AC 43-204 Appendix D 8/14/97 Pratt & Whitney PW4000 SERIES ENGINE MANUAL (PN 50A443) ENGINE GENERAL - INSPECTION/CHECK-01A
- BORESCOPE PROBE
COWL CLEARANCE
PROBE OVERALL LENGTH
PRIMARY GAS PATH
- PROBE WORKING LENGTH
INSPECTION DEPTH L-A0650 Borescope Probe Working Specifications Figure 804 (Task 72-00-00-990-009) Page 808 EFF: ALL Page 8
Appendix D ENGINE GENERAL - INSPECTION/CHECK-01A WARNING: BORESCOPE INSPECTIONS MUST BE PERFORMED IN A PROTECTED AREA. IF INSPECTIONS ARE PERFORMED
IN WET WEATHER, APPROPRIATE PROTECTION MUST
BE USED TO PREVENT DAMAGE TO EQUIPMENT OR POSSIBLE ELECTRICAL SHOCK TO THE OPERATOR.
CAUTION: TESTING AND STRUCTURAL ANALYSIS. CONTINUED BORESCOPE INSPECTION LIMITS ARE DERIVED FROM
SERVICE OF PARTS AT OR NEAR MAXIMUM LIMITS MAY
NOT BE ECONOMICALLY SOUND BECAUSE OF PERFORMANCE LOSS OR REDUCED PART LIFE.
The provisions for borescope inspection of the engine represent a significant aid to effective maintenance. Borescope access is incorporated at 15 locations (16 for engines utilizing AP-11) along the engine gaspath, allowing for detailed examination of critical internal engine areas.
NOTE: Borescope ports used in the following procedures are identified by their AP" (access port) designation as shown in Figures 801 and 802 The regular inspection interval referred to in this procedure is obtained from the Maintenance Planning Guide. The reduced inspection interval is set at half that value. These inspection intervals may be adjusted based on operator experience and consultation with the local regulatory agency.
C. Special Borescope Equipment CAUTION: TEMPERATURES IN AREAS TO BE BORESCOPED SHOULD BE PERMITTED TO COOL TO BELOW 150°F
(65.6°C) FOLLOWING ENGINE OPERATION. DAMAGE
RESULT TO BORESCOPE EQUIPMENT IF
EQUIPMENT IS EXPOSED TO GASPATH OR METAL TEMPERATURES IN EXCESS OF 150°F (65.6°C). AS A
GUIDE - IF ADJACENT CASES ARE TOO HOT TO TOUCH COMFORTABLY, INSPECTION SHOULD BE DELAYED.
(1) requirements of CTE 6181 as published by Support Equipment Engineering, Borescope inspection equipment for the PW4000 engine should satisfy the Pratt & Whitney, Commercial Products Division, Middletown, CT 06457.
(2) Specification CTE 6181 identifies the equipment and associated hardware (such as power source, light cables, adapter etc.) required during borescope inspection and sets the quality and functional standards for this equipment.
In summary the following borescope equipment is recommended:
(a) Low magnification rigid borescope,. ..AP2-7, 9
(0.270 inch/(6.8 mm) barrel diameter maximum)
(b) High magnification rigid borescope... ...AP8, 11
(0.444 inch/(11.3 mm) barrel diameter maximum)
(c) Flexible borescope... ...AP-1. (optional for AP2-7)
(0.270 inch/(6.8 mm › cable diameter maximum ) Page 809 EFF: ALL Page 9
AC 43-204 Appendix D 8/14/97 Pratt & Whitney PW4000 SERIES ENGINE MANUAL (PN 50A443)
(3) Optional borescope equipment and sizes are also provided in CTE 6181 to enhance the borescoping capability and ease the task for the inspector. These items range from clamping equipment to hold the borescope in position to optical video equipment to view and videotape record the borescoping session for later in depth review.
D. Rotation Of High Pressure Rotor During Borescope Inspection See Figure 803.
(1) Full 360 degree borescope inspection of the high pressure rotor can be accomplished using the rotor-cranking provision on the gearbox.
(2) Remove manual crank pad cover (Figure 803) on main gearbox.
CAUTION: DO NOT REMOVE THE GEARBOX (SCAVENGE PUMP DRIVE) BEARING HOUSING ASSEMBLY.
INSTALLATION OF THE BEARING HOUSING ASSEMBLY IS DIFFICULT. INCORRECT INSTALLATION WILL DAMAGE THE BEARING.
