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
Appendix E
SAMPLE VISUAL INSPECTION PROCEDURE FLEXIBLE BORESCOPE:
d. ONE FORWARD VIEWING ENDOSCOPE OF ANY DIAMETER WITH 30 INCH MINIMUM LENGTH SUCH AS:
(2) OLYMPUS MODEL 1F8D3, 29.8-INCH (757 MM) LONG, 0.315-INCH DIAMETER.
(2) COLD LIGHT SUPPLY NUMBER 1LK-4 (100 TO 230 VOLT).
INSPECTION PROCEDURE VISUAL INSPECTION PROCEDURE A:
SEQUENCE 1:
(1) PERFORM MIRROR/FLASHLIGHT OR ENDOSCOPE INSPECTION OF UPPER FUSELAGE TEE SECTIONS FROM LONGERON L7 LEFT SIDE TO LONGERON L7 RIGHT SIDE, LOWER FUSELAGE LONGERON L17 LEFT SIDE TO LONGERON L20 LEFT SIDE, AND LONGERON L17 RIGHT TO LONGERON L19 RIGHT SIDE
(2) PERFORM ENDOSCOPE OR FLEXIBLE BORESCOPE INSPECTION OF LOWER FUSELAGE TEE SECTIONS FROM LONGERON L19 RIGHT SIDE TO LONGERON L20 RIGHT SIDE.
SEQUENCE 2:
(1) PERFORM MIRRORFLASHLIGHT OR ENDOSCOPE INSPECTION OF
LOWER FUSELAGE TEE SECTION THROUGH THRUST REVERSER LOCKOUT ACCESS OPENING 5902A FROM LONGERON L20 RIGHT SIDE TO LONGERON L24 RIGHT SIDE.
NOTE: SEQUENCE 2 AND 3 MAY BE ACCOMPLISHED USING
INSPECTION MIRROR AND FLASHLIGHT IF SUFFICIENT ACCESS IS AVAILABLE.
AFT PRESSURE BULKHEAD TEE - INSPECTION FIGURE 3 (SHEET 2 OF 14) Bulletin XX-XXX March 28/90 Page 14
Appendix E
SAMPLE VISUAL INSPECTION PROCEDURE SEQUENCE 3:
(1) PERFORM VISUAL INSPECTION OF LOWER FUSELAGE TEE SECTIONS WITH FLASHLIGHT FROM LONGERON L23 LEFT SIDE TO LONGERON L24 RIGHT SIDE.
REMOVE SEALANT FROM INSPECTION AREA OF TEE SECTIONS THAT MAY HINDER INSPECTION. CLEAN DIRT, GREASE, AND ALL FOREIGN MATERIALS
FROM INSPECTION AREA OF TEE SECTIONS USING LINT-FREE WIPER AND
1.1.1 TRICHLOROETHANE SOLVENT OR EQUIVALENT. PERFORM INSPECTION SEQUENCES 1 THROUGH 3 AFTER CLEANING THE TEE SECTIONS.
FUSELAGE LONGERON NUMBERING VIEW LOOKING
FORWARD AT AFT PRESSURE BULKHEAD TEE
ENDOSCOPE OR
FLEXISCOPE USELAG
USP LIN
FUSELAGI
USP LIM 2526/28/30128 26 25 27 29 29
IMSPECTIOM SEQUENCE J
AFT PRESSURE BULKHEAD TEE - INSPECTION FIGURE 3 (SHEET 3 OF 14) March 28/90 Bulletin XX-XXX Page 15
Appendix E
SAMPLE VISUAL INSPECTION PROCEDURE 5910130-51 OR 5910130-389 TEE 12 4 12 13 L8
- 2=74 5910130-53 L10 2=03051 OR L10 5910130-54 5910130-391 _ 111 OR TEE 111 L12 5910130-392 L12 - 2=48 TEE
- L13 L13 - LL UPPER 1747=34 PYLON-
• Z=24 L15- -L16 LL UPPER PYLON -L17 -2=14 FRP -119 L19- 120 L20° L21 5910130-56 5910130-55 L21 L22 5910130-394 OR OR TEE 5910130-393 L22 L23 TEE L23 L24 L25 L25 126 127 L27 L26 L28 L29 L30 L29 L28 5910130-47 OR FRP = FUSELAGE REFERENCE PLANE 5910130-387 LL = LOFT LINE TEE S = PRODUCTION SPLICE = STATION
VIEW LOOKING FORWARD DC-9 VENTRAL AFT PRESSURE BULKHEAD SCHEMATIC DIAGRAM SHOWING TEE LOCATIONS
AFT PRESSURE BULKHEAD TEE - INSPECTION FIGURE 3 (SHEET 4 OF 14) Bulletin XX-XXX March 28/90 / Page 16
Appendix E
SAMPLE VISUAL INSPECTION PROCEDURE
- ANGLE 5910130
BULKHEAD TEE FWD
• VISUA
INSPECTION INBD AREA CRACX
- EB 70° OR 90° ENDOSCOPE
DETAIL A - ENDOSCOPE VISUAL IMSPECTION ANGLE CRACK 5910130 • VISUAL INSPECTIOM
