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DOUGLAS AIRCRAFT COMPANY MCDONNELL DOUGLAS ALERT D C-9 OONPORATION
SERVICE BULLETIN
REVISION TRANSMITTAL SHEET BULLETIN A53-144 FUSELAGE - Main Frame - Inspect/Repair Aft Fuselage Ventral Pressure Bulkhead Web.
This page transmits Revision 2 for DC-9 Service Bulletin A53-144 to incorporate the following changes:
NOTE: This revision constitutes a complete reissue.
Reason for Revision: To incorporate engineering released subsequent to prior issues of this Service Bulletin which adds eddy current inspection instructions.
No additional work is required by this revision for aircraft modified per prior issue of this Service Bulletin.
Pages 2 Revised Service Bulletin effectivity to reflect current operators of and 3: affected aircraft.
Pages 4 Revised Description.
thru 7:
Revised Compliance.
Added eddy current inspection to Manpower requirements.
Revised Approval paragraph.
Page 10: Changed referenced Service Bulletin to 53-166, was 53-139.
Changed identification of service sketch to 3110 "g", was 3110 "New".
Pages 1. Added eddy current as an authorized procedure for inspection.
thru 13: Added change letter "g" to service sketch 3110.
Pages 17 Changed unit net prices to reflect current pricing policy.
and 18:
Revision Sequence Original Date May 16/80 Revision 1 September 8/80 Revision 2 February 23/84 OJH JEM-1 May 16/80 Bulletin A53-144 Revision 2 February 23/84 Page 1 of 1
DOUGLAS AIRCRAFT COMPANY • ALERT
MCDONNELL DOUGLAS
OC-S COMFORATION Long Beach, Calilornia 90801 3855 Lakewood Boulevard BULLETIN A53-144
SERVICE BULLETIN FUSELAGE - Main Frame - Inspect/Repair Aft Fuselage Ventral Pressure Bulkhead web.
NOTE This Service Bulletin is applicable only to aircraft equipped with the aft ventral pressure. bulkhead.
This Service Bulletin is issued as a partial record-type change. Engineering drawings or aperture cards are furnished in lieu of illustrations.
Operators with aircraft listed under Group I of this Service Bulletin which have five-leaf doublers incorporated per 0C-9 Service Bulletin 53-49, are to accomplish instructions outlined for Group Il aircraft for purposes of this Service Bulletin.
This Service Bulletin supersedes. but does not cancel the requirements of DC-9 Service Bulletin 53-49.
Accomplishment of the following constitutes closing action for this Service Bulletin:
1. Repair and/or replace AD4 rivets with AD5 rivets at all horizontal stiffeners, in firex wye support vertical stiffeners, and in scallops of upper diagonal doublers.
2. Install/replace five-leaf doublers at upper and lower ends of firex wye support vertical stiffeners using ADS rivets.
1. Planning Information:
A. Effectivity:
(1) Aircraft Affected• Model DC-9, Series 10, 30, and 40
MCDONNELL DOUGLAS CORPORATION (MOC) PROPRIETARY RIGHTS ARE INCLUDED IN THE INFORMATION DISCLOSED
HEREIN AND RECIPIENT BY ACCEPTING THIS DOCUMENT AGREES THAT THE INFORMATION IS PROPRIETARY TO MOC
MOC AUTHORIZES RECIPIENT TO REPRODUCE SUCH INFORMATION IN OTHER DOCUMENTS CREATED FOR INTERNAL
USE IF THESE DOCUMENTS ARE PROTECTED SIMILARLY BY A PROPRIETARY LEGEND May 16/80 Bulletin A53-144 Revision 2 February 23/84 Page 1 of 19
ALERT MCDONNELL DOUGLAS. SERVICE BULLETIN ALERT Operator Factory Serial No. Operator Factory Serial No.
Group I AL 47026 Oz 45772 and 45773 47050 thru 47052 45798 and 45799 47001 AM 45785 47027 thru 47029 47006 47033 AO 47080 RC 45787 45827 AZ 47038 and 47039 47063 and 47064 47073 CO 45786 47078 EA 47098 TN 47007 47009 GB 45717 VE 45710 800L* 47025 IB LEOLD LOLD XZD 45826 47011 YA 45732 IH 45724 47003 and 47004 IW 45841 ZN3 47012 ML 47005 47014 NY 47067 ZRS 45797 47094 ZS8 47013 00 47010 47015 ZVB 47000 ZAH 45731 Group II AL 47099 AZ 47046 and 47047 47130 47101 47146 47128 and 47129 AM 47106 CO 45788 47062 AO 47091 and 47092 47110 thru 47112 AY 47044 and 47045 EA 47120 Bulletin A53-144 May 16/80 Page 2 Revision 2 February 23/84
ALERT MCDONNELL DOUGL SERVICE BULLETIN ALERT Operator Factory Serial No. Operator Factory Serial No.