(a) Remove two bolts and two washers securing manual crank pad cover.
Using PWA 85768 Puller, remove crank pad cover. Discard packing from stem of cover.
(b) Attach PWA 85572-1 Foot Operated Rotator or PWA 85572-2 Hand Operated Rotator to N2 rotator pad. Make sure socket drive in the angle drive adapter aligns correctly with hex end of oil pump idler gear in gearbox and secure using two 1/4 - 28 cap screws provided. Attach an air supply to the pneumatic motor. Actuate using foot or hand NOTE: Use of motor-drive unit will free operator to use both hands to position and adjust the borescope. It is recommended that rotation be stopped as each rotor blade is positioned properly for inspection. This will allow thorough, detailed appraisal of each blade's condition.
(3) Install manual crank pad cover.
(8) Install packing lubricated with Engine Oil (P03-001), in groove on stem of manual crank pad cover. Install cover and secure with two washers and two bolts lubricated with Antigalling Compound (P06-003).
Torque bolts to 62 - 72 Ib-in. (7.005 - 8.135 N.m).
EFF: ALL Page 8010 Page 10
Appendix E APPENDIX E. DC-9 SERVICE BULLETIN
SAMPLE INSPECTION PROCEDURE Excerpts of Douglas Aircraft Company McDonnell Douglas DC-9 Service Bulletin Alert. Bulletin A53-232, March 28/90.
Retyped with permission of Douglas Aircraft Company McDonnell Douglas Page
AC 43-204 Appendix E 8/14/97
SAMPLE VISUAL INSPECTION PROCEDURE
DOUGLAS AIRCRAFT COMPANY
MCDONNELL DOUGLAS ALERT DC-S P.О. Box 1711 BULLETIN Long Beach, CA 90801
SERVICE BULLETIN FUSELAGE - Main Frame - Inspect/Repair Aft Fuselage Ventral Pressure Bulkhead Tee.
SUMMARY This Alert Service Bulletin is affected by Federal Aviation Administration Airworthiness Directive No. 89-16-12: Amendment 39-6287. effective September 7, This Alert Service Bulletin is applicable only to aircraft equipped with ventral aft pressure bulkhead which have accumulated 35,000 or more landings.
Replacement of all six aft pressure bulkhead tee sections with new improved parts per this Alert Service Bulletin constitutes closing action for the repetitive inspection.
requirements of this Alert Service Bulletin.
This Alert Service Bulletin supersedes but does not cancel the requirements of DC-9 Alert Service Bulletin XXXXX. Only aircraft listed in this Alert Service Bulletin that are contained in the Affectivity of Alert Service Bulletin XX-XXX are affected by this contingency.
This Alert Service Bulletin is issued as a partial record-type change. A service rework drawing or aperture cards are furnished in lieu of illustrations.
1. Planning Information:
A Affectivity:
‹1) Aircraft Affected:
DC-9, Series 10, 20. 30, 40, 50, and C-9, DC-9-81. -82, and -83 (MD-81, -82, and -83) McDonnell Douglas Corporation (MDC) proprietary rights are included in the information disclosed herein, and recipient by accepting this document agrees that the information is proprietary to MDC MDC authorizes recipient to reproduce such information in other documents created for internal use if these documents are protected similarly by a proprietary legend.
