**McDonnell Douglas** 

### Commercial **Airplanes** 

# MD90 Service Bulletin **ALERT Number: MD90-53A031**  Original Issue: April 10, 2009 ATA System: 5310 **SUBJECT:** FUSELAGE - Fuselage Main Frame - Inspect Overwing Frames for Cracks 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## BOEING PROPRIETARY, CONFIDENTIAL, AND/OR TRADE SECRET Copyright © 2009 The Boeing Company Unpublished Work - All Rights Reserved Boeing claims copyright in each page of this document only to the extent that the page contains copyrightable subject matter.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, 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BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: April 10, 2009 MD90-53A031 1 of 35 2.0BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: April 10, 2009 MD90-53A031 2 of 35 **BOEING SERVICE BULLETIN MD90-53A031 ALERT**  **ALERT**

BLANK PAGE**Table of Contents** Summary ..................................................... 5 1. PLANNING INFORMATION......................................... 9 A. Effectivity ................................................ 9 1. Airplanes ............................................. 9 2. Spares Affected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 B. Concurrent Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 C. Reason . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 D. Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 E. Compliance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 F. Approval . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 G. Manpower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 H. Weight and Balance Changes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 I. Electrical Load Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 J. References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 1. Existing Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 2. Data supplied with this Service Bulletin . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 3. Installation Drawings Used in the Preparation of this Service Bulletin. . . . . . . . . . . . 15 K. Publications Affected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 L. Interchangeability and Intermixability of Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 2. MATERIAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 A. Material - Price and Availability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 B. Industry Support Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 C. Parts Necessary For Each Airplane. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 1. Kits/Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 2. Parts and Materials Supplied by the Operator . . . . . . . . . . . . . . . . . . . . . . . . 22 3. Parts Modified and Reidentified . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 4. Parts Removed and Not Replaced . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 D. Parts Necessary to Change Spares. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 E. Special Tooling - Price and Availability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 F. Special Tooling Necessary to do this Service Bulletin . . . . . . . . . . . . . . . . . . . . . . . 24 3. ACCOMPLISHMENT INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 A. GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 B. WORK INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 FIGURE 1: DETAILED VISUAL INSPECTION - OVERWING FRAMES . . . . . . . . . . . . . . . . . 29 FIGURE 2: EDDY CURRENT, HIGH FREQUENCY INSPECTION - OVERWING FRAMES . . . . . . 31 FIGURE 3: BLEND-OUT REPAIR - FRAME TAB UPPER RADIUS . . . . . . . . . . . . . . . . . . . . 33

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: April 10, 2009 MD90-53A031 3 of 35 **BOEING SERVICE BULLETIN MD90-53A031 ALERT**  **ALERT**BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: April 10, 2009 MD90-53A031 4 of 35 **BOEING SERVICE BULLETIN MD90-53A031 ALERT**  **ALERT**

BLANK PAGE**McDonnell Douglas** 

### Commercial **Airplanes** 

# MD90 Service Bulletin **ALERT Summary**  **Number: MD90-53A031** Original Issue: April 10, 2009 ATA System: 5310 **SUBJECT:** FUSELAGE - Fuselage Main Frame - Inspect Overwing Frames for Cracks 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** There have been over forty reports of overwing frames cracking on MD-80 airplanes having logged between 19,876 and 41,166 flight cycles. There is no report of a cracked overwing frame on an MD-90 airplane but due to similarity in frame design, the MD-90's are susceptible to cracks. The cracks, which originate in the upper radius of the frame inboard tab just below the floor, were caused by fatigue. Boeing has determined that MD-90 overwing frames at Stations 883, 902, 924, 943 and 962 are also susceptible to this type of failure. All the noted frames are a part of MD-90 Principal Structural Element (PSE) 53.12.09.1 Inspection of the overwing frames from Station 883 to 962 on left and right sides will determine if cracks exist. If not corrected, an undetected crack may sever the frame, which may increase the loading of adjacent frames and result in damage to adjacent structure and extensive repair, or ultimately could lead to the loss of overall structural integrity of the airplane. **ACTION** This service bulletin provides instructions to do a general visual inspection and a high frequency eddy current inspection of the overwing frames at Stations 883, 902, 924, 943 and 962 on left and right sides. The purpose of these inspections is to detect fatigue cracks in the upper radius of the frame tab. Based on inspection results, do as follows: **Condition 1 (No Crac k)**  1. Does repetitive inspections of the overwing frames for cracks. **Condition 2 (Crac k Less than 0.125 Inc** **h in Depth)** 1. Does a blend-out repair of the crack. 2. Does repetitive inspections of the overwing frames for cracks.

