. AND 2,100 landings Within 15,200landings after repairInspect the repair at station Xrs= 251.000 left and/or right wing using the inspection defined in DC-8 SID, Volume II, Chapter 57-10-06, Method 101 for the length of the repair.

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: May 05, 2010 DC8-57A103 19 of 62 **BOEING SERVICE BULLETIN DC8-57A103 ALERT**  **ALERT TABLE 1, GROUP 1, OPTION 1 (EDDY CURRENT, HIGH FREQUENCY INSPECTION (ETHF) - IN**  **SPECT CENTER SPAR CAP Repeat Interval**  **(Not to Exceed) Compliance Time** **(Whichever Oc curs Later)**  **Action Condition** 

Before further flight Repair crack(s) in accor-dance with Work Instructions, Paragraph 3.B. Condition 4 Crack Found at Station Xrs = 358.00 Left and/or Right Wing AND 6,000 landings Inspect the non-repairedarea of the inboard fastener of the access opening doubler on the left and right wing center spar lower cap at stations Xrs=168.00, Xrs=251.00 and Xrs=358.00 forcracks using Eddy Current, High Frequency Inspection in accordance with Work Instructions, Paragraph 3.B. AND 1,400 landings Within 7,600 land- ings after repairInspect the repair at station Xrs=358.00 left and/or right wing using the inspections defined in DC-8 SID, Volume II, Chapter 57-10-16, Method 101, for the length of the repair, and DC-8 SID, Volume II, Chapter 57-10-16, Method 104 at the end of the spar cap repair at the end four fasteners.

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: May 05, 2010 DC8-57A103 20 of 62 **BOEING SERVICE BULLETIN DC8-57A103 ALERT**  **ALERT TABLE 2, GROUP 1, OPTION 2 (EDDY CURRENT, LOW FREQUENCY INSPECTION (ETLF)) - IN**  **SPECT CENTER SPAR CAP Repeat Interval**  **(Not to Exceed) Compliance Time** **(Whichever Oc curs Later)**  **Action Condition** 

20,000 total landings Inspect the left and right wing center spar lower cap at stations Xrs=168.00, Xrs=251.00 and Xrs=358.00 for cracks in the spar cap using Eddy Current, Low Frequency in accordance with Work Instructions, Paragraph 3.B. All Airplanes

or 3,000 landingsfrom the original issue date of this service bulletin

1,750 landings Inspect the left and right wing center spar lower cap at stations Xrs=168.00, Xrs=251.00 and Xrs=358.00 for cracks in the spar cap using Eddy Current, Low Frequency in accordance with Work Instructions, Paragraph 3.B. Condition 1 No Crack(s) Found

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: May 05, 2010 DC8-57A103 21 of 62 **BOEING SERVICE BULLETIN DC8-57A103 ALERT**  **ALERT TABLE 2, GROUP 1, OPTION 2 (EDDY CURRENT, LOW FREQUENCY INSPECTION (ETLF)) - IN**  **SPECT CENTER SPAR CAP Repeat Interval**  **(Not to Exceed) Compliance Time** **(Whichever Oc curs Later)**  **Action Condition** 

Before further flight Repair crack(s) in accor-dance with Work Instructions, Paragraph 3.B. Crack Found at Station Xrs = 168.00, Left and/or Right Wing AND 1,750 landings Inspect the non-repaired left and right wing center spar lower cap at stations Xrs=168.00, Xrs=251.00 and Xrs=358.00 for cracks in the spar cap using Eddy Current, Low Frequency in accordance with Work Instructions, Paragraph 3.B. AND 2,100 landings Within 15,200landings after repairInspect the repair at station Xrs=168.00 left and/or right wing using the inspection defined in DC-8 SID, Volume II, Chapter 57-10-06, Method 101 for the length of the repair.

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: May 05, 2010 DC8-57A103 22 of 62 **BOEING SERVICE BULLETIN DC8-57A103 ALERT**  **ALERT TABLE 2, GROUP 1, OPTION 2 (EDDY CURRENT, LOW FREQUENCY INSPECTION (ETLF)) - IN**  **SPECT CENTER SPAR CAP Repeat Interval**  **(Not to Exceed) Compliance Time** **(Whichever Oc curs Later)**  **Action Condition** 

Before further flight Repair crack(s) in accor-dance with Work Instructions, Paragraph 3.B. Crack Found at Station Xrs = 251.00, Left and/or Right Wing AND 1,750 landings Inspect the non-repaired left and right wing center spar lower cap at stations Xrs=168.00, Xrs=251.00 and Xrs=358.00 for cracks in the spar cap using Eddy Current, Low Frequency in accordance with Work Instructions, Paragraph 3.B. AND 2,100 landings Within 15,200landings after repairInspect the repair at station Xrs=251.00 left and/or right wing using the inspection defined in DC-8 SID, Volume II, Chapter 57-10-06, Method 101 for the length of the repair.

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: May 05, 2010 DC8-57A103 23 of 62 **BOEING SERVICE BULLETIN DC8-57A103 ALERT**  **ALERT TABLE 2, GROUP 1, OPTION 2 (EDDY CURRENT, LOW FREQUENCY INSPECTION (ETLF)) - IN**  **SPECT CENTER SPAR CAP Repeat Interval**  **(Not to Exceed) Compliance Time** **(Whichever Oc curs Later)**  **Action Condition** 

Before further flight Repair crack(s) in accor-dance with Work Instructions, Paragraph 3.B. Condition 4 Crack Found at Station 358.00 Left and/or Right Wing AND 1,750 landings Inspect the non-repaired left and right wing center spar lower cap at stations Xrs=168.00, Xrs=251.00 and Xrs=358.00 for cracks in the spar cap using Eddy Current, Low Frequency in accordance with Work Instructions, Paragraph 3.B. AND 1,400 landings Within 7,600 land- ings after repairInspect the repair at station Xrs=358.00 left and/or right wing using the inspections defined in DC-8 SID, Volume II, Chapter 57-10-16, Method 101, for the length of the repair, and DC-8 SID, Volume II, Chapter 57-10-16, Method 104 at the end of the spar cap repair at the end four fasteners.

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: May 05, 2010 DC8-57A103 24 of 62 **BOEING SERVICE BULLETIN DC8-57A103 ALERT**  **ALERT TABLE 3, GROUP 2, OPTION 1 (EDDY CURRENT, HIGH FREQUENCY INSPECTION (ETHF) ) - IN**  **SPECT CENTER SPAR CAP Repeat Interval**  **(Not to Exceed) Compliance Time** **(Whichever Oc curs Later)**  **Action Condition** 

20,000 total landings Inspect the area of the inboard fastener of the access opening doubler on the left and right wing center spar lower cap at stations Xrs=168.00, Xrs=251.00 and Xrs=358.00 for cracks using Eddy Current, High Frequency Inspection inaccordance with Work Instructions, Paragraph 3.B. All Airplanes

or 3,000 landingsfrom the original issue date of this service bulletin

6,000 landings Inspect the area of the inboard fastener of the access opening doubler on the left and right wing center spar lower cap at stations Xrs=168.00, Xrs=251.00 and Xrs=358.00 for cracks using Eddy Current, High Frequency Inspection inaccordance with Work Instructions, Paragraph 3.B. Condition 1 No Crack(s) Found

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: May 05, 2010 DC8-57A103 25 of 62 **BOEING SERVICE BULLETIN DC8-57A103 ALERT**  **ALERT TABLE 3, GROUP 2, OPTION 1 (EDDY CURRENT, HIGH FREQUENCY INSPECTION (ETHF) ) - IN**  **SPECT CENTER SPAR CAP Repeat Interval**  **(Not to Exceed) Compliance Time** **(Whichever Oc curs Later)**  **Action Condition** 

Before further flight Repair crack(s) in accor-dance with Work Instructions, Paragraph 3.B. Condition 2 Crack Found at Station X=rs 168.00, Left and/or Right Wing AND 6,000 landings Inspect the non-repairedarea of the inboard fastener of the access opening doubler on the left and right wing center spar lower cap at stations Xrs=168.00, Xrs=251.00 and Xrs=358.00 forcracks using Eddy Current, High Frequency Inspection in accordance with Work Instructions, Paragraph 3.B. AND 5,300 landings Within 43,000landings after repairInspect the repair at station Xrs= 168.00 left and/or right wing using the inspection defined in DC-8 SID, Volume II, Chapter 57-10-06, Method 101 for the length of the repair.