Bulletin XX-XXX March 28/90 Page 2
8/14/97 FOE-EE DE
FUS (FSN) FUS (FSN) FUS (NSE) FUS (FSN) NSET STE FUS (FSN) 1160 (49257) 1185 (49265) 1210 (49291) 1235 (49236) 1260 (49415) 1285 (49394) 1161 (49258) (0976) 98 (Z6Z67) IIZ (8) 97 1261 (49402) 1286 (49395) 1162 (49259) (8876 18 (886) (9) 890 1287 (49386) 1163 (49263) (9076) 887 (6867) 8I8 (996 88 (767) 897 1288 (49387) 1164 (49269) (L076P) 681X (967) (1967) 1264 (49422) 1289 (49324) 1165 (49270) (80767) 06T (97767) 0771 1265 (49318) 1290 (49352) 1166 (49271) (60767) 1611 (87767) 1887 1266 (49319) 1291 (49443) 1167 (49272) 1192 (49210) (86867) LI ZEZI (49429) (0Z867) 29Z1 1292 (49501) 1168 (49273) 1193 (49289) (6) 87 (6) 7 (L6) 8971 (8) 7 1169 (49252) 1194 (49280) (98867 77 (0) 690 1294 (49358) 1170 (49202) (06767) 961 (71Z67) 9781 1270 (49391) 1295 (49326) 1171 (49264) 1196 (49366) 1221(49302) 1246 (49309) 1271 (49416) 1296 (49327) 1172 (49188) 1197 (49367) 1222 (49303) 1247 (49310) 1272 (49392) 1297 (49479) 1173 (49189) 1198 (49368) 1223 (49304) 1248 (49311) 1273 (49321) 1298 (49480)
(0) LI (6986) 66I 1224 (49355) 1249 (49312) 1274 (49218) 1299 (49283) (98767) 9LII 1225 (49380) 1250 (49356) 1275 (896) 1300 (49502) 1176 (49287) 1201 (49373) 1226 (49305) 1251 . (49357) 1276 (49364) 1301 (49328) 1177 (49231) 1202 (49211) 1227 (49306) 1252 (49372) 1277 (49365) 1302 (49329) 1178 (49232) (49233) 1228 (49307) 1253 (49215) 1278 (49417) 1303 (49436) 1179 (49204) 1229 (49308) 1254 (49420) 1279 (49393) 1304 (49440) 1180 (49190) 1230 (49279) 1255 (49313) 08ZT 1305 (49396) 1231 (49381) 1256 (49314) 1281 (49323) 1306 (49331) 1182 (49164) 1207 (49371) 1232 (49382) 1257 (49315) 1282 (49282) 1307 (49332) 1183 (49278) 1208 (49374) 1233 (49212) 1258 (49316) ESZI (8767) 1184 (49205) 1209 (49284) 1234 (49235) 1259 (49317) 1284 (49424) 1309 (49482)
(a) Operator and Aircraft Number:
This modification will be incorporated prior to delivery on all applicable DC-9, Series MD-80; MD-88 aircraft, manufacturer's fuselage number 1310 and subsequent.
(2) Spares Affected:
None:
B. Reason:
Eight operators have reported cracks in the ventral aft pressure bulkhead attach tee sections on eight aircraft. The affected aircraft had accumulated between 45,492 and 60,969 landings when the cracks were found. The predominant areas of cracks are at the upper pylon attach angle between longerons 13 and 14 (6 cases) and lower pylon attach angle between longerons 16 and 17 (2 cases). Longerons 2, 7, 11, and 18 each had one crack. The cracks exhibited similar bebavior, cracking circumferentially approximately 1.9 inches outboard of the inboard edge of the upstanding leg of the bulkhead attach tee sections. Cracks were found up to 8.8 inches in length. Analysis of failed parts revealed that the cracks initiated at multiple sites on the forward surface of the upstanding leg of the tee as the result of fatigue due primarily to bending loads. If cracks are not detected and repaired. they could progress to the point March 28/90 Bulletin XX-XXX Page 3
AC 43-204 Appendix E 8/14/97
SAMPLE VISUAL INSPECTION PROCEDURE accomplishment of repairs based on condition will allow continued flight operation. that rapid decompression could occur. Inspection of high cycle aircraft and
c. Description:
This Service Bulletin accomplishes the following on the fuselage aft pressure bulkhead.
Inspection from Aft Side of Bulkhead Performs visual inspections for cracked aft pressure bulkhead web-to-fuselage tee sections around entire periphery of the fuselage from aft side of bulkhead and accomplishes the following:
Condition 1 (No Crack) Repetitively visually inspects for cracks from aft side of bulkbead at intervals specified in Compliance paragraph.
Condition 2 (Crack) Replaces cracked tee section with new or improved part and repetitively visually and for cracks from aft side of bulkhead at intervals specified in Compliance paragraph.
D. Compliance:
It is recommended that initial inspection/repair of aft pressure bulkhead tee be accomplished as follows on aircraft having logged over 35,000 landings.
Accumulated Landings Initial Inspection 35,000 to 49,999 Within 1500 landings from issue date of this Service Bulletin.
50,000 to 59,999 Within 100 landings from issue date of this Service Bulletin.
60.000 and over Within 300 landings from issue date of this Service Bulletin.
When aft pressure bulkhead tee section is replaced with new like part, the repetitive inspection for that section of tee may be discontinued until the aircraft has accumulated an additional 35.000 landings at which time the repetitive inspection for that section of tee are reinstated along with the ongoing repetitive inspections of the remaining original sections of tee.