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: April 10, 2009 MD90-53A031 5 of 35**Condition 3 (Crac k is Equal** **T o or Greater** **Than 0.125 Inc h in Depth)**  1. Replaces the cracked overwing frame. 2. Does repetitive inspections of the overwing frames for cracks. **EFFECTIVITY** All MD-90-30 Airplanes. Refer to Paragraph 1.A.1., Airplanes for the list of affected airplanes. **COMPLIANCE** Refer to Paragraph 1.E., Compliance. The Federal Aviation Administration (FAA) will possibly release an Airworthiness Directive related to this service bulletin. The Airworthiness Directive will make the compliance tasks and times given in this service bulletin mandatory. **INDUSTRY SUPPORT INFORMATION** Boeing warranty remedies are not available for the inspection and/or repair procedures given in this service bulletin. **MANPOWER** Refer to Paragraph 1.G., Manpower. **MATERIAL INFORMATION** Boeing Supplied Kits/Parts. Refer to Paragraph 2.A., Material - Price and Availability.

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: April 10, 2009 MD90-53A031 6 of 35 **BOEING SERVICE BULLETIN MD90-53A031 ALERT**  **ALERT**BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: April 10, 2009 MD90-53A031 7 of 35 **BOEING SERVICE BULLETIN MD90-53A031 ALERT**  **ALERT**BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: April 10, 2009 MD90-53A031 8 of 35 **BOEING SERVICE BULLETIN MD90-53A031 ALERT**  **ALERT**

BLANK PAGE**McDonnell Douglas** 

### Commercial **Airplanes** 

# MD90 Service Bulletin **ALERT Number: MD90-53A031**  Original Issue: April 10, 2009 ATA System: 5310 **SUBJECT:** FUSELAGE - Fuselage Main Frame - Inspect Overwing Frames for Cracks 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** All MD-90 Airplanes

- 1

Airplane Models: MD-90-30 **Group Fuselage Num-**  **ber** 1 2094 - 2100 1 2115 1 2117 1 2120 1 2122 - 2123 1 2125 - 2126 1 2129 1 2131 1 2133

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: April 10, 2009 MD90-53A031 9 of 35**Group Fuselage Num-**  **ber** 1 2136 1 2138 1 2140 - 2144 1 2146 - 2147 1 2149 - 2150 1 2153 - 2154 1 2156 - 2159 1 2161 - 2166 1 2169 - 2171 1 2173 1 2175 1 2177 1 2179 1 2181 - 2182 1 2184 1 2186 1 2190 - 2191 1 2193 - 2195 1 2197 - 2198 1 2200 1 2202 - 2203 1 2205 1 2207 1 2209 - 2213 1 2215 - 2217 1 2219 - 2233 1 2235 - 2237 1 2240 1 2243 1 2245 1 2248 1 2250 - 2251

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: April 10, 2009 MD90-53A031 10 of 35 **BOEING SERVICE BULLETIN MD90-53A031 ALERT**  **ALERT Group**  **Fuselage Num- ber**  1 2253 1 2255 - 2263 1 2288 - 2290 1 4001 - 4002 2. Spares Affected None. **B. Concurrent Requirements** None. **C. Reason** There have been over forty reports of overwing frames cracking on MD-80 airplanes having logged between 19,876 and 41,166 flight cycles. There is no report of a cracked overwing frame on an MD-90 airplane but due to similarity in frame design, the MD-90's are susceptible to cracks.The cracks, which originate in the upper radius of the frame inboard tab just below the floor, were caused by fatigue. Boeing has determined that MD-90 overwing frames at Stations 883, 902, 924, 943 and 962 are also susceptible to this type of failure. All the noted frames are a part of MD-90 Principal Structural Element (PSE) 53.12.09.1 Inspection of the overwing frames from Station 883 to 962 on left and right sides will determine if cracks exist. If not corrected, an undetected crack may sever the frame, which may increase the loading of adjacent frames and result in damage to adjacent structure and extensive repair, or ultimately could lead to the loss of overall structural integrity of the airplane. **D. Description** This service bulletin provides instructions to do a general visual inspection and a high frequency eddy current inspection of the overwing frames at Stations 883, 902, 924, 943 and 962 on left and right sides. The purpose of these inspections is to detect fatigue cracks in the upper radius of the frame tab. Based on inspection results, does as follows: **Condition 1 (No Crac k)**  1. Does repetitive inspections of the overwing frames for cracks. **Condition 2 (Crac k Less than 0.125 Inc** **h in Depth)** 1. Does a blend-out repair of the crack. 2. Does repetitive inspections of the overwing frames for cracks. **Condition 3 (Crac k is Equal** **T o or Greater** **Than 0.125 Inc h in Depth)**  1. Replaces the cracked overwing frame. 2. Does repetitive inspections of the overwing frames for cracks.