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: May 05, 2010 DC8-57A103 26 of 62 **BOEING SERVICE BULLETIN DC8-57A103 ALERT**  **ALERT TABLE 3, GROUP 2, OPTION 1 (EDDY CURRENT, HIGH FREQUENCY INSPECTION (ETHF) ) - IN**  **SPECT CENTER SPAR CAP Repeat Interval**  **(Not to Exceed) Compliance Time** **(Whichever Oc curs Later)**  **Action Condition** 

Before further flight.Repair crack(s) in accordance with Work Instructions, Paragraph 3.B. Condition 3 Crack Found at Station Xrs = 251.00, Left and/or Right Wing AND 6,000 landings Inspect the non-repairedarea of the inboard fastener of the access opening doubler on the left and right wing center spar lower cap at stations Xrs=168.00, Xrs=251.00 and Xrs=358.00 forcracks using Eddy Current, High Frequency Inspection in accordance with Work Instructions, Paragraph 3.B. AND 5,300 landings Within 43,000landings after repairInspect the repair at station Xrs=251.00 left and/or right wing using the inspection defined in DC-8 SID, Volume II, Chapter 57-10-06, Method 101 for the length of the repair.

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: May 05, 2010 DC8-57A103 27 of 62 **BOEING SERVICE BULLETIN DC8-57A103 ALERT**  **ALERT TABLE 3, GROUP 2, OPTION 1 (EDDY CURRENT, HIGH FREQUENCY INSPECTION (ETHF) ) - IN**  **SPECT CENTER SPAR CAP Repeat Interval**  **(Not to Exceed) Compliance Time** **(Whichever Oc curs Later)**  **Action Condition** 

Before further flight Repair crack(s) in accor-dance with Work Instructions, Paragraph 3.B. Condition 4 Crack Found at Station Xrs = 358.00 Left and/or Right Wing AND 6,000 landings Inspect the non-repairedarea of the inboard fastener of the access opening doubler on the left and right wing center spar lower cap at stations Xrs=168.00, Xrs=251.00 and Xrs=358.00 forcracks using Eddy Current, High Frequency Inspection in accordance with Work Instructions, Paragraph 3.B. AND 4,100 landings Within 21,600landings after repairInspect the repair at station Xrs=358.00 left and/or right wing using the inspections defined in DC-8 SID, Volume II, Chapter 57-10-16, Method 101, for the length of the repair, and DC-8 SID, Volume II, Chapter 57-10-16, Method 104 at the end of the spar cap repair at the end four fasteners.

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: May 05, 2010 DC8-57A103 28 of 62 **BOEING SERVICE BULLETIN DC8-57A103 ALERT**  **ALERT TABLE 4, GROUP 2, OPTION 2 (EDDY CURRENT, LOW FREQUENCY INSPECTION (ETLF))- IN**  **SPECT CENTER SPAR CAP Repeat Interval**  **(Not to Exceed) Compliance Time** **(Whichever Oc curs Later)**  **Action Condition** 

20,000 total landings Inspect the left and right wing center spar lower cap at stations Xrs=168.00, Xrs=251.00 and Xrs=358.00 for cracks in the spar cap using Eddy Current, Low Frequency Inspection inaccordance with Work Instructions, Paragraph 3.B. All Airplanes

or 3,000 landingsfrom the original issue date of this service bulletin

1,750 landings Inspect the left and right wing center spar lower cap at stations Xrs=168.00, Xrs=251.00 and Xrs=358.00 for cracks in the spar cap using Eddy Current, Low Frequency in accordance with Work Instructions, Paragraph 3.B. Option 2 (Eddy Current, Low Frequency Inspection (ETLF)) Condition 1 No Crack(s) Found

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: May 05, 2010 DC8-57A103 29 of 62 **BOEING SERVICE BULLETIN DC8-57A103 ALERT**  **ALERT TABLE 4, GROUP 2, OPTION 2 (EDDY CURRENT, LOW FREQUENCY INSPECTION (ETLF))- IN**  **SPECT CENTER SPAR CAP Repeat Interval**  **(Not to Exceed) Compliance Time** **(Whichever Oc curs Later)**  **Action Condition** 

Before further flight Repair crack(s) in accor-dance with Work Instructions, Paragraph 3.B. Option 2 (ETLF) Condition 2 Crack Found at Station Xrs = 168.00, Left and/or Right Wing AND 1,750 landings Inspect the non-repaired left and right wing center spar lower cap at stations Xrs=168.00, Xrs=251.00 and Xrs=358.00 for cracks in the spar cap using Eddy Current, Low Frequency in accordance with Work Instructions, Paragraph 3.B. AND 5,300 landings Within 43,000landings after repairInspect the repair at station Xrs= 168.00 left and/or right wing using the inspection defined in DC-8 SID, Volume II, Chapter 57-10-06, Method 101 for the length of the repair.

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: May 05, 2010 DC8-57A103 30 of 62 **BOEING SERVICE BULLETIN DC8-57A103 ALERT**  **ALERT TABLE 4, GROUP 2, OPTION 2 (EDDY CURRENT, LOW FREQUENCY INSPECTION (ETLF))- IN**  **SPECT CENTER SPAR CAP Repeat Interval**  **(Not to Exceed) Compliance Time** **(Whichever Oc curs Later)**  **Action Condition** 

Before further flight Repair crack(s) in accor-dance with Work Instructions, Paragraph 3.B. Condition 3 (ETLF) Crack Found at Station Xrs = 251.00, Left and/or Right Wing AND 1,750 landings Inspect the non-repaired left and right wing center spar lower cap at stations Xrs=168.00, Xrs=251.00 and Xrs=358.00 for cracks in the spar cap using Eddy Current, Low Frequency in accordance with Work Instructions, Paragraph 3.B. AND 5,300 landings Within 43,000landings after repairInspect the repair at station Xrs= 251.00 left and/or right wing using the inspection defined in DC-8 SID, Volume II, Chapter 57-10-06, Method 101 for the length of the repair.

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: May 05, 2010 DC8-57A103 31 of 62 **BOEING SERVICE BULLETIN DC8-57A103 ALERT**  **ALERT TABLE 4, GROUP 2, OPTION 2 (EDDY CURRENT, LOW FREQUENCY INSPECTION (ETLF))- IN**  **SPECT CENTER SPAR CAP Repeat Interval**  **(Not to Exceed) Compliance Time** **(Whichever Oc curs Later)**  **Action Condition** 

Before further flight Repair crack(s) in accor-dance with Work Instructions, Paragraph 3.B. Condition 4 (ETLF) Crack Found at Station Xrs = 358.00 Left and/or Right Wing AND 1,750 landings Inspect the non-repaired left and right wing center spar lower cap at stations Xrs=168.00, Xrs=251.00 and Xrs=358.00 for cracks in the spar cap using Eddy Current, Low Frequency in accordance with Work Instructions, Paragraph 3.B. AND 4,100 landings Within 21,600landings after repairInspect the repair at station Xrs=358.00 left and/or right wing using the inspections defined in DC-8 SID, Volume II, Chapter 57-10-16, Method 101, for the length of the repair, and DC-8 SID, Volume II, Chapter 57-10-16, Method 104 at the end of the spar cap repair at the end four fasteners.