When aft pressure bulkhead tee section is replaced with new improved part per this Service Bulletin, the repetitive inspection for that section of tee may be discontinued as this constitutes closing action for that section of tee. Perform the recommended repetitive inspections on the remaining original tee sections.
Bulletin XX-XXX March 28/90 Page 4
Appendix E
SAMPLE VISUAL INSPECTION PROCEDURE Replacement of all six aft pressure bulkhead tee sections with new improved parts per this Alert Service Bulletin constitutes closing action for the inspection requirements of this Alert Service Bulletin.
It is recommended that repetitive inspection/repair of aft pressure bulkhead tee be accomplished as follows:
Inspection from Aft Side of Bulkhead It is recommended that repetitive visual inspection of top and lower areas from longeron 7 left side to longeron 7 right side, and lower fuselage longeron 17 to longeron 20 on fuselage left and right sides, be accomplished at intervals not to exceed 1500 landings.
It is recommended that repetitive visual inspection for cracks of bottom areas from longeron 20 left side to longeron 20 right side, be accomplished at intervals not to exceed 3500 landings.
It is recommended that cracked tee section be replaced prior to further pressurized flight E. Approval:
The resultant modification described in paragraph 1.C 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, on February 13, 1990 and is approved as an alternate means of compliance with paragraphs A and B of Airworthiness Directive 89-16-12.
Manpower:
NOTE: Man-bours are estimated based on work to be performed by skilled personnel on aircraft/unit which has ben placed in a maintenance status. The manhour/elapsed time estimates do not include:
1. Preparation for the modification: Examples; defueling, purging, placing work stands, opening standard access doors, obtaining tools, and jacking when not essential to the modification.
2. Nonproductive elapsed time: Examples; sealant or adhesive cure time, cleaning, paint drying time, lunch and/or rest periods, and quality assurance inspections.
March 28/90 Bulletin XX-XXX Page 5
Appendix E
SAMPLE VISUAL INSPECTION PROCEDURE Administrative functions: Examples; planning, engineèring liaison.
parts requisition, shift change coordination, and report writing.
Operations should take the above into consideration when scheduling this modification.
Inspection from Aft Side of Bulkhead Optically aided visual inspection from the aft side of the fuselage aft pressure bulkhead may be accomplished in approximately 22.0 man-hours or 11.0 elapsed hours per aircraft.
Man-hours do not include time for fabrication of flexible borescope guide tube.
G. Material - Cost and Availability:
(1) Aircraft:
Parts and materials required to accomplish this modification are listed in paragraph 3.A and are to be procured as indicated. Parts bearing Douglas Aircraft Company part numbers are proprietary parts and must be procured under the spare parts article of the purchase agreement, unless methods of manufacture are shown.
Cost and availability of parts are to be negotiated between the operator and Douglas Aircraft Company. Reference this Service Bulletin number and direct inquiries to:
Douglas Aircraft Company P.O. Box 1771 Long Beach, California 90801 Atta: Parts Sales - Commercial 73-44 (DC-9 Service Bulletin A53-232)
(2) Spares:
Not applicable.
H. Tooling - Price and Availability:
Inspection from Aft Side of Bulkhead
(1) Special test equipment is required to accomplish visual inspection outlined in this Service Bulletin. Special test equipment is to be procured from operator's stock, or other sources.
Bulletin XX-XXX March 28/90 Page 6
Appendix E
SAMPLE VISUAL INSPECTION PROCEDURE
(2) Procurement and availability of Special Test Equipment should be negotiated between the operator and the Douglas Aircraft Company. Specify this Service Bulletin number and direct inquiries to:
Douglas Aircraft Company 910 East 236th Street Carson, California 92805 Attn: Manager, Recovery & Modification Services (RAMS) (DC-9 Service Bulletin A53-232) I. Weight and Balance:
Weight change at appropriate fuselage stations by incorporation of any part of this Service Bulletin is contingent upon the modification of each particular aircraft.
Weight data is to be computed by the operator by weighing parts installed and parts removed during modification. Necessary revisions should be made to the appropriate weight and balance report.
J. Reference:
(1) Federal Aviation Administration Airworthiness Directive No. 89-16-12:
Amendment 39-6287, effective September 7, 1989.
(2) Data used in preparation of this Alert Service Bulletin:
Data Identification Change Type of Data DMS 2082 Douglas Material Specification J060157 A Service Rework Shoring J060157 B Advance E.O.