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: April 10, 2009 MD90-53A031 11 of 35 **BOEING SERVICE BULLETIN MD90-53A031 ALERT**  **ALERT**The work in this service bulletin is done in the maintenance zone(s) given below.
**Affected Maintenance Zones Zone**  **Model** 151, 161 MD-90-30 **E. Compliance** The Federal Aviation Administration (FAA) will possibly release an Airworthiness Directive related to this service bulletin.The Airworthiness Directive will make the compliance tasks and times given in this service bulletin mandatory. **T**

**ab le 1:** **Inspect Left and Right Side Overwing Frames f or Crac** **ks fr om Station 883 to 962**  **Repeat Interval (Not to Exceed)**  **Compliance Time (Whichever Occurs Later )**  **Action Condition** 

- Within 60 monthsafter the original issue date on this service bulletin.Before the accumulation of 20,000 total flight cycles.Do a general visual inspection and a high frequency eddy current inspection ofthe overwing frames in accordance with Accomplishment Instructions 3.B. All Airplanes

5,900 flight cycles.

- - Do repeat general visual in- spection and high frequency eddy current inspection ofthe overwing frames in accordance with Accomplishment Instructions 3.B. Condition 1 (No Crack Found)

- - Before further flight.Repair the cracked overwing frame in accordancewith Accomplishment Instructions 3.B. Condition 2 (Crack Found is Less Than 0.125 Inch in Depth) AND 5,900 flight cycles.

- - Do a general visual inspec-tion and high frequency eddy current inspection of the repaired overwing frame inaccordance with Accomplishment Instructions 3.B.

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: April 10, 2009 MD90-53A031 12 of 35 **BOEING SERVICE BULLETIN MD90-53A031 ALERT**  **ALERT T**  **ab le 1:** **Inspect Left and Right Side Overwing Frames f or Crac** **ks fr om Station 883 to 962**  **Repeat Interval (Not to Exceed)**  **Compliance Time (Whichever Occurs Later )**  **Action Condition** 

- - Before further flight.Replace the cracked overwing frame in accordancewith Accomplishment Instructions 3.B. Condition 3 (Crack Found is Equal To OR Greater Than 0.125 Inch in Depth) AND 5,900 flight cycles.

- Within 20,000 flightcycles after replacement.Do a general visual inspection and high frequency eddy current inspection of the replacement overwing frame in accordance withAccomplishment Instructions 3.B. **F. Approval** The resultant modification described in Paragraph 1.D has been shown to comply with the applicable Federal Aviation Regulations and is approved by the Manager, Los Angeles Aircraft Certification Office, FAA Northwest Mountain Region. **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. **Condition 1 Elapsed Hours**  **Task Hours Number of Persons**  **Task** 8.0 32.0 4 Open Access 5.0 5.0 1 Visual Inspect 5.0 5.0 1 ETHF Inspect 8.0 32.0 4 Close Access 26.0 74.0 TOTAL FOR EACH AIRPLANE
**NO TE:**  Maximum total task hours and elapsed hours are given for inspection per airplane.

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: April 10, 2009 MD90-53A031 13 of 35 **BOEING SERVICE BULLETIN MD90-53A031 ALERT**  **ALERT Condition 2**  **Elapsed Hours Task Hours**  **Number of Persons Task**  8.0 32.0 4 Open Access 5.0 5.0 1 Visual Inspect 5.0 5.0 1 ETHF Inspect 8.0 8.0 1 Remove Cusp Membrane 2.0 2.0 1 Blendout Repair 8.0 8.0 1 Install Cusp Mem- brane 8.0 32.0 4 Close Access 44.0 92.0 TOTAL FOR EACH AIRPLANE
**NO TE:**  Maximum total task hours and elapsed hours are given for the blendout repair of one frame. Additional task hours and elapsed hours for the repair of other cracked frames are contingent upon inspection results and are to be estimated by the operator. **Condition 3 Elapsed Hours**  **Task Hours Number of Persons**  **Task** 8.0 32.0 4 Open Access 5.0 5.0 1 Visual Inspect 5.0 5.0 1 ETHF Inspect 8.0 8.0 1 Remove Cusp Membrane 10.0 20.0 2 Remove Frame 24.0 48.0 2 Install Frame 8.0 8.0 1 Install Cusp Mem- brane 8.0 32.0 4 Close Access 76.0 158.0 TOTAL FOR EACH AIRPLANE
**NO TE:**  Maximum total task hours and elapsed hours are given for the replacement of one frame. Additional task hours and elapsed hours for the replacement of other cracked frames, are contingent upon inspection results and are to be estimated by the operator. **H. Weight and Balance Changes** None.