**F. Approval** This service bulletin was examined by the Federal Aviation Administration (FAA). The changes specified in this service bulletin comply with the applicable regulations and are FAA approved. This service bulletin and its approval were based on the airplane in its original Boeing delivery configuration or as modified by other approved Boeing changes. If an airplane has a non-Boeing modification or repair that affects a component or system also affected by this service bulletin, the operator is responsible for obtaining appropriate regulatory agency approval before incorporating this service bulletin.

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: May 05, 2010 DC8-57A103 32 of 62 **BOEING SERVICE BULLETIN DC8-57A103 ALERT**  **ALERT**In addition, the Manager of the FAA Los Angeles Aircraft Certification Office approves the action (i.e. inspection or repair) defined in this service bulletin as an alternative method of compliance to the requirements of paragraphs (i), (i)(1), (i)(2), (j)(1) and (j)(2) and (l) of AD 2008-25-05 with respect to PSEs 57.08.013/014 and 57.08.035/036. All provisions of AD 2008-25-05 that are not specifically referenced in the above statement remain fully applicable and must be complied with. **G. Manpower** The table below shows an estimate of the task hours necessary to do this inspection for each airplane. This estimate is for direct labor only, done by an experienced crew. Adjust the estimate with operator task hour data if necessary. The estimate does not include lost time. These are some examples of lost time: • Time to adjust to the workplace • Time to schedule the work • Time to inspect the work • Time to cure the materials • Time to make the parts • Time to find the tools. **Option 1 Elapsed Hours**  **Task Hours Number of Persons**  **Task** 8.0 16.0 2 Open Access 6.0 6.0 1 Inspect 4.0 8.0 2 Close Access 18.0 30.0 TOTAL FOR EACH AIRPLANE
**NOTE:**Task hours for the repair(s), if required, are not included. Operator's are to estimate the task hours required based on inspection results. **Option 2 Elapsed Hours**  **Task Hours Number of Persons**  **Task** 6.0 6.0 1 Inspect 6.0 6.0 TOTAL FOR EACH AIRPLANE
**NOTE:**Task hours for the repair(s), if required, are not included. Operator's are to estimate the task hours required based on inspection results. **H. Weight and Balance Changes** Weight and balance changes affected by incorporation of this service bulletin are contingent upon the changes to each particular airplane. Weight data is to be computed by the operator by weighing parts removed and parts installed during this change. Necessary revisions should be made to the appropriate airplane weight and balance report.

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: May 05, 2010 DC8-57A103 33 of 62 **BOEING SERVICE BULLETIN DC8-57A103 ALERT**  **ALERT I. Electrical Load Data**  Not changed. **J. References** 1. Existing Data a. Aircraft Maintenance Manual (AMM) 28-00-0. b. Nondestructive Testing Standard Practice Manual (NDTSPM) Part 06-10-01.001. c. Structural Repair Manual (SRM) 51. d. Supplemental Inspection Document (SID), Volume II, Chapter 57-10-06, 57-10-16. e. FAA Airworthiness Directive 2008-25-05. 2. Data supplied with this Service Bulletin No data is supplied with this service bulletin. To obtain the data necessary to support this service bulletin submit a data request to: Data and Services Management MS D800-0019 3855 Lakewood Boulevard Long Beach, California 90846 Phone: (562) 593-6996 Fax: (562) 593-2001 E-mail: dse.boecom@boeing.com a. Drawings:
**ADCN DCN/REV**  **Sheet Title**  **Drawing No** D

- DWG WING REPAIR - CENTER SPAR CAP ANDWEB, DC-8 Xrs = 251.00 SERVICE REWORK DRAWING SR08570005

B

- DWG SPAR, CENTER, LOWER, WING -DBLR INSTL Xrs =358.000 SERVICE REWORK DRAWING SR08570015

B

- DWG WING REPAIR - CENTER SPAR CAP AND WEB, Xrs = 168.00 SERVICE REWORK DRAWING SR08570022

3. Installation Drawings Used in the Preparation of this Service Bulletin **Change Title**  **Document Number** AS SPAR ASSEMBLY - WING, CENTER SPAR 5613192

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: May 05, 2010 DC8-57A103 34 of 62 **BOEING SERVICE BULLETIN DC8-57A103 ALERT**  **ALERT**This drawing was used to prepare this service bulletin. This drawing is not necessary to make the specified changes, and is not supplied with this service bulletin. This drawing may not be applicable to all airplane configurations or operators. **K. Publications Affected** 1. Publications: None. 2. Damage Tolerance Based Structural Inspections: Boeing has evaluated the repairs and/or changes in this service bulletin for effects on Fatigue Critical Structure (FCS) and for changes to Damage Tolerance Inspections (DTI) required in the Maintenance Program. This service bulletin affects FCS. DTI requirements for the structure affected are contained in Paragraph 1.E., Compliance of this service bulletin. **L. Interchangeability and Intermixability of Parts** Accomplishment of this service bulletin does not affect interchangeability or intermixability of parts.

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: May 05, 2010 DC8-57A103 35 of 62 **BOEING SERVICE BULLETIN DC8-57A103 ALERT**  **ALERT**BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: May 05, 2010 DC8-57A103 36 of 62 **BOEING SERVICE BULLETIN DC8-57A103 ALERT**  **ALERT**

BLANK PAGE**2. MATERIAL INFORMATION A. Material - Price and Availability**  None. **B. Industry Support Information** Boeing warranty remedies are not available for the inspection and/or repair procedures given in this service bulletin. **C. Parts Necessary For Each Airplane** 1. Kits/Parts None. 2. Parts and Materials Supplied by the Operator **NOTE:**Parts required are based on inspection results, and should be established by operator. **SERVICE REWORK DRAWING SR08570005, STATION Xrs=251.00, LEFT WING**
**Notes Material Size**  **QTY Name**  **Part Number/Speci- fication**  (a) .063 x 29.00 x 32.00 Inches 1 Doubler SR08570005-3 (a) .063 x 5.00 x 20.00 Inches 1 Doubler SR08570005-5 (b) 1/4 x 5.00 x 34.00 Inches, Grain lengthwise 1 Plate SR08570005-7 (d) (g) 31.00 Inches 1 Angle SR08570005-9 (a) .160 x 2.00 x 35.00 Inches 1 Strap SR08570005-11 (c) 2.00 x 4.00 x 29.00 Inches 1 Stiffener SR08570005-13 (a) .063 x 2.00 x 5.00 Inches 1 Filler SR08570005-15 (b) 5/16 x 2.00 x 5.00 Inches, Grain lengthwise 1 Filler SR08570005-17 (a) .063 x 1.00 x 30.00 Inches 1 Strap SR08570005-19 (a) .063 x 6.00 x 7.00 Inches 2 Splice SR08570005-21 (e) (h)

- 27 Pin HL328-8

- 18 Nut MS21042L4 (f)

- 33 Nut 3D0006-3 (f)

- 9 Nut 3D0006-4 (e) (h)