Group II (cont) IB 47084 RC 47031 47088 thru 47090 (cont) 47083 47093 47086 47312 47103 47149 KL 47102 47153 47131 thru 47133 47155 and 47156 47190 47160 47204 and 47205 NY 45789 47113 SK 47114 and 47115 OD 47152 SR 45790 OZ 47030 VE 47104 and 47105 47035 47107 thru 47109 ZBM 47087 47172 47154 47248 47251 ZCA 47061 RC 45828 •ZN3 47055 47016 thru 47018.
This modification was incorporated prior to delivery on all DC-9 and C-9 series aircraft, manufacturer's fuselage number 268 and subsequent, as applicable.
(2) Spares Affected:
None.
Reason:
Recent tests revealed fatigue cracks in the bulkhead web area under the firex wye support vertical stiffeners, horizontal stiffeners, and upper diagonal doublers due to cyclic loading. Crack activity has been detected during test of components at approximately 72,000 pressurization cycles. Cracks which are not corrected could progress and cause web failure resulting in loss of pressurization. Inspection of the forward and aft sides of the aft fuselage pressure bulkhead will determine condition of web. Accomplishment of this Service Bulletin will ensure structural integrity and enhance web service life.
May 16/80 Bulletin A53-144 Revision 2 February 23/84 Pade 3
ALERT MCDONNELL DOUGLAS SERVICE BULLETIN ALERT C. Description:
This Service Bulletin accomplishes the following on the forward and aft sides of the aft fuselage pressure bulkhead.
Group I Visually inspects bulkhead web for cracks at upper and lower ends of firex wye support vertical stiffeners.
or Performs eddy current or fluorescent penetrant inspection of bulkhead web for cracks at upper and lower ends and at attach rivet holes for firex wye support vertical stiffeners, at rivet holes for horizontal stiffeners, and at rivet holes for scallops of upper diagonal doublers, and accomplishes the following:
Condition 1 (No Cracks) Repetitively inspects until five-leaf doublers are installed with AD5 rivets at upper and lower ends of firex wye support vertical stiffeners and all AD4 rivets in firex wye support vertical stiffeners, in horizontal stiffeners, and in scallops of upper diagonal doublers are replaced with ADS rivets.
Conditions 2 thru 16 (Cracks) Removes doublers, as applicable, and installs reinforcing doublers and shims..
Group !!
Performs eddy current or fluorescent penetrant inspection of bulkhead web at rivet holes for scallops of five-leaf doublers at upper and lower ends and along attach rivets for firex wye support vertical stiffeners, along rivet holes for horizontal stiffeners, and at rivet holes for scallops of upper diagonal doublers, and accomplishes the following:
Condition L No Cracks) Replaces existing five-leaf doublers at upper and lower ends of firex wye support vertical stiffeners using AD5 rivets and replaces all AD4 rivets in firex wye vertical stiffeners, in horizontal stiffeners, and in scallops of upper diagonal doublers with AD5 rivets.
Conditions 2 thru 16 (Cracks) Removes doublers, as applicable, and installs reinforcing doublers and shims.
Bulletin A53-144 May 16/80 Page 4 Revision 2 February 23/84
ALERT MCDONNELL DOUGLA SERVICE BULLETIN ALERT D. Compliance:
It is recommended that this inspection/repair/modifcation be accomplished as follows:
Repetitive Initial Inspection Accumulated Inspection Intervals Special Group Landings (Landings)* (Landings) ** Instructions Less than 4000 4000 1/ 2/ 5/ 40,000 More than 2000 1/ 3/ 5/ 40,000 More than 1000 4/ 51 60,000 More than 4000 5/ 6/ 40,000 More than 1000 5/ 6/ 60,000 *Indicates after issue date of this Service Bulletin or after aircraft reaches next higher accumulated landings increment.
**Indicates after completion of initial inspection.
1/ Visually inspect bulkhead web for cracks at upper and lower ends of firex wye support vertical stiffeners.
If no cracks are found, repetitively inspect until five-leaf doublers are installed with ADS rivets at upper and lower ends of firex wye support vertical stiffeners.
3/ If no cracks are found, perform eddy current or fluorescent penetrant inspection, accomplish repairs if required, and accomplish modifications as described in special instructions 4/ and 6/ within 2000 landings after initial visual inspection.