BULKHEAD AREA TEE - WEB
IMSPECTION MIRROR
FLASHLIGHT
DETAIL B - MIRROR FLASHLIGHT VISUAL INSPECTION SEQUENCE 1 VISUAL AND ENDSCOPE INSPECTION OF BULKHEAD TEE
AFT PRESSURE BULKHEAD TEE - INSPECTION FIGURE 3 (SHEET 5 OF 14) March 28/90 Bulletin XX-XXX Page 17
AG 43-204 8/14/97 Appendix E
SAMPLE VISUAL INSPECTION PROCEDURE
LOOKING FORWARD TEE SPLICE PLATE• CRACK CRACK WEB WEB OUT8D FWD ANGLE
SECTION A-A SECTION B-B DC-9 VENTRAL AFT PRESSURE BULKHEAD. TEE CAP CRACKS
AFT PRESSURE BULKHEAD TEE - INSPECTION FIGURE 3 (SHEET 6 OF 14) Bulletin XX-XXX March 28/90 Page 18
Appendix E
SAMPLE VISUAL INSPECTION PROCEDURE C. The basis for the following tooling data is per operator.
NOTE: CAGE indicates Commercial and Government Entity code for Manufacturers/Distributors.
(1) Option I - Test equipment to be procured from operator's stock or sources indicated.
Test Equipment Type Qty CAGE Supplier Endoscope 70 Degree Model 54341 Expanded Optics.
(Fore oblique) Angle 10320D Incorporated 19-Inch (482.6 MM) Long 301-C West Dyer Road
0.217-Inch Santa Ana, California Diameter 92702-3427 or Equivalent NOTE: One 70 or 90 degree endoscope of any diameter with 18-inch (457.2 MM) minimum length and matching light source may be used.
Fiber Optic Model 1 54341 Expanded Optics, Light Bundle 1F8D3 Incorporated 301-C West Dyer Road Santa Ana, California 92702-3427 and Endoscope Light Source No. 00482 54341 Expanded Optics, 110 or 220 Volt OI Incorporated No. E0590 301-C West Dyer Road Santa Ana, California 92702-3427 and Sylvania Projector Lamp 1 54341 Expanded Optics, 150 Watt, 120 Volt Incorporated 301-C West Dyer Road Santa Ana, California 92702-3427 NOTE: Similar or equivalent endoscopes and illuminators may be obtained from the following sources.
March 28/90 Bulletin XX-XXX Page 19
Appendix E
SAMPLE VISUAL INSPECTION PROCEDURE Test Equipment Type Qtr CAGE Supplier Alva Ingenieros Velazquez 121 Madrid 6, Spain or Automation Instruments Service 47 Birch Street Bankston 2200, Australia or 3 G Electronics Sede Commercial 20135 Milano Via Perugino 9, Italy or 50958 Richard Wolf Medical Instrument Corporation 7046 Lyndon Avenue Rosemont, minois 60018-3410 or Inspection Instruments NDT Limited 32 Duncan Terrace London N188R, England or Karl Storz KG D 7200 Tuttlingen West Germany Flexible Borescope Model 1 32212 Olympus Corporation
29.8-Inch (757 MM) Long 1F8D3 Scientific Products Group
0.315-Inch 4 Nevada Drive Diameter Lake Success, New York 11040-1114 Cold Light Supply No. 1LK-4 32212 Olympus Corporation 100 to 230 Volt Scientific Products Group 4 Nevada Drive Lake Success, New York 11040-1114 Or Equivalent Bulletin XX-XXX March 28/90 Page 20
8/14/97 AC 43-204 Appendix F APPENDIX F. BOEING 747 SERVICE BULLETIN
SAMPLE INSPECTION PROCEDURE Excerpts of Boeing Service Bulletin 747-53-2307, Dec 21/89.
Retyped with permission of Boeing Commercial Airplane Group.
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