- 335 Pin HLT428-6 (e) (h) 112 Pin HLT425-6

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: May 05, 2010 DC8-57A103 37 of 62 **BOEING SERVICE BULLETIN DC8-57A103 ALERT**  **ALERT SERVICE REWORK DRAWING SR08570005, STATION Xrs=251.00, LEFT WING** 
**Notes Material Size**  **QTY Name**  **Part Number/Speci- fication**  (e) (h)

- 83 Pin HL328-6 (e) (h)

- 18 Pin HL329-6

- 515 Washer NAS1252-10L

- 18 Washer NAS1252-416L

- 515 Nut MS21042L3
ALUMINIUM CLAD SHEET, 7075-T6, MATERIAL PER QQ-A-250/13 TEMPER T-6 (a)
ALUMINIUM PLATE 7075-T651, MATERIAL PER QQ-A-250/12 TEMPER T651 (b)
ALUMINIUM BAR, 7075-T7351, MATERIAL PER QQ-A-229/9 TEMPER T7351 (c) Part Number 60-3362 Angle, Aluminium Alloy, 7075-T76511 (d) CAGE Hi-Shear Corporation Can be purchased from: (e) 73197 2600 Skypark Drive Torrance, California 90505 81205 The Boeing Company Can be purchased from: (f) 7755 East Marginal Way South Seattle, Washington 98108-40023YWN1 Transtar Metals Corporation Can be purchased from: (g) DBA Castle Metals Aerospace 970 West 190th Street Suite 700 Torrance, California 90502 Grip length to be determined on installation. (h) **SERVICE REWORK DRAWING SR08570005, STATION Xrs=251.00, RIGHT WING**
**Notes Material Size**  **QTY Name**  **Part Number/Speci- fication**  (a) .063 x 29.00 x 32.00 Inches 1 Doubler SR08570005-3 (a) .063 x 5.00 x 20.00 Inches 1 Doubler SR08570005-5 (b) 1/4 x 5.00 x 34.00 Inches, Grain lengthwise 1 Plate SR08570005-8 (d) (g) 31 Inches 1 Angle SR08570005-10 (a) .160 x 2.00 x 35.00 Inches 1 Strap SR08570005-12 (c) 2.00 x 4.00 x 29.00 Inches 1 Stiffener SR08570005-14 (a) .063 x 2.00 x 5.00 Inches 1 Filler SR08570005-15

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: May 05, 2010 DC8-57A103 38 of 62 **BOEING SERVICE BULLETIN DC8-57A103 ALERT**  **ALERT SERVICE REWORK DRAWING SR08570005, STATION Xrs=251.00, RIGHT WING** 
**Notes Material Size**  **QTY Name**  **Part Number/Speci- fication**  (b) 5/16 x 2.00 x 5.00 Inches, Grain lengthwise 1 Filler SR08570005-18 (a) .063 x 1.00 x 30.00 Inches 1 Strap SR08570005-19 (a) .063 x 6.00 x 7.00 Inches 2 Splice SR08570005-21 (e) (h)

- 27 Pin HL328-8

- 18 Nut MS21042L4 (f)

- 33 Nut 3D0006-3 (f)

- 9 Nut 3D0006-4 (e) (h)

- 335 Pin HLT428-6 (e) (h)

- 112 Pin HLT425-6 (e) (h)

- 83 Pin HL328-6 (e) (h)

- 14 Pin HL329-6

- 515 Washer NAS1252-10L

- 18 Washer NAS1252-416L

- 515 Nut MS21042L3
ALUMINIUM CLAD SHEET, 7075-T6, MATERIAL PER QQ-A-250/13 TEMPER T-6 (a)
ALUMINIUM PLATE 7075-T651, MATERIAL PER QQ-A-250/12 TEMPER T651 (b)
ALUMINIUM BAR, 7075-T7351, MATERIAL PER QQ-A-229/9 TEMPER T7351 (c) Part Number 60-3362 Angle, Aluminium Alloy, 7075-T76511 (d) CAGE Hi-Shear Corporation Can be purchased from: (e) 73197 2600 Skypark Drive Torrance California 90505 81205 The Boeing Company Can be purchased from: (f) 7755 East Marginal Way South Seattle, Washington 98108-40023YWN1 Transtar Metals Corporation Can be purchased from: (g) DBA Castle Metals Aerospace 970 West 190th Street Suite 700 Torrance, California 90502 Grip length to be determined on installation. (h)

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: May 05, 2010 DC8-57A103 39 of 62 **BOEING SERVICE BULLETIN DC8-57A103 ALERT**  **ALERT SERVICE REWORK DRAWING SR08570015, STATION XRS=358.00, LEFT WING** 
**Notes Material Size**  **QTY Name**  **Part Number/Speci- fication**  (a) .100 x 1.45 x 35.00 Inches 1 Strap SR08570015-3 (b) 3.00 x 7.00 x 30.00 Inches, Grain lengthwise 1 Angle SR08570015-5 (b) .08 x 1.00 x 30.00 Inches 1 Spacer SR08570015-7 (c) (g) 6.00 Inches 1 Fitting SR08570015-9 (d) (g) 24.00 Inches 1 Aft Tee SR08570015-11 (a) .150 x 5.00 x 36.00 Inches 1 Strap SR08570015-13 (d) (g) 24.00 Inches 1 Fwd Tee SR08570015-15 (a) .187 x 2.00 x 19.00 Inches 2 Shim SR08570015-17 (a) .063 x 2.00 x 19.00 Inches 1 Shim SR08570015-19 (e) 1.75 x 2.00 x 34.00 Inches 1 Stiffener SR08570015-21 (a) .150 x 8.00 x 10.00 Inches 1 Splice SR08570015-23 (a) .150 x 8.00 x 10.00 Inches 1 Splice SR08570015-25 (a) .150 x 2.00 x 5.00 Inches 1 Shim SR08570015-27 (f) (g) 13.00 Inches 1 Angle SR08570015-29 (h)

- 12 Pin HLT425-6-10 (h)

- 14 Pin HLT425-6-11 (h)

- 48 Pin HLT425-6-12 (h)

- 23 Pin HLT425-6-13 (h)

- 1 Pin HLT425-6-4 (h)

- 1 Pin HLT425-6-8 (h)

- 8 Pin HLT425-6-9 (h)

- 1 Pin HLT425-8-12 (h)

- 1 Pin HLT425-8-8 (h)

- 15 Pin HLT428-6-10 (h)

- 10 Pin HLT428-6-11 (h)

- 18 Pin HLT428-6-13 (h)

- 2 Pin HLT428-6-4 (h)

- 42 Pin HLT428-6-5 (h)

- 37 Pin HLT428-6-6 (h)

- 36 Pin HLT428-6-7

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: May 05, 2010 DC8-57A103 40 of 62 **BOEING SERVICE BULLETIN DC8-57A103 ALERT**  **ALERT SERVICE REWORK DRAWING SR08570015, STATION XRS=358.00, LEFT WING** 
**Notes Material Size**  **QTY Name**  **Part Number/Speci- fication**  (h)

- 12 Pin HLT428-6-8 (h)

- 36 Pin HLT428-6-9 (h)

- 4 Pin HLT428-6-10 (h)

- 10 Pin HLT428-6-11 (h)

- 2 Pin HLT428-6-13 (h)

- 16 Pin HLT428-8-3 (h)

- 4 Pin HLT428-8-4 (h)

- 4 Pin HLT428-8-7 (h)

- 13 Pin HL328-6-3 (h)

- 45 Pin HL328-6-4 (h)