41 Remove appropriate AD4 rivets and perform eddy current or fluorescent penetrant inspection of bulkhead web for cracks at rivet holes at upper and lower ends and at attach holes for firex.
wye support vertical stiffeners, at rivet holes for horizontal stiffeners, and at rivet holes for scallops of upper diagonal doublers. If no cracks are found, install five-leaf doublers at upper and lower ends of vertical stiffeners with AD5 rivets and replace all AD4 rivets in stiffeners and in scallops of upper diagonal doublers with AD5 rivets.
May 16/80 Bulletin A5:-144 Revision 2 February 23/84 Pege 5
ALERT MCDONNELL DOUGLAS → SERVICE BULLETIN ALERT Remove appropriate AD4 rivets and perform eddy current or fluorescent penetrant inspection of bulkhead web for cracks at rivet holes for scallops of five-leaf doublers at upper and lower ends and at attach rivet holes for firex wye support vertical stiffeners, at rivet holes for horizontal stiffeners, and at rivet holes in scallops of upper diagonal doublers. If no cracks are found, replace existing five-leaf doublers using ADS rivets and replace all AD4 rivets in stiffeners and in scallops of upper diagonal doublers with AD5 rivets.
6/ Repair cracks per appropriate condition shown in paragraph 2, Table I or II.
NOTE: Accomplishment of the following constitutes closing action for this Service Bulletin:
(1) Repair and/or replace AD4 rivets with AD5 rivets at all horizontal stiffeners, in firex wye support vertical stiffeners, and in scallops of upper diagonal doublers.
(2) Install/replace five-leaf doublers at upper and lower ends of firex wye support vertical stiffeners using ADS rivets.
E. Approval:
The resultant modification described in paragraph 1.C has been shown to comply with the applicable Federal Aviation Regulations and Revision 2 is approved by the Manager, Los Angeles Area Aircraft certification Office, FAA Northwest Mountain Region, on February 10, 1904.
F. Manpower:
Groups I The visual inspection may be accomplished in the following approximate man-hours or elapsed hours per aircraft:
Work Phases Man-Hours Gain Access 8.0 Inspect 1.0 Close Up 9.5 Total Man-Hours 18.5 Total Elapsed Hours 7.5 Bulletin A53-144 May 16/80 Page 6 Revision 2 February 23/84
ALERT MCDONNELL DOVaLA SERVICE BULLETIN ALERT Group ! or I!
The eddy current or fluorescent penetrant inspection may be accomplished in the following approximate man-hours or elapsed hours per aircraft:
Work Phases Man-Hours Gain Access 47.0 Inspect 32.0 Close Up 53.5 Functional Check 0.5 Total Man-Hours 133.0 Total Elapsed Hours 36.3 The repairs or mdifications may be accomplished in the following approximate man-hours or elapsed hours per aircraft:
Man-Hours Conditions 3 and 4 and 5 and 7 and 8 9 and I1 13 and Work Phases 15 12 16 10 14 Modify (Aircraft) 61.6 Repair 30.0 40.0 43.1 41.7 16.0 24.1 14.6 26.2 44.2 Total Man-Hours 61.6 30.0 40.0 43.1 41.7 16.0 24.1 14.6 26.2 44.2 Total Elapsed 30.8 15.0 20.0 21.6 20.8 8.0 12.0 7.3 13.1 22.1 Hours NOTE: Man-hour estimates are calculated based on the assumption that the aircraft/unit has been placed in a maintenance status. The man-hour/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.
Nonproductive elapsed time: Examples; sealant or adhesive cure time, cleaning, paint drying time, lunch and/or rest periods, and quality assurance inspections.
3. Administrative functions: engineering liaison, parts requisition, shite change coordination, and report writing. Examples; planning, Operators should take the above into consideration when scheduling this modification.
May 16/80 Bulletin A53-144 Revision 2 February 23/84 Page 7
ALERT MCDONNELL DOUGLAS SERVICE BULLETIN ALERT G. Material - Cost and Availability:
(2) Aircraft:
Parts required to accomplish this modification are listed in paragraph 3.A and are to be procured as indicated. Parts with unit net prices are proprietary parts and must be purchased as end item spares from the Douglas Aircraft Company under the spare parts article of the purchase agreement. unit net prices are subject to change by current pricing policies. Parts will b available in approximately 15 days after receipt of purchase order.
The purchase order must specify this Service Bulletin number and only parts listed herein. Direct purchase order to:
Douglas Aircraft Company P.O. Box 1771 Long Beach, California 90801 Attn: Parts Sales - Commercial 7-21.
(DC-9 Alert Service Bulletin A53-144)
(2) Spares:
Not applicable.
H. Tooling - Price and Availability:
None.