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: April 10, 2009 MD90-53A031 14 of 35 **BOEING SERVICE BULLETIN MD90-53A031 ALERT**  **ALERT I. Electrical Load Data**  Not changed. **J. References** 1. Existing Data a. Non-Destructive Test Standard Practices Manual (NDTSPM) 06-10-01.001, 09-00-04 and 09-00-06. b. Standard Overhaul Practices Manual (SOPM) 20-10-10. c. MD90 Aircraft Maintenance Manual (AMM) 06-31-00, 07-10-00, 07-20-00, 08-10-00, 12-11-10, 20-20-03, 25-21-00, 25-21-03, 25-23-00, 25-27-00, 52-21-00 and 53-21-01. d. MD90 Structural Repair Manual (SRM), Volume 2, 51-10-03, 51-10-05, 51-20-00, 51-30-01, 51-30-02, 51-30-03, 51-30-05 and 51-40-00. 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**

- - DWG FRAME INSTALLATION - OVERWING REPLACEMENT SR90530027
3. Installation Drawings Used in the Preparation of this Service Bulletin None. **K. Publications Affected** 1. Publications: **Chapter-Section Publication**  Maintenance Planning Document 2. Damage Tolerance Based Structural Inspections:

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: April 10, 2009 MD90-53A031 15 of 35 **BOEING SERVICE BULLETIN MD90-53A031 ALERT**  **ALERT**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 but no new DTIs are necessary. **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: April 10, 2009 MD90-53A031 16 of 35 **BOEING SERVICE BULLETIN MD90-53A031 ALERT**  **ALERT 2. MATERIAL INFORMATION**  **A. Material - Price and Availability** Boeing can supply the Kits shown in Paragraph 2.C., Parts Necessary for Each Airplane as shown below. Kit availability is shown in the Reorder Lead Time (ROLT). ROLT is calculated from the date Boeing gets the purchase order. A limited quantity of kits are available. Once consumed, refer to the standard ROLT listed below.
**Unit Price thru December 31, 2009**  **ROLT (Weeks) Name**  **Number** $32,200.00 17 Service Kit SA90530031-3 32,200.00 17 Service Kit SA90530031-5 33,157.00 17 Service Kit SA90530031-7 33,156.00 17 Service Kit SA90530031-9 33,192.00 17 Service Kit SA90530031-11 33,192.00 17 Service Kit SA90530031-13 37,096.00 17 Service Kit SA90530031-15 37,096.00 17 Service Kit SA90530031-17 36,851.00 17 Service Kit SA90530031-19 36,851.00 17 Service Kit SA90530031-21

The kits are subject to the terms and conditions of the Boeing standard purchase order acknowledgment. After the Unit Price date, new price and ROLT data is applicable. Prices are in United States dollars. Terms: Net 30 days. Reference this service bulletin and submit your purchase order by one of the methods that follow: 1. Order on-line via ATA Spec 2000 or Boeing Part Page 2. Fax to (206) 662-7145 3. Mail to: Spares Customer Support - MC 36-65 Boeing Spares Department P.O. Box 3707 Seattle, Washington 98124-2207 USA **B. Industry Support Information** Boeing warranty remedies are not available for the inspection and/or repair procedures given in this service bulletin.

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: April 10, 2009 MD90-53A031 17 of 35 **BOEING SERVICE BULLETIN MD90-53A031 ALERT**  **ALERT C. Parts Necessary For Each Airplane**  1. Kits/Parts To get the kits/parts shown below, refer to Paragraph 2.A., Material - Price and Availability. **NO TE:**  One top kit and the items shown in Paragraph 2.C.2., Parts and Materials Supplied by the Operator, are necessary for each airplane. **Ser vice Kit Matrix** 
**Station Location Position**  **Drawing Configuration Service Kit**  Y= 883.000 Left SR90530027-7001 SA90530031-3 Right SR90530027-7003 SA90530031-5 Y= 902.000 Left SR90530027-7005 SA90530031-7 Right SR90530027-7007 SA90530031-9 Y= 924.000 Left SR90530027-7009 SA90530031-11 Right SR90530027-7011 SA90530031-13 Y= 943.000 Left SR90530027-7013 SA90530031-15 Right SR90530027-7015 SA90530031-17 Y= 962.000 Left SR90530027-7017 SA90530031-19 Right SR90530027-7019 SA90530031-21
**Kit SA90530031 Notes**  **Existing Part Number**  **Name QTY**  **New Part Number -13**  **-11 -9**  **-7 -5**  **-3** CLIP

. . 1 1

. . 2913797-1 CLIP 1 1 1 1

. . 2913870-1 CLIP 1 1

. . . . 2920753-1 CLIP

. . 1 1

. . 2920754-1 CLIP 1

. 1

. . . 2920756-1 CLIP

. 1

. 1

. . 2920756-2 NUT ASSY 58 58 58 58 24 24 3D0006-3 NUT ASSY

. . . . 2 2 3D0006-4 PIN

. . 1 1

. . 3D0010-6-6 PIN 12 12 14 14

. . 3D0010-6-7 PIN 13 13 5 5

. . 3D0010-6-8 PIN 1 1 6 6

. . 3D0010-6-9

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: April 10, 2009 MD90-53A031 18 of 35 **BOEING SERVICE BULLETIN MD90-53A031 ALERT**  **ALERT Kit SA90530031**  **Notes Existing Part**  **Number Name**  **QTY New Part Number**  **-13 -11**  **-9 -7**  **-5 -3**  CLIP