- 12 Pin HL328-6-5 (h) 18 Pin HL328-6-6 (h) 36 Pin HL328-6-7 (h) 5 Pin HL328-6-8 (h) 1 Pin HL328-6-9 14 Rivet MS20470AD8-9 372 Nut MS21042-L3 42 Nut MS21042-L4 372 Washer NAS1252-10L 42 Washer NAS1252-416L (g) 73 Nut Assy 3D0006-3 ALUMINIUM CLAD SHEET, 7075-T6, MATERIAL PER QQ-A-250/13 TEMPER T-6 (a)
ALUMINIUM PLATE 7075-T651, MATERIAL PER QQ-A-250/12 TEMPER T651 (b)
Make from S1285512- extrusion (c) Make from S2640548- extrusion (d)ALUMINIUM BAR, 7075-T7351, MATERIAL PER QQ-A-229/9 TEMPER T7351 (e)
Make from S2931482- extrusion (f)

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: May 05, 2010 DC8-57A103 41 of 62 **BOEING SERVICE BULLETIN DC8-57A103 ALERT**  **ALERT**81205 The Boeing Company Can be purchased from: (g) 7755 East Marginal Way South Seattle, Washington 98108-4002CAGE Hi-Shear Corporation Can be purchased from: (h) 73197 2600 Skypark Drive Torrance California 90505 **SERVICE REWORK DRAWING SR08570015, STATION XRS=358.00, RIGHT WING**
**Notes Material Size**  **QTY Name**  **Part Number/Speci- fication**  (a) .100 x 1.45 x 35.00 Inches 1 Strap SR08570015-3 (b) 3.00 x .70 x 30.00 Inches, Grain lengthwise 1 Angle SR08570015-6 (b) .080 x 1.00 x 30.00 Inches 1 Spacer SR08570015-7 (c) (g) 6.00 Inches 1 Fitting SR08570015-10 (d) (g) 24.00 Inches 1 Aft Tee SR08570015-12 (a) .150 x 5.00 x 36.00 Inches 1 Strap SR08570015-13 (d) (g) 24.00 Inches 1 Fwd Tee SR08570015-16 (a) .187 x 2.00 x 19.00 Inches 2 Shim SR08570015-17 (a) .063 x 2.00 x 19.00 Inches 1 Shim SR08570015-19 (e) 1.75 x 2.00 x 34.00 Inches 1 Stiffener SR08570015-22 (a) .150 x 8.00 x 10.00 Inches 1 Splice SR08570015-23 (a) .150 x 8.00 x 10.00 Inches 1 Splice SR08570015-25 (a) .150 x 2.00 x 5.00 Inches 1 Shim SR08570015-27 (f) (g) 13.00 Inches 1 Angle SR08570015-29 (h)

- 12 Pin HLT425-6-10 (h)

- 14 Pin HLT425-6-11 (h)

- 48 Pin HLT425-6-12 (h)

- 23 Pin HLT425-6-13 (h)

- 1 Pin HLT425-6-4 (h)

- 1 Pin HLT425-6-8 (h)

- 8 Pin HLT425-6-9 (h)

- 1 Pin HLT425-8-12 (h)

- 1 Pin HLT425-8-8 (h)

- 15 Pin HLT428-6-10 (h)

- 10 Pin HLT428-6-11

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: May 05, 2010 DC8-57A103 42 of 62 **BOEING SERVICE BULLETIN DC8-57A103 ALERT**  **ALERT SERVICE REWORK DRAWING SR08570015, STATION XRS=358.00, RIGHT WING** 
**Notes Material Size**  **QTY Name**  **Part Number/Speci- fication**  (h)

- 18 Pin HLT428-6-13 (h)

- 2 Pin HLT428-6-4 (h)

- 42 Pin HLT428-6-5 (h)

- 37 Pin HLT428-6-6 (h)

- 36 Pin HLT428-6-7 (h)

- 12 Pin HLT428-6-8 (h)

- 36 Pin HLT428-6-9 (h)

- 4 Pin HLT428-6-10 (h)

- 10 Pin HLT428-6-11 (h)

- 2 Pin HLT428-6-13 (h)

- 16 Pin HLT428-8-3 (h)

- 4 Pin HLT428-8-4 (h)

- 4 Pin HLT428-8-7 (h)

- 13 Pin HL328-6-3 (h)

- 45 Pin HL328-6-4 (h)

- 12 Pin HL328-6-5 (h) 18 Pin HL328-6-6 (h) 36 Pin HL328-6-7 (h) 5 Pin HL328-6-8 (h) 1 Pin HL328-6-9 14 Rivet MS20470AD8-9 372 Nut MS21042-L3 42 Nut MS21042-L4 372 Washer NAS1252-10L 42 Washer NAS1252-416L (g) 73 Nut Assy 3D0006-3 ALUMINIUM CLAD SHEET, 7075-T6, MATERIAL PER QQ-A-250/13 TEMPER T-6 (a)
ALUMINIUM PLATE 7075-T651, MATERIAL PER QQ-A-250/12 TEMPER T651 (b)
Make from S1285512- extrusion (c)

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: May 05, 2010 DC8-57A103 43 of 62 **BOEING SERVICE BULLETIN DC8-57A103 ALERT**  **ALERT**Make from S2640548- extrusion (d)ALUMINIUM BAR, 7075-T7351, MATERIAL PER QQ-A-229/9 TEMPER T7351 (e)
Make from S2931482- extrusion (f) CAGE The Boeing Company Can be purchased from: (g) 81205 7755 East Marginal Way South Seattle, Washington 98108-400273197 Hi-Shear Corporation Can be purchased from: (h) 2600 Skypark Drive Torrance California 90505 **SERVICE REWORK DRAWING SR08570022, STATION 168.00, LEFT WING**
**Notes Material Size**  **QTY Name**  **Part Number/Speci- fication**  (a) .100 x 2.00 x 8.00 1 Strap SR08570022-3 (b) 3.00 x 7.00 x 31.00 Inches, Grain lengthwise 1 Angle SR08570022-5 (b) .080 x 1.00 x 11.00 Inches, Grain lengthwise 1 Strap SR08570022-7 (c) 1.75 x 2.00 x 6.00 Inches 1 Corner Seal SR08570022-9 (d) (f) 34.00 Inches 1 Aft Tee SR08570022-11 (a) .160 x 6.00 x 36.00 Inches 1 Doubler SR08570022-13 (d) (f) 34.00 Inches 1 Fwd Tee SR08570022-15 (a) .190 x 2.00 x 28.00 Inches 2 Shim SR08570022-17 (a) .063 x 2.00 x 28.00 Inches 1 Shim SR08570022-19 (b) 1.00 x 2.00 x 5.00 Inches 1 Angle SR08570022-21 (a) .160 x 7.00 x 8.00 Inches 1 Splice SR08570022-23 (a) .160 x 6.00 x 7.00 Inches 1 Splice SR08570022-25 (a) .100 x 2.00 x 20.00 Inches 1 Strap SR08570022-27 (e) (f) 13.00 Inches 1 Angle SR08570022-29 (a) .190 x 4.00 x 4.00 Inches 1 Filler SR08570022-31 (a) .125 x 1.00 x 5.00 Inches 1 Filler SR08570022-33 (a) .080 x 1.00 x 19.00 Inches 1 Strap SR08570022-35 (g) 8 Pin HLT425-6-10 (g) 16 Pin HLT425-6-11 (g) 16 Pin HLT425-6-12 (g) 43 Pin HLT425-6-13