MM Chapters 6, 20, Maintenance Manual 21, 25, 26, 36, 49, 52, and 53 NDT Chapter 1-3 Nondestructive Testing Manual SRM Chapters 51 and 53 Structural Repair Manual SR09530001 C Service Rework Drawing SR09530001 D Advance E.O.
SR09530048 New Service Rework Drawing SR09530056 Service Rework Drawing SR09530056 D Advance E.O.
SR09530083 New Service Rework Drawing 0510160 DY 5930760 AM Drawing
(3) Data supplied in support of this Alert Service Bulletin:
Data Identification Change Type of Data J060157 Service Rework Shoring J060157 B Advance E.O.
March 28/90 Bulletin XX-XXX Page 7
Appendix E
SAMPLE VISUAL INSPECTION PROCEDURE SR09530001 Service Rework Shoring SR09530001 D Advance E.O.
SR09530048 Yew Service Rework Drawing SR09530056 Service Rework Drawing SR09530056 D Advance E.O.
SR09530083 New Service Rework Drawing Publications Affected:
The modification outlined in this Service Bulletin affects the DAC DC-9 Weight and Balance Charts.
2. Accomplishment Instructions:
WARNING: TO AVOID INJURY TO MAINTENANCE PERSONNEL OR DAMAGE TO
EQUIPMENT, MAKE CERTAIN ADEQUATE PRECAUTIONS ARE TAKEN
WHILE PERFORMING ANY WORK IF ELECTRICAL POWER IS APPLIED TO THE AIRCRAFT.
CAUTION: ELECTRICALLY GROUND THE AIRCRAFT.
GENERAL NOTES:
1. Refer to sections of the Maintenance Manual (MM), Structural Repair Manual (SRM).
Refer to the following manual chapters for applicable operations:
Manual Chapter Operation MIM 20-30-0 Sealant Application SRM 51-10-4 Drilling And Countersinking SRM 51-30-1 Installing Bolts, Screws, and Washers SRM 51-30-2 Removing And Installing Rivets SRM 51-30-3 Removing And Installing Lockbolts SRM 51-30-5 Removing And Installing Pins
3. For approved fastener and process material substitutions, see DC-9 SRM chapter 51-60-0, paragraph entitled "Interchangeability of Fasteners" and "Interchangeability of Materials."
4. If the length of the fasteners specified in this Service Bulletin do not meet acceptable installation standards. fasteners of the same type, or approved substitutions, one increment longer or shorter in length may be used.
Or A combined total of two (maximum) 116-inch thick washers or four (maximum / 1/32-inch thick washers or any combination thereof not exceeding 1/8-inch total stackup thickness of the washer types called from in this Service Bulletin XX-XXX March 28/90 Page 8
8/14/97 AC 43-204 Appendix E
SAMPLE VISUAL INSPECTION PROCEDURE Bulletin may be used under fastener head or nut to counteract accumulation of tolerances.
5. If substitutions are used other than those in Douglas approved publications, operator must obtain FAA approval from local authorized agency.
Inspection from Aft Side of Bulkhead Operator's Option • Access doors may be installed in skin on bottom of fuselage forward of auxiliary power unit (APU) door per service rework drawing SR09530048 to facilitate inspection.
B. Operator's Option - Fabricate guide tube (to be used with flexiscope) from flexible or thin wall tubing to fit outside diameter of flexiscope as shown on Figure 1.
C. Gain access to inspection areas on aft side of bulkhead by opening or removing and retaining the following access doors/panels as applicable to accomplish visual inspection;
Access No. Access Area MM Chapter 5806A Auxiliary Exit Door, 6-12-0 Non-Ventral Bulkhead 5901A Thrust Reverser Control 6-11-4 Valve (Left Side) 5902A Thrust Reverser Control 6-11-4 Valve (Right Side) 5903A APU Service (Left Side) 6-11-4 5904A APU Service (Right Side) 6-11-4 5910A Ventral Stair Ceiling 6-12-0 5911A Ventral Stair (Right Side) 6-12-0 5912A Ventral Stair (Left Side) 6-12-0 NOTE: The following paragraphs 2.D through 2.H may be accomplished at operator's option and are applicable to visual inspection requirements.
D. Remove and retain APU and attaching parts. (See MM chapter 49-10-0, paragraph entitled "Removal/Installation Power Plant.") E. Remove and retain APU compartment enclosure and attaching parts. (See MM chapter 53-20-5, paragraph entitled "Removal/Installation APU Compartment Enclosure.") March 28/90 Bulletin XX-XXX Page 9