. . . 1

. . 9919669-17 CLIP

. . 1

. . . 9919669-18 FRAME

. . . 1

. . 9923405-505 FRAME

. . 1

. . . 9923405-506 FRAME 1

. . . . . 9923405-507 FRAME

. 1

. . . . 9923405-508 CLIP

. . . . 4 4 9935997-7 FRAME

. . . . . 1 9936471-501 FRAME

. . . . 1

. 9936471-502 CLIP

. . . . 1 1 9957901-9 CLIP 1

. . . . . 9964454-17 CLIP

. 1

. . . . 9964454-18 CLIP 1 1

. . . . 9964454-19 CLIP 1 1

. . . . 9964454-21 PIN 1 1 1 1

. . HL329-6-11 PIN 1 1 1 1

. . HLT425-6-5 PIN 1 1 1 1

. . HLT425-6-6 PIN 4 4 4 4

. . HLT425-6-7 PIN 1 1 1 1 1 1 HLT426-10-10 O/S FASTENER

. . . . 2 2 HLT426-12-11 O/S FASTENER 2 2

. . . . HLT426-12-13 PIN

. . 2 2

. . HLT426-12-9 PIN 1 1 1 1

. . HLT426-6-10 PIN 19 19 8 8

. . HLT426-6-3 PIN 13 13 20 20 2 2 HLT426-6-4 PIN 11 11 11 11 22 22 HLT426-6-5 PIN 11 11 11 11 9 9 HLT426-6-6 PIN

. . . . 1 1 HLT426-6-7 PIN 9 9 9 9 9 9 HLT426-6-8 PIN 1 1 1 1

. . HLT426-6-9 PIN 3 3 3 3 3 3 HLT426-8-10

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: April 10, 2009 MD90-53A031 19 of 35 **BOEING SERVICE BULLETIN MD90-53A031 ALERT**  **ALERT Kit SA90530031**  **Notes Existing Part**  **Number Name**  **QTY New Part Number**  **-13 -11**  **-9 -7**  **-5 -3**  PIN 1 1 1 1

. . HLT426-8-7 PIN

. . . . 1 1 HLT426-8-8 PIN 3 3 3 3 2 2 HLT426-8-9 PIN 1 1 1 1 1 1 HLT435-6-10 PIN

. . . . 1 1 HLT435-6-11 PIN 2 2 2 2 18 18 HLT435-6-6 PIN 58 58 58 58 27 27 HLT435-6-7 PIN 1 1 1 1 6 6 HLT435-6-8 PIN

. . . . 1 1 HLT435-6-9 RIVET 10 10 10 20 3 3 MS20470AD5-10D RIVET 21 21 1 1 3 3 MS20470AD5-11D RIVET 1 1 20 20

. . MS20470AD5-12D RIVET

. . . . 24 24 MS20470AD5-6D RIVET

. . . . 6 6 MS20470AD5-7D RIVET

. . . . 3 3 MS20470AD5-8D RIVET

. . 1 1

. . MS20470AD5-9D RIVET 1 1

. . . . MS20470AD6-12D RIVET

. . 1 1

. . MS20470AD6-14D NUT 101 101 97 97 73 73 MS21042L3 NUT 7 7 7 7 2 2 MS21042L4 NUT 1 1 1 1 1 1 MS21042L5 NUT 2 2 2 2 2 2 MS21042L6 WASHER 97 97 93 93 41 41 NAS1252-10H WASHER 5 5 5 5 32 32 NAS1252-10L WASHER 7 7 7 7 2 2 NAS1252-416H WASHER 1 1 1 1 1 1 NAS1252-516H WASHER 2 2 2 2 2 2 NAS1252-616H NUT 1 1 1 1

. . NAS679A3

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: April 10, 2009 MD90-53A031 20 of 35 **BOEING SERVICE BULLETIN MD90-53A031 ALERT**  **ALERT Kit SA90530031**  **Notes Existing Part**  **Number Name**  **QTY New Part Number**  **-21 -19**  **-17 -15**  CLIP 1 1 1 1 2913870-1 CLIP 1 1 1 1 2920753-1 CLIP 1

. . 1 2920756-1 CLIP

. 1 1

. 2920756-2 NUT ASSY 65 65 64 64 3D0006-3 PIN 1 1

. . 3D0010-6-5 PIN 9 9

. . 3D0010-6-6 PIN 6 6

. . 3D0010-6-7 PIN 10 10

. . 3D0010-6-8 CLIP

. 1 1

. 9919671-17 CLIP 1

. . 1 9919671-18 CLIP 1 1 1 1 9919671-19 CLIP 1 1 1 1 9919671-21 FRAME

. . . 1 9923406-503 FRAME

. . 1

. 9923406-504 FRAME

. 1

. . 9923407-503 FRAME 1

. . . 9923407-504 PIN 1 1

. . HL329-6-10 PIN, OVERSIZE 2 2 2 2 HLT426-12-10 PIN

. . 1 1 HLT426-6-10 PIN 15 15 15 15 HLT426-6-3 PIN 14 14 14 14 HLT426-6-4 PIN 12 12 13 13 HLT426-6-5 PIN 16 16 21 21 HLT426-6-6 PIN 10 10 2 2 HLT426-6-7 PIN 1 1 7 7 HLT426-6-8 PIN 1 1 1 1 HLT426-6-9 PIN 4 4 4 4 HLT426-8-10 PIN 1 1

