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
Appendix E
SAMPLE VISUAL INSPECTION PROCEDURE Remove and retain lower firex bottle and attaching parts. (See MM chapter 26-20-1, paragraph entitled "Removal/Installation Fire Extinguishing Containers.") G. Remove and retain right pneumatic crossfeed valve pushrod and attaching parts. (See MM chapter 36-10-3, paragraph entitled "Removal/Installation Pneumatic Crossfeed Valve.") H. Remove and retain two upper conditioned air duct assemblies, check valves, and attaching parts aft of pressure bulkhead center ceiling. (See MM chapter 21-20-2, paragraph entitled "Removal/Installation Conditioned and Cold Air Check Valve.") Roll back or remove and retain insulation blankets from aft side of aft pressure bulkhead. (See MM chapter 25-22-0, paragraph entitled Removal/Installation Insulation Blankets.") eJ. Perform optically aided visual inspection/repair of the aft pressure bulkhead web to fuselage skin attach tee sections from the aft side of the bulkhead as follows:
Inspect the upstanding leg of 5910130 ventral bulkhead tee sections from aft side of bulkhead around the periphery of the bulkhead as shown on Figure 3 and accomplish the following:
Condition 1 (No Crack)
(2) Perform repetitive visual inspections from aft side of bulkhead at intervals specified in Compliance paragraph.
Condition 2 (Crack)
(3) Replace cracked tee section with new like or improved part per Figure 4 (See Table I for configuration) prior to further pressurized flight. Perform repetitive visual from aft side of bulkhead at intervals specified in Compliance paragraph.
(4) If any tee section is to be replaced, remove and retain engines 1 and 2. (See MM chapter 71-00-0, paragraph entitled "Removal/Installation Power Plant.")
(5) Shore aircraft as shown on Figure 5.
K Record and report all results, both negative and positive of inspection to DAC. Include fuselage number, factor serial number, crack location, crack length, flight-hours, and accumulated landings of aircraft. forward to:
Douglas Aircraft Company P.O. Box 1771 Long Beach, California 90801 Attn: Manager. Customer Service 73-30 (DC-9 Alert Service Bulletin A53-232) Bulletin XX-XXX March 28/90 Page 10
Appendix E
SAMPLE VISUAL INSPECTION PROCEDURE Apply PR-1422 B-2 sealant around entire periphery of the bulkhead tee sections, as applicable.
Reinstall retained insulation blankets on aft side of aft pressure bulkhead. (See MM chapter 25-22-0, paragraph entitled "Removal/Installation Insulation Blankets.") N. Reinstall right pneumatic crossfeed valve pushrod and attaching parts as applicable.
(See MM chapter 36-10-3, paragraph entitled 'Removal/Installation Pneumatic Crossfeed Valve.") O. Reinstall two upper conditioned air duct assemblies, check valves, and attaching parts as applicable. (See MM chapter 21-20-2, paragraph entitled "Removal/Installation Conditioned and Cold Air Check Valve.") P. Reinstall lower firex bottle and attaching parts as applicable. (See MM chapter 26-20- 1, paragraph entitled "Removal/Installation Fire Extinguishing Containers.") Q. Reinstall APU compartment enclosure, as applicable. (See MM chapter 53-20-5.
paragraph entitled "Removal/Installation APU Compartment Enclosure.") R. Reinstall APU and attaching parts as applicable. (See MM chapter 49-10-0, paragraph entitled "Removal/Installation Power Plant.") S. Reinstall engines 1 and 2 as applicable. (See MM chapter 71-00-0, paragraph entitled "Removal/Installation Power Plant.") T. Remove shoring as shown on Figure 5 as applicable.
U. Close/reinstall access doors/panels as outlined under Option I paragraph 2.C.
March 28/90 Bulletin XX-ХХХ Page 11
Appendix E
SAMPLE VISUAL INSPECTION PROCEDURE FIT O. D. FLEXISCOPE STA X==20.000 • FLEXISCOPE GUIDE TUBE - STA 2=40.000
FLEXIBILE OR THIN WALL TUBING APPROX 3 FEET DETAIL FLEXISCOPE GUIDE TUBE MAKE FROM COMMERCIAL FLEXIBLE OR THIN HALL TUBING 3/8 OR 1/2-INCH DIAMETER STA X==10.000 • INTERCOSTAL VIEW LOOKING FORWARD RIGHT SIDE AT FRAME INSTALLATION AFT OF PRESSURE BULKHEAD ILLUSTRATION OF-GUIDE TUBE USE ol APPROX 2-3 INCHES
FLEXIBLE BORESCOPE GUIDE TUBE - FABRICATION AND USE Bulletin XX-XXX March 28/90 rage 12
Appendix E
SAMPLE VISUAL INSPECTION PROCEDURE GENERAL NOTES:
PERFORM INSPECTION PROCEDURE A, SEQUENCES 1 THROUGH 3 BEFORE CLEANING THE TEE AND AFTER CLEANING THE TEE AS NOTED.
PROCEDURE A - DESCRIBES AN OPTICALLY AIDED VISUAL INSPECTION OF DC-9 AFT PRESSURE BULKHEAD WEB TO FUSELAGE SKIN ATTACH TEE SECTIONS TO DETECT FATIGUE CRACKS IN THE UPSTANDING LEG OF TEE SECTIONS.
3. INSPECTION OF THE BULKHEAD TEE FOR CRACKS BY PROCEDURE A IS MADE FROM THE AFT SIDE OF THE AFT PRESSURE BULKHEAD.
ACCESS LOCATION. INSPECTION BY PROCEDURE A IS DIVIDED INTO THREE SEQUENCES BASED ON
5. SIGNS OF NICOTINE STAINS MAY INDICATE CRACKS.
6. THE FOLLOWING EQUIPMENT OR EQUIVALENT IS REQUIRED:
SEE PARAGRAPH 3.C FOR TEST EQUIPMENT SUPPLIERS.
VISUAL EQUIPMENT
a. FLASHLIGHT.
b. INSPECTION MIRROR WITH ADJUSTABLE VIEWING ANGLE.
ENDOSCOPE EQUIPMENT:
c. ONE 70 OR 90 DEGREE ENDOSCOPE OF ANY DIAMETER WITH 18-INCH
(457.2 MM)) MINIMUM LENGTH AND LIGHT SOURCE SUCH AS:
ENDOSCOPE MODEL 10320D, 70 DEGREE (FOREOBLIQUE) ANGLE, 19-INCH (482.6 MM) LONG, 0.217-INCH DIAMETER.
(2) FIBER OPTIC LIGHT BUNDLE MODEL 495NL.
(3) ENDOSCOPE LIGHT SOURCE NUMBER 00482(110 OR 220 VOLT) OR NUMBER E0590 (110 VOLT ONLY).
(4) SYLVANIA PROJECTOR LAMP (150 WATT, 120 VOLT).
AFT PRESSURE BULKHEAD TEE - INSPECTION FIGURE 3 (SHEET 1 OF 14) March 28/90 Bulletin XX-XXX Page 13