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: May 05, 2010 DC8-57A103 44 of 62 **BOEING SERVICE BULLETIN DC8-57A103 ALERT**  **ALERT SERVICE REWORK DRAWING SR08570022, STATION 168.00, LEFT WING** 
**Notes Material Size**  **QTY Name**  **Part Number/Speci- fication**  (g) 20 Pin HLT425-6-14 (g) 1 Pin HLT425-6-5 (g) 2 Pin HLT425-6-9 (g) 1 Pin HLT425-8-13 (g) 2 Pin HLT425-8-9 (g) 8 Pin HLT428-6-10 (g) 4 Pin HLT428-6-11 (g) 20 Pin HLT428-6-13 (g) 2 Pin HLT428-6-4 (g) 33 Pin HLT428-6-5 (g) 112 Pin HLT428-6-6 (g) 22 Pin HLT428-6-7 (g) 17 Pin HLT428-6-8 (g) 44 Pin HLT428-6-9 (g) 4 Pin HLT428-8-10 (g) 9 Pin HLT428-8-11 (g) 1 Pin HLT428-8-13 (g) 3 Pin HLT428-8-4 (g) 2 Pin HLT428-8-5 (g) 5 Pin HLT428-8-6 (g) 16 Pin HLT428-8-7 (g) 59 Pin HL328-6-3 (g) 45 Pin HL328-6-4 (g) 22 Pin HL328-6-5 (g) 19 Pin HL328-6-6 (g) 41 Pin HL328-6-7 (g) 16 Pin HL328-6-8 (g) 3 Pin HL328-6-9 58 Rivet MS20470AD8-9D 503 Nut MS21042-L3 43 Nut MS21042-L4

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: May 05, 2010 DC8-57A103 45 of 62 **BOEING SERVICE BULLETIN DC8-57A103 ALERT**  **ALERT SERVICE REWORK DRAWING SR08570022, STATION 168.00, LEFT WING** 
**Notes Material Size**  **QTY Name**  **Part Number/Speci- fication**  503 Washer NAS1252-10L 43 Washer NAS1252-416L (f) 72 Nut Assy 3D0006-3 ALUMINIUM CLAD SHEET, 7075-T6, MATERIAL PER QQ-A-250/13 TEMPER T-6 (a)
ALUMINIUM PLATE 7075-T651, MATERIAL PER QQ-A-250/12 TEMPER T651 (b)
ALUMINIUM BAR, 7075-T6, MATERIAL PER QQ-A-225/9 TEMPER T6 (c) Make from S1641827 extrusion (d) Make from S2931482T extrusion (e) CAGE The Boeing Company Can be purchased from: (f) 81205 7755 East Marginal Way South Seattle, Washington 98108-400273197 Hi-Shear Corporation Can be purchased from: (g) 2600 Skypark Drive Torrance California 90505 **SERVICE REWORK DRAWING SR08570022, STATION 168.00, RIGHT WING**
**Notes Material Size**  **QTY Name**  **Part Number/Speci- fication**  (a) .100 x 2.00 x 8.00 1 Strap SR08570022-3 (b) 3.00 x 7.00 x 31.00 Inches, Grain lengthwise 1 Angle SR08570022-6 (b) .080 x 1.00 x 11.00 Inches, Grain lengthwise 1 Strap SR08570022-7 (c) 1.75 x 2.00 x 6.00 Inches 1 Corner Seal SR08570022-10 (d) (f) 34.00 Inches 1 Aft Tee SR08570022-12 (a) .160 x 6.00 x 36.00 Inches 1 Doubler SR08570022-13 (d) (f) 34.00 Inches 1 Fwd Tee SR08570022-16 (a) .190 x 2.00 x 28.00 Inches 2 Shim SR08570022-17 (a) .063 x 2.00 x 28.00 Inches 1 Shim SR08570022-19 (b) 1.00 x 2.00 x 5.00 Inches 1 Angle SR08570022-21 (a) .160 x 7.00 x 8.00 Inches 1 Splice SR08570022-23 (a) .160 x 6.00 x 7.00 Inches 1 Splice SR08570022-25

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: May 05, 2010 DC8-57A103 46 of 62 **BOEING SERVICE BULLETIN DC8-57A103 ALERT**  **ALERT SERVICE REWORK DRAWING SR08570022, STATION 168.00, RIGHT WING** 
**Notes Material Size**  **QTY Name**  **Part Number/Speci- fication**  (a) .100 x 2.00 x 20.00 Inches 1 Strap SR08570022-27 (e) (f) 13.00 Inches 1 Angle SR08570022-29 (a) .190 x 4.00 x 4.00 Inches 1 Filler SR08570022-31 (a) .125 x 1.00 x 5.00 Inches 1 Filler SR08570022-33 (a) .080 x 1.00 x 19.00 Inches 1 Strap SR08570022-35 (g) 8 Pin HLT425-6-10 (g) 16 Pin HLT425-6-11 (g) 16 Pin HLT425-6-12 (g) 43 Pin HLT425-6-13 (g) 20 Pin HLT425-6-14 (g) 1 Pin HLT425-6-5 (g) 2 Pin HLT425-6-9 (g) 1 Pin HLT425-8-13 (g) 2 Pin HLT425-8-9 (g) 8 Pin HLT428-6-10 (g) 4 Pin HLT428-6-11 (g) 20 Pin HLT428-6-13 (g) 2 Pin HLT428-6-4 (g) 33 Pin HLT428-6-5 (g) 112 Pin HLT428-6-6 (g) 22 Pin HLT428-6-7 (g) 17 Pin HLT428-6-8 (g) 44 Pin HLT428-6-9 (g) 4 Pin HLT428-8-10 (g) 9 Pin HLT428-8-11 (g) 1 Pin HLT428-8-13 (g) 3 Pin HLT428-8-4 (g) 2 Pin HLT428-8-5 (g) 5 Pin HLT428-8-6 (g) 16 Pin HLT428-8-7 (g) 59 Pin HL328-6-3

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: May 05, 2010 DC8-57A103 47 of 62 **BOEING SERVICE BULLETIN DC8-57A103 ALERT**  **ALERT SERVICE REWORK DRAWING SR08570022, STATION 168.00, RIGHT WING** 
**Notes Material Size**  **QTY Name**  **Part Number/Speci- fication**  (g) 45 Pin HL328-6-4 (g) 22 Pin HL328-6-5 (g) 19 Pin HL328-6-6 (g) 41 Pin HL328-6-7 (g) 16 Pin HL328-6-8 (g) 3 Pin HL328-6-9 58 Rivet MS20470AD8-9D 503 Nut MS21042-L3 43 Nut MS21042-L4 503 Washer NAS1252-10L 43 Washer NAS1252-416L (f) 72 Nut Assy 3D0006-3 ALUMINIUM CLAD SHEET, 7075-T6, MATERIAL PER QQ-A-250/13 TEMPER T-6 (a)
ALUMINIUM PLATE 7075-T651, MATERIAL PER QQ-A-250/12 TEMPER T651 (b)
ALUMINIUM BAR, 7075-T6, MATERIAL PER QQ-A-225/9 TEMPER T6 (c) Make from S1641827 extrusion (d) Make from S2931482T extrusion (e) CAGE The Boeing Company Can be purchased from: (f) 81205 7755 East Marginal Way South Seattle, Washington 98108-400273197 Hi-Shear Corporation Can be purchased from: (g) 2600 Skypark Drive Torrance California 90505
3. Parts Modified and Reidentified The parts shown below are changed as shown in this service bulletin. The quantity (QTY) is the number of parts changed on each airplane.
**Notes New Part Number**  **Name QTY**  **Existing Part Number**  (a) SR08570005-13 Tee 1 3616951-1 (a) SR08570005-14 Tee 1 3616951-2

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: May 05, 2010 DC8-57A103 48 of 62 **BOEING SERVICE BULLETIN DC8-57A103 ALERT**  **ALERT Notes**  **New Part Number Name**  **QTY Existing Part**  **Number** (a) Make the change in accordance with Service Rework Drawing SR08570005. 4. Parts Removed and Not Replaced None. **D. Parts Necessary to Change Spares** None **E. Special Tooling - Price and Availability** None. **F. Special Tooling Necessary to do this Service Bulletin** No special tools or equipment are necessary to do the change in this service bulletin. But, maintenance and overhaul tools in the manuals given in Paragraph 1.J., References, can be necessary. Examine operator tool supply to make sure all necessary tools are available.