. . HLT426-8-8 PIN 3 3 4 4 HLT426-8-9 PIN

. . 1 1 HLT435-6-10

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: April 10, 2009 MD90-53A031 21 of 35 **BOEING SERVICE BULLETIN MD90-53A031 ALERT**  **ALERT Kit SA90530031**  **Notes Existing Part**  **Number Name**  **QTY New Part Number**  **-21 -19**  **-17 -15**  PIN 2 2 32 32 HLT435-6-6 PIN 57 57 28 28 HLT435-6-7 PIN 5 5 3 3 HLT435-6-8 PIN 1 1

. . HLT435-6-9 RIVET

. . 3 3 MS20470AD5-10D RIVET 18 18 3 3 MS20470AD5-11D RIVET 2 2

. . MS20470AD5-12D RIVET

. . 36 36 MS20470AD5-6D RIVET

. . 12 12 MS20470AD5-7D RIVET 10 10

. . MS20470AD5-8D RIVET 2 2

. . MS20470AD5-9D RIVET 1 1

. . MS20470AD6-13D NUT 95 95 74 74 MS21042L3 NUT 8 8 8 8 MS21042L4 NUT 2 2 2 2 MS21042L6 WASHER 95 95 74 74 NAS1252-10H WASHER 1 1

. . NAS1252-10L WASHER 8 8 8 8 NAS1252-416H WASHER 2 2 2 2 NAS1252-616H NUT 1 1

. . NAS679A3

2. Parts and Materials Supplied by the Operator **NO TE:**  Refer to Non-Destructive Testing Standard Practice Manual (NDTSPM) Part 06 and Part 09 for the required materials to be used in the inspections.
**Notes Name**  **QTY Part Number / Specification**  (a) Tape, Cloth Coated 1 Roll PC21F (DMS 1968 Type 2) OR (b) Tape, Cloth Coated 1 Roll Polyken 225 (DMS 1968 Type 2) OR

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: April 10, 2009 MD90-53A031 22 of 35 **BOEING SERVICE BULLETIN MD90-53A031 ALERT**  **ALERT Notes**  **Name QTY**  **Part Number / Specification** (c) Tape, Adhesive 1 Roll 770-3 FRD (DMS 1984 Type 6 Class 2) OR (d) Tape, Adhesive 1 Roll OT-16A (DMS 1984 Type 6 Class 2) (e) Sealing Compound 1 Quart PR-1422 Class B-2 (DMS 2082) OR Equivalent
CAGE Shurtape Technologies, LLC May be purchased from: (a) 4L0S0 1506 Highland Avenue Hickory, North Carolina 28601 80769 Covalence Specialty Adhesives May be purchased from: (b) 2320 Bowling Green Road Franklin, Massachusetts 02038 9U930 Annitti Enterprises Incorporated May be purchased from: (c) 138 Grand Street Paterson, New Jersey 07501 23788 Orcon Corporation May be purchased from: (d) 251 rope Mill Parkway STE 1 Woodstock, Georgia 30188 92108 PRC-DeSoto International, Incorporated May be purchased from: (e) 5454 San Fernando Road Glendale, California 91203

3. Parts Modified and Reidentified None. 4. Parts Removed and Not Replaced None. **D. Parts Necessary to Change Spares** None **E. Special Tooling - Price and Availability** General visual inspection equipment and high frequency eddy current inspection equipment required to accomplish this service bulletin are listed in the Non-Destructive Testing Standard Practice Manual (NDTSPM) and are to be procured from operator’s stock or sources indicated.

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: April 10, 2009 MD90-53A031 23 of 35 **BOEING SERVICE BULLETIN MD90-53A031 ALERT**  **ALERT 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: April 10, 2009 MD90-53A031 24 of 35 **BOEING SERVICE BULLETIN MD90-53A031 ALERT**  **ALERT 3. ACCOMPLISHMENT INSTRUCTIONS**  **A. GENERAL INFORMATION W** 