I. Weight and Balance:
Group I or Il This modification will increase the weight of the aircraft as follows:
APPROXIMATE STATION MFR'S EMPTY MOMENT CHANGE INDEX UNIT
SERIES LOCATION OF WEIGHT (MEW) CHANGE CONDITION AIRCRAFT WEIGHT INCREASE INCREASE LBS IN.-LBS (MEW) 10 None None None None 30 None None None None 40 None None None None 2 10 817.0 +1.4 +332 +0.3 30 996.0 +1.4 +423 +0.4 40 1072.0 +1.4 +476 +0.5 10 817.0 +1.5 +356 +0.4 30 996.0 +1.5 +453 +0.5 40 1072.0 +1.5 +510 +0.5 Bulletin A53-144 May 16/80 Page 8 Revision 2 February 23/84
ALERT MCDONNELL DOUGI SERVICE BULLETIN ALERT
APPROXIMATE STATION MFR'S EMPTY MOMENT CHANGE INDEX UNIT
SERIES -OCATION OF WEIGHT (MEW) (MEW) CHANGE CONDITION AIRCRAFT WEIGHT INCREASE INCREASE LBS IN.-LBS (MEW) 10 817.0 +2.0 +474 +0.5 30 996.0 +2.0 +604 +0.6 40 1072.0 - +2.0 +680 +0.7 10 817.0 +1.7 +403 +0.4 and 12 30 996.0 +107 +513 +0.5 40 1072.0 +1.7 +578 +0.6 7 10 817.0 +0.6 +142 +0.1 30 996.0 +0.6 +181 +0.2 40 1072.0 +0.6 +204 +0.2 8 10 817.0 +1.0 +237 +0.2 30 996.0 + 1.0 +302 +0.3 40 1072.0. +1.0 +340 +0.3 9 and 10 817.0 +0.5 +119 +o.i 10 30 996.0 +0.5 +151 +0.2 40 1072.0 +0.5 +170 +0.2 10 817.0 +1.2 +284 +0.3 30 996.0 +1.2 +362 +0.4 40 1072.0 +1.2 +408 +0.4 13 thru 10 817.0 +1.8 +427 +0.4 15 30 996.0 +1.8 +544 +0.5 40 1072.0 +1.8 +612 +0.6 16 10 817.0 +0.7 +166 +0.2 30 996.0 +0.7 +211 +0.2 40 1072.0 +0.7 +238 +0.2 May 16/80 Bulletin A53-144 Revision 2 February 23/84 Page 9
ALERT MCDONNELL DOUGLA SERVICE BULLETIN ALERT J. References:
(1) This Service Bulletin supersedes but does not cancel the requirements of DC-9 Service Bulletin 53-49.
(2) This Service Bulletin may be accomplished in conjunction with DC-9 Service Bulletin 53-166 for convenience of maintenance.
(3) Data used in preparation of this Service Bulletin:
Data Identification Change Type of Data DMS 2082 Douglas Material Specification DPM 3279 Douglas Process Material J060111 New Service Rework Drawing MM Chapters 6, 21, 25, Maintenance Manual 26, 52, and 53 3109 New Service Sketch (Attached) 3110 Service Sketch (Attached)
(4) Service rework drawing J060111 "New" is supplied in support of this Service Bulletin.
NOTE: One reproducible and two copies or aperture cards of service rework drawing J060111 "New" are being furnished to each affected operator.
Publications Affected:
The modification outlined in this Service Bulletin affects the DAC DC-9 Weight and Balance charts.
Bulletin A53-144 May 16/80 Page 10 Revision 2 February 23/84
ALERT MCDONNELL DOUGLA - SERVICE BULLETIN ALERT
2. Accomplishment Instructions:
WARNING: TO AVOID INJURY TO 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.
NOTE: Chapters within parentheses refer to sections of the Maintenance Manual.
Conditions relative to service rework drawing J06011l configurations are as follows:
Condition Drawing J060111 Condition Drawing J060111 -1 10 -521 -503 -501 -507 12 -505 -511 13 - 509 -515 14 -513 -527 15 -517 -519 16 -525 -523 Groups I Visual Inspection A. Remove and retain firex bottles and attaching parts. See chapter 26-20-1, paragraph entitled, "Removal/Installation Fire Extinguishing Containers.i) Roll back or remove and retain insulation material from aft side of ventried, teresa/i statation insulation 8125225." paragraph Visually inspect upper and lower ends of firex wye support vertical stiffeners as shown on service sketch 3109 (attached) and accomplish the following:
Condition 1 (No Cracks) Perform repetitive visual inspection until five-leaf doublers are installed with AD5 rivets as shown on service sketch 3110B (attached).
Condition 2, 3, and 4 (Cracks) Accomplish required repairs per applicable condition in Table I.
May 16/80 Bulletin A53-144 Revision 2 February 23/84 Page 11