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: May 05, 2010 DC8-57A103 49 of 62 **BOEING SERVICE BULLETIN DC8-57A103 ALERT**  **ALERT**BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: May 05, 2010 DC8-57A103 50 of 62 **BOEING SERVICE BULLETIN DC8-57A103 ALERT**  **ALERT**

BLANK PAGE**3. ACCOMPLISHMENT INSTRUCTIONS A. GENERAL INFORMATION**  **WARNING:**IF ELECTRICAL POWER IS APPLIED TO THE AIRPLANE, MAKE SURE YOU OBEY ALL PRECAUTIONS WHILE YOU DO WORK. IF YOU DO NOT OBEY THE PRECAUTIONS, DEATH OR INJURY TO PERSONS, AND DAMAGE TO THE AIRPLANE CAN OCCUR. **CAUTION:**ELECTRICALLY GROUND THE AIRPLANE. THIS WILL HELP TO PREVENT DAMAGE TO THE AIRPLANE OR EQUIPMENT. **CAUTION:**KEEP THE WORK AREA, WIRES AND ELECTRICAL BUNDLES CLEAN OF METAL PARTICLES OR CONTAMINATION WHEN YOU USE TOOLS. UNWANTED MATERIAL, METAL PARTICLES OR CONTAMINATION CAUGHT IN WIRE BUNDLES CAN CAUSE DAMAGE TO THE BUNDLES. DAMAGED WIRE BUNDLES CAN CAUSE SPARKS OR OTHER ELECTRICAL DAMAGE. **NOTE:**1. The instructions identified in Paragraph 3.B., Work Instructions, and the Figure(s) give the recommended sequence of steps. The sequence of steps to do this service bulletin can be changed. 2. Manual titles are referred to by acronyms. Refer to Paragraph 1.J., References, for definition of the acronyms. 3. Equivalent parts are listed in the AEPL, Drawing 7595071. 4. Use the approved fastener and process material substitutions, in accordance with DC-8 SRM Chapter 51. 5. If the length of any fastener specified in this service bulletin does not meet the installation standards in DC-8 SRM Chapter 51, then a fastener of the same specification, or an approved substitute, with a length which meets the installation standards in DC-8 SRM Chapter 51 may be used. 6. A 1/8-inch thick stack of the same type washers called for in this service bulletin is the maximum thickness which may be used under fastener head or nut to counteract accumulation of tolerances. EXCEPTION: When the available fastener length increments are greater than 1/16-inch, a 3/16-inch thick stack of the same type washers may be used. 7. Unless shown differently, these dimensions and tolerances are used: – Linear dimensions are in inches – Tolerance on linear dimensions, other than rivet and bolt edge margins, is plus or minus 0.03 inch. – Tolerance on rivet and bolt edge margin is plus or minus 0.05 inch – Angular tolerance is plus or minus 2 degrees – Hole dimensions for standard solid rivets are in DC-8 SRM Chapter 51. – Torque limits to tighten nuts and bolts are in DC-8 SRM Chapter 51. 8. Obey all of the warnings and cautions given in the specified manual sections.

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: May 05, 2010 DC8-57A103 51 of 62 **BOEING SERVICE BULLETIN DC8-57A103 ALERT**  **ALERT**9. A Detailed Inspection is defined as: An intensive examination of a specific item, installation, or assembly to detect damage, failure, or irregularity. Available lighting is normally supplemented with a direct source of good lighting at an intensity deemed appropriate. Inspection aids such as mirrors, magnifying lenses, etc. may be necessary. Surface cleaning and elaborate procedures may be required. 10. A General Visual Inspection is defined as: A visual examination of an interior or exterior area, installation or assembly to detect obvious damage, failure or irregularity. This level of inspection is made from within touching distance unless otherwise specified. A mirror may be necessary to enhance visual access to all exposed surfaces in the inspection area. This level of inspection is made under normally available lighting conditions such as daylight, hangar lighting, flashlight or drop-light and may require removal or opening of access panels or doors. Stands, ladders or platforms may be required to gain proximity to the area being checked. 11. These work instructions refer to procedures included in other Boeing documents. When the words "refer to" are used and the operator has an accepted alternative procedure, the accepted alternative procedure can be used. When the words "in accordance with" are included in the instruction, the procedure in the Boeing document must be used. **B. WORK INSTRUCTIONS Option 1 (Eddy Current, High Frequency)**  1. Make the left and right wing fuel tanks safe for entry. Refer to DC-8 AMM 28-00-0 as an accepted procedure. 2. Gain access to the areas to be inspected by opening the access panels as follows:
**Location Access Panel**  Left/Right Wing, Upper Surface 505B Left/Right Wing, Upper Surface 505C Left/Right Wing, Upper Surface 506B Internal Access Door 580D Internal Access Door 560D 3. Do an Eddy Current, High Frequency Inspection in the area around the indicated fasteners of the access opening doubler on the left and right wing center spar lower cap in accordance with the instructions in Figure 1 and establish the following condition(s). **NOTE:**It is possible to have more than one condition on an individual airplane.
**CONDITION 1 (No Crack(s) Found)** a. Go to work step 4

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: May 05, 2010 DC8-57A103 52 of 62 **BOEING SERVICE BULLETIN DC8-57A103 ALERT**  **ALERT CONDITION 2 (Crack Found at Station Xrs=168.00, Left and/or Right Wing)**  a. Repair crack in accordance with Service Rework Drawing SR08570022. b. Go to work step 4. **CONDITION 3 (Crack found at station Xrs=251.00, Left and/or Right Wing)** a. Repair crack in accordance with Service Rework Drawing SR08570005. b. Go to work step 4. **CONDITION 4 (Crack Found at Station Xrs=358.00, Left and/or Right Wing)** a. Repair crack in accordance with Service Rework Drawing SR08570015. b. Go to work step 4. 4. Install removed access panels. 5. Put the airplane back in serviceable condition. 6. Do repetitive inspections of the non-repaired center spar lower cap of the left and right wing center spar, and any repairs if installed, at intervals defined in Paragraph 1.E., Compliance. **Option 2 (Eddy Current, Low Frequency)** 1. Do an Eddy Current, Low Frequency Inspection of the center spar lower cap of the left and right wing center spar at the locations shown in Figure 2 to establish the following condition(s): **NOTE:**It is possible to have more than one condition on an individual airplane. **CONDITION 1 (No Crack(s) Found)** a. Go to work step 2. **CONDITION 2 (Crack Found at Station Xrs=168.00, Left and/or Right Wing)** a. Make the left and/or right wing fuel tanks safe for entry. Refer to DC-8 AMM 28-00-0 as an accepted procedure. b. Gain access to the area(s) to be repaired by opening the applicable access panels as follows:
**Location Access Panel**  Left/Right Wing, Upper Surface 505B Left/Right Wing, Upper Surface 505C Left/Right Wing, Upper Surface 506B Internal Access Door 580D

