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.
Page
A043-204 8/14/97 Appendix F
SAMPLE VISUAL INSPECTION PROCEDURE
SERVICE BULLETIN
SUMMARY BOEING COMVERCIAL AIRPLANES POST OFFICE BOX 3707 SEATTLE, WASHINGTON 88124-2207
BACKGROUND This inspection will detect corrosion and fatigue cracks in upper body skin longitudinal lap joints caused by-disbonding of the cold bond at the joint. Continued operation of an airplane that has corrosion or fatigue cracking in lap joints could lead to separation of the skin at the lap joint causing rapid decompression of the airplane.
Several operators have reported corrosion, and associated bulging of skin at upper body lap joints para on airplanes with 26,733 to 70.000 flight-hours. One operator reported cracking and corrosion of the lap joint at Stringer 12 from Station 1515 to 1735 and Stringer 4L at Station 1710 on an airplane with 35,134 flight-hours. One other operator reported corrosion and cracking at the lap joint at Stringer 4R, Station 1500 on an airplane with 49,024 flight-hours. Another operator reported a one-inch crack at Stringer O, Station 738 suspected to have been caused by corrosion from disbonding at the cold-bonded lap joint. There have been numerous additional instances of corrosion reported at the Stringer 23 lap joint.
This bulletin supersedes that portion of Service Bulletin 747-53-2157 which addresses the upper body skin longitudinal lap joints.
Airplanes previously inspected per Service Bulletin 747-53-2157 require additional inspection of lap joint areas as described herein.
Any lap joint areas repaired per Service bulletin 747-53-2157 do not require further repair or Lospection.
This bulletin does not supersede Service Bulletin 747-53-2253 or Service Bulletin 747-53A2303 which address the upper body skin longitudinal lap joints at Stringer 6 in Section 41.
This service bulletin is the subject of Federal Aviation Administration (FAA) Notice of Proposed Rulemaking 88-NM-194-AD dated February 9, 1989.
ACTION Within 1,000 flight-cycles after receipt of this bulletin, conduct a detailed external visual inspection of the upper body longitudinal lap joints at Stringers 23 and above from Station 140 to 2360 (except Stringer 7 from Station 340 to 520). Visually inspect all lap joints for evidence of corrosion or cracking. Evidence of corrosion includes missing or distressed fasteners, white powder protruding from the lap joint, or bulging or pillowing of the lap joint between fasteners. Repair any corrosion beyond allowable limits or cracking, as specified herein, prior to further flight.
Repeat these visual inspections at intervals not to exceed 1,000 flight-cycles for the lap joints in Sections 41. 42. and 46. Repeat the visual inspections at 2,000 flight-cycle intervals for the lap joints in Section 44.
Dec 21/89 747-53-2307 Page 2
8/14/97 A043-204 Appendix F BOEING SERVICE BULLETIN 747-53-2307
SECTION STA 2360
LAP JOINT S-12 (TYPICAL) STA 1480 S-6 S-19 S -0 S-14 STA 4 4 1000 STA RIGHT SIDE SHOWN 42 520
LEFT SIDE OPPOSITS STA 4 1 140
SECTIONS
INSPECT LAP JOINTS FOR CORRORSION, CRACKS OR PILLOWING
OF SKIN, AND MISSING OR DISTRESSED FASTENERS Dec 21/89 747-53-2307 Page 3
Appendix F BOEING SERVICE BULLETIN 747-53-2307 In lieu of continued reinspections, terminating action may be accomplished. Terminating action is accomplished when an uncorroded lap joint area is separated between adjacent circumferential splices, adhesive removed, faying surface sealant is applied, and joint is refastened per 747 Structural Repair Manual Subject 43-30-03. Terminating action in a corroded or cracked lap joint area may be accomplished when the area is repaired per 747 Structural Repair Manual Subject 53-
EFFECTIVITY 747 Airplanes line position 001 through 200
MANPOWER Visual Inspection:
Total Manhours - 152 per Airplane Elapsed Time - 38 Hours
MATERIAL INFORMATION None.
Dec 21/89 747-53-2307 Page 4
8/14/97 AC 43-204 Appendix F BOEING SERVICE BULLETIN 747-53-2307 BOEING COMMERCIAL AIRPLANES BOEING SEATTLE. WASHINGTON 88124-2207
SERVICE BULLETIN Л4₴ ATA SYSTEM: 5310 NUMBER: 747-53-2307 DATE: December 21, 1989 5331 SUBJECT: FUSELAGE - SKIN - UPPER BODY SKIN LONGITUDINAL LAP JOINT (STRINGERS 23 AND ABOVE) INSPECTION AND REPAIR
PLANNING INFORMATION A Effectivity
1. Airplanes Affected See Service Bulletin Index Part 3 for cross reference of Variable Number to Airplane Serial Number.
This change is applicable only to airplanes listed below.
CODE VARIABLE NUMBER ACN RA743 AFA RA251-RA259 AIN RA722-RA724 ARL RA203 RA501-RA502 BAB RA217 RA301-RA308 RA310 RA312 RA702 CAL RA51-RA552 CLX RA023 RA025 Dec 21/89 747-53-2307 Page 5