**ARNING:** 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. **CA UTION:**  ELECTRICALLY GROUND THE AIRPLANE. THIS WILL HELP TO PREVENT DAMAGE TO THE AIRPLANE OR EQUIPMENT. **CA UTION:**  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. **NO TE:**  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 MD90 SRM, Chapter 51, Volume 2. 5. If the length of any fastener specified in this service bulletin does not meet the installation standards in MD90 SRM Chapter 51, then a fastener of the same specification, or an approved substitute, with a length which meets the installation standards in MD90 SRM Chapter 51, Volume 2, 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. Oversize fasteners must be used when the hole diameter exceeds the maximum diameter specified. 8. Refer to the manuals that follow as an accepted procedure: **Operation Accepted Procedure**  Sealant Application MD90 AMM 20-20-03 Corrosion/Erosion Control and Prevention MD90 SRM 51-10-03

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: April 10, 2009 MD90-53A031 25 of 35 **BOEING SERVICE BULLETIN MD90-53A031 ALERT**  **ALERT Operation**  **Accepted Procedure** Drilling and Countersinking MD90 SRM 51-10-05 Repair Sealing MD90 SRM 51-20-00 Installing Bolts, Screws, and Washers MD90 SRM 51-30-01 Installing and Removing Rivets MD90 SRM 51-30-02 Installing and Removing Lockbolts MD90 SRM 51-30-03 Installing and Removing Hi-Lok Attachments MD90 SRM 51-30-05 Substitution and Interchangeability MD90 SRM 51-40-00
9. Obey all of the warnings and cautions given in the specified manual sections. 10. 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. 11. 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 ensure visual access to all surfaces in the inspection area. This level of inspection is made under normal 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. 12. 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** 1. Remove and keep the following items and attaching parts, as applicable, to get access to the left and right side overwing frames at Stations 883, 902, 924, 943 and 962. **Accepted Procedure Item**  MD90 AMM 25-23-00 Passenger Seats MD90 AMM 25-21-00 Passenger Compartment Lining MD90 AMM 25-21-03 Passenger Compartment Insulation MD90 AMM 25-27-00 Passenger Compartment Floor Covering MD90 AMM 53-21-01 Passenger Compartment Floor Panels

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: April 10, 2009 MD90-53A031 26 of 35 **BOEING SERVICE BULLETIN MD90-53A031 ALERT**  **ALERT Accepted Procedure**  **Item** MD90 AMM 52-21-00 Overwing Emergency Exit Doors 2. Remove tape from the cutout between the cusp membrane and frame to get access to the frame inspection area. 3. Remove and keep the cusp membrane, as necessary, to get access to the frame inspection area. 4. Do a General Visual inspection and an Eddy Current, High Frequency (ETHF) inspection of the upper radius of the frame tab of the overwing frames in accordance with Figures 1 and 2. Based on findings do as follows: **Condition 1 (No Crac k)**  a. Install kept cusp membrane if it was removed to get access to the frame inspection area. b. Install tape to seal along the cutout between the cusp membrane and frame. c. Do repeat inspections of the overwing frames. **Condition 2 (Crac k less than 0.125 Inc** **h in Depth)** a. If installed, remove and keep the cusp membrane to get access to the cracked frame. b. Do a blend-out repair of the crack in accordance with Figure 3. c. Install kept cusp membrane. d. Install tape to seal along the cutout between the cusp membrane and frame. e. Do repeat inspections of the overwing frames. **Condition 3 ( Crac k 0.125 Inc** **h in Depth or Greater)** a. Defuel the airplane. Refer to MD90 AMM 12-11-10 as an accepted procedure. b. Raise and level the airplane. Refer to MD90 AMM 07-10-00 and MD90 AMM 08-10-00 as an accepted procedure. **NO TE:**  Boeing recommends each frame be replaced separately. If two or more frames are replaced at the same time, shoring the airplane is recommended. Refer to MD90 AMM 07-20-00 as an accepted procedure. c. If installed, remove and keep the cusp membrane to get access to the cracked frame. d. Remove and keep the applicable wing to fuselage fillet panels 150CL, 150FL and 150ML on the left side and 160CR, 160FR and 160MR on the right side to get access to the cracked frame. Refer to MD90 AMM 06-31-00 as an accepted procedure. e. Replace cracked overwing frame in accordance with Service Rework Drawing SR90530027.

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: April 10, 2009 MD90-53A031 27 of 35 **BOEING SERVICE BULLETIN MD90-53A031 ALERT**  **ALERT NO** **TE:** Apply PR-1422 sealant on all faying surfaces and wet install all fasteners during frame replacement. f. Install kept cusp membrane. g. Install tape to seal along the cutout between the cusp membrane and frame. h. Install kept applicable wing to fuselage fillet panels 150CL, 150FL and 150ML on the left side and 160CR, 160FR and 160MR on the right side. Refer to MD90 AMM 06-31-00. i. Remove any shoring and lower the airplane. Refer to MD90 AMM 07-10-00 and MD90 AMM 08-10-00 as an accepted procedure. j. Do repeat inspections of the overwing frames. 5. Install all kept items and attaching parts, as applicable from Station 883.000 to 962.000. **Accepted Procedure Item**  MD90 AMM 25-23-00 Passenger Seats MD90 AMM 25-21-00 Passenger Compartment Lining MD90 AMM 25-21-03 Passenger Compartment Insulation MD90 AMM 25-27-00 Passenger Compartment Floor Covering MD90 AMM 53-21-01 Passenger Compartment Floor Panels MD90 AMM 52-21-00 Overwing Emergency Exit Doors 6. Put the airplane back to a serviceable condition.