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: May 05, 2010 DC8-57A103 53 of 62 **BOEING SERVICE BULLETIN DC8-57A103 ALERT**  **ALERT Location**  **Access Panel** Internal Access Door 560D c. Repair crack in accordance with Service Rework Drawing SR08570022. d. Install removed access panels. e. Put the airplane back in serviceable condition. f. Go to work step 2. **CONDITION 3 (Crack Found at Station Xrs=251.00, Left and/or Right Wing)** a. Make the left and/or right wing fuel tanks safe for entry. Refer to DC-8 AMM 28-00-0 as an accepted procedure. b. Gain access to the area(s) to be repaired by opening the applicable access panels as follows:
**Location Access Panel**  Left/Right Wing, Upper Surface 505B Left/Right Wing, Upper Surface 505C Left/Right Wing, Upper Surface 506B Internal Access Door 580D Internal Access Door 560D c. Repair crack in accordance with Service Rework Drawing SR08570005. d. Install removed access panels. e. Put the airplane back in serviceable condition. f. Go to work step 2. **CONDITION 4 (Crack Found at Station Xrs=358.00, Left and/or Right Wing)** a. Make the left and/or right wing fuel tanks safe for entry. Refer to DC-8 AMM 28-00-0 as an accepted procedure. b. Gain access to the area(s) to be repaired by opening the applicable access panels as follows:
**Location Access Panel**  Left/Right Wing, Upper Surface 505B Left/Right Wing, Upper Surface 505C Left/Right Wing, Upper Surface 506B Internal Access Door 580D

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: May 05, 2010 DC8-57A103 54 of 62 **BOEING SERVICE BULLETIN DC8-57A103 ALERT**  **ALERT Location**  **Access Panel** Internal Access Door 560D c. Repair crack in accordance with Service Rework Drawing SR08570015. d. Install removed access panels. e. Put the airplane back in serviceable condition. f. Go to work step 2. 2. Do repetitive Eddy Current, Low Frequency Inspections of the non-repaired center spar lower cap of the left and right wing at the locations shown in Figure 2, and any repairs if installed, at intervals defined in Paragraph 1.E., Compliance.

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: May 05, 2010 DC8-57A103 55 of 62 **BOEING SERVICE BULLETIN DC8-57A103 ALERT**  **ALERT FIGURE 1: INSPECT THE LEFT AND RIGHT WING CENTER SPAR - EDDY CURRENT, HIGH FREQUENCY**  **INSPECTION METHOD (SHEET 1 OF 4)** 

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: May 05, 2010 DC8-57A103 56 of 62 **BOEING SERVICE BULLETIN DC8-57A103 ALERT**  **ALERT FIGURE 1: INSPECT THE LEFT AND RIGHT WING CENTER SPAR - EDDY CURRENT, HIGH FREQUENCY**  **INSPECTION METHOD (SHEET 2 OF 4)** 

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: May 05, 2010 DC8-57A103 57 of 62 **BOEING SERVICE BULLETIN DC8-57A103 ALERT**  **ALERT FIGURE 1: INSPECT THE LEFT AND RIGHT WING CENTER SPAR - EDDY CURRENT, HIGH FREQUENCY**  **INSPECTION METHOD (SHEET 3 OF 4)** 

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: May 05, 2010 DC8-57A103 58 of 62 **BOEING SERVICE BULLETIN DC8-57A103 ALERT**  **ALERT**The step numbers shown below agree with the numbers shown in the circle symbols in the figure.
**Notes Station**  **Action Step**  Perform a High Frequency Eddy Current surface inspection of the spar cap adjacent to the indicated fastener in the left and right wings. Scan around the fastener looking for cracks originating at fastener hole and propagating radially from the fastener hole. Scan using the instructions found in the Nondestructive Testing Standard Practice Manual (NDTSPM) 06-10-01.001 (HFET - Procedure 1). Use Calibration Method "K" and Scan Method "44." Xrs = 168.00 Inspect 1

Perform a High Frequency Eddy Current surface inspection of the spar cap adjacent to the indicated fastener in the left and right wings. Scan around the fastener looking for cracks originating at fastener hole and propagating radially from the fastener hole. Scan using the instructions found in the Nondestructive Testing Standard Practice Manual (NDTSPM) 06-10-01.001 (HFET - Procedure 1). Use Calibration Method "K" and Scan Method "44." Xrs = 251.00 Inspect 2

Perform a High Frequency Eddy Current surface inspection of the spar cap adjacent to the indicated fastener in the left and right wings. Scan around the fastener looking for cracks originating at fastener hole and propagating radially from the fastener hole. Scan using the instructions found in the Nondestructive Testing Standard Practice Manual (NDTSPM) 06-10-01.001 (HFET - Procedure 1). Use Calibration Method "K" and Scan Method "44." Xrs = 358.00 Inspect 3

**FIGURE 1: INSPECT THE LEFT AND RIGHT WING CENTER SPAR - EDDY CURRENT, HIGH FREQUENCY INSPECTION METHOD**  **(SHEET 4 OF 4)**

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: May 05, 2010 DC8-57A103 59 of 62 **BOEING SERVICE BULLETIN DC8-57A103 ALERT**  **ALERT FIGURE 2: INSPECT THE LEFT AND RIGHT WING CENTER SPAR -EDDY CURRENT, LOW FREQUENCY**  **INSPECTION METHOD (SHEET 1 OF 3)** 

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: May 05, 2010 DC8-57A103 60 of 62 **BOEING SERVICE BULLETIN DC8-57A103 ALERT**  **ALERT FIGURE 2: INSPECT THE LEFT AND RIGHT WING CENTER SPAR -EDDY CURRENT, LOW FREQUENCY**  **INSPECTION METHOD (SHEET 2 OF 3)** 

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: May 05, 2010 DC8-57A103 61 of 62 **BOEING SERVICE BULLETIN DC8-57A103 ALERT**  **ALERT**The step numbers shown below agree with the numbers shown in the circle symbols in the figure. Do an Eddy Current, Low Frequency Inspection of the left and right wings through the skin into the spar cap to confirm intact center spar lower cap. Inspections should start at the bulkhead stations and continue to wing stations as follows:
**Notes Station**  **Action Step**  Do an Eddy Current, Low Frequency Inspection of the left and right wings through the skin into the spar cap to confirm intact center spar lower cap. Inspect a minimum of 7 inches inboard from noted bulkhead station. Inspect per Supplemental Inspection Document (SID) Volume II, PSE 57.08.013/014 using chapter 57-10-06 Sequence 1, Method 1. Xrs = 168.00 Inspect 1

Do an Eddy Current, Low Frequency Inspection of the left and right wings through the skin into the spar cap to confirm intact center spar lower cap. Inspect a minimum of 7 inches inboard from noted bulkhead station. Inspect per Supplemental Inspection Document (SID) Volume II, PSE 57.08.013/014 using chapter 57-10-06 Sequence 1, Method 1. Xrs = 251.00 Inspect 2

Do an Eddy Current, Low Frequency Inspection of the left and right wings through the skin into the spar cap to confirm intact center spar lower cap. Inspect a minimum of 7 inches inboard from noted bulkhead station. Inspect per Supplemental Inspection Document (SID) Volume II, PSE 57.08.35/036 using chapter 57-10-16 Sequence 1, Method 1. Xrs = 358.00 Inspect 3

**FIGURE 2: INSPECT THE LEFT AND RIGHT WING CENTER SPAR -EDDY CURRENT, LOW FREQUENCY INSPECTION METHOD**  **(SHEET 3 OF 3)**

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: May 05, 2010 DC8-57A103 62 of 62 **BOEING SERVICE BULLETIN DC8-57A103 ALERT**  **ALERT**