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: April 10, 2009 MD90-53A031 28 of 35 **BOEING SERVICE BULLETIN MD90-53A031 ALERT**  **ALERT FIGURE 1: DETAILED VISUAL INSPECTION - OVERWING FRAMES**  **(SHEET 1 OF 2)**

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: April 10, 2009 MD90-53A031 29 of 35 **BOEING SERVICE BULLETIN MD90-53A031 ALERT**  **ALERT**The step numbers shown below agree with the numbers shown in the circle symbols in the figure.
**MORE DATA**  **IDENTIFICATION STATION LOCA-**  **TION NAME**  **PROCEDURE TASK**  **STEP** (a) (b) (c) 9936471-501/-502 Station 883 Frame Detailed Visual Inspect 1 9923405-505/-506 Station 902 9923405-507/-508 Station 924 9923406-503/-504 Station 943 9923407-503/-504 Station 962 (a) Do a Detailed inspection the frame in the shaded area at all accessible locations using remote visual devices at Stations 883, 902, 924, 943 and 962 left and right sides. (b) Utilize adjacent lightening holes for the remote visual inspection looking for cracks propagating inboard and down from the upper radius of the frame tab. (c) Refer to Non-Destructive Testing Standard Practice Manual NDTSPM 09-00-06 for remote visual device usage and NDTSPM 09-00-04 for current supplier/vendor information.

**FIGURE 1: DETAILED VISUAL INSPECTION - OVERWING FRAMES (SHEET 2 OF 2)** 

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: April 10, 2009 MD90-53A031 30 of 35 **BOEING SERVICE BULLETIN MD90-53A031 ALERT**  **ALERT FIGURE 2: EDDY CURRENT, HIGH FREQUENCY INSPECTION - OVERWING FRAMES**  **(SHEET 1 OF 2)**

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: April 10, 2009 MD90-53A031 31 of 35 **BOEING SERVICE BULLETIN MD90-53A031 ALERT**  **ALERT**The step numbers shown below agree with the numbers shown in the circle symbols in the figure.
**MORE DATA**  **IDENTIFICATION STATION LOCA-**  **TION NAME**  **PROCEDURE TASK**  **STEP** (a) (b) 9936471-501/-502 Station 883 Frame Eddy Current, High Frequency Inspect 1 9923405-505/-506 Station 902 9923405-507/-508 Station 924 9923406-503/-504 Station 943 9923407-503/-504 Station 962 (a) Do a Detailed inspection the upper radius of the frame tab in the shaded area looking for cracks propagating in the forward and aft direction. Refer to Non-Destructive Testing Standard Practice Manual NDTSPM 06- 10-01.001, Procedure 1, Calibration Method "G" and Scan Method "69". (b) Any indication 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 is considered a crack.

**FIGURE 2: EDDY CURRENT, HIGH FREQUENCY INSPECTION - OVERWING FRAMES (SHEET 2 OF 2)** 

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: April 10, 2009 MD90-53A031 32 of 35 **BOEING SERVICE BULLETIN MD90-53A031 ALERT**  **ALERT FIGURE 3: BLEND-OUT REPAIR - FRAME TAB UPPER RADIUS**  **(SHEET 1 OF 3)**

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: April 10, 2009 MD90-53A031 33 of 35 **BOEING SERVICE BULLETIN MD90-53A031 ALERT**  **ALERT FIGURE 3: BLEND-OUT REPAIR - FRAME TAB UPPER RADIUS**  **(SHEET 2 OF 3)**

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: April 10, 2009 MD90-53A031 34 of 35 **BOEING SERVICE BULLETIN MD90-53A031 ALERT**  **ALERT**The step numbers shown below agree with the numbers shown in the circle symbols in the figure.
**MORE DATA QTY**  **IDENTIFICATION NAME**  **TASK STEP**  (a) (b) (c) (d) (e)

- - Frame Repair 1 (a) Repairable crack limit: blend-out not deeper than 0.125 inch with minimum 0.44R and verify crack is removed. (b) Radius corners 0.060 / 0.030. (c) Surface finish 63 micro-inch finish or better. (d) Glass bead peen or flap peen the frame tab surfaces. Refer to SOPM 20-10-10 as an accepted procedure. (e) Apply Alodine and FR Primer on all bare metal surfaces.

**FIGURE 3: BLEND-OUT REPAIR - FRAME TAB UPPER RADIUS (SHEET 3 OF 3)** 

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: April 10, 2009 MD90-53A031 35 of 35 **BOEING SERVICE BULLETIN MD90-53A031 ALERT**  **ALERT**