# Boeing Service Bulletin DC9-A53-144: Revision 2 - Rights: © The Boeing Company. Filed by the FAA in regulations.gov docket FAA-2013-0706, the docket of AD 2013-25-12. Not covered by OpenAirDocs’ CC0 dedication. - Document: [Boeing Service Bulletin DC9-A53-144](https://openairdocs.org/service-documents/boeing/dc9-a53-144.md) - Title as filed: U.S. DOT/FAA - SB-DC9-A53-144-r2 - Pages: 34 - PDF: https://openairdocs.org/files/sha256/39/93/39933a202d8403d92e46648555ea91e203c2c6520910c1e71e2ddcface7dcd0b - Page: https://openairdocs.org/service-documents/boeing/dc9-a53-144/file/39933a202d84 ## Text This text is OCR from a scan. OCR can misread letters and numbers. Each page's text from the PDF; open the PDF at a page with #page=N. ### Page 1 (OCR) 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 ### Page 2 (OCR) 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 ### Page 3 (OCR) 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 ### Page 4 (OCR) 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 ### Page 5 (OCR) 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 ### Page 6 (OCR) 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 ### Page 7 (OCR) 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 ### Page 8 (OCR) 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 ### Page 9 (OCR) 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 ### Page 10 (OCR) 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 ### Page 11 (OCR) 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 ### Page 12 (OCR) 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 ### Page 13 (OCR) ALERT MODONNELL DOUGLAS SERVICE BULLETIN ALERT Eddy Current Or Fluorescent Penetrant Inspection A. Remove and retain passenger aft entrance door and attaching parts. (See chapter 52-12-0, paragraph entitled, Removal/Installation Passenger Aft Entrance Door.i) 8. Remove and retain lavatory equipment and attaching parts. (See chapter 25-41-0, paragraph entitled, "Removal/Installation Lavatory Equipment.") C. Remove and retain firex bottles and attaching parts. (See chapter 26-20-1, paragraph entitled, Removal/Installation Fire Extinguishing Containers.") D. Remove and retain access panels 5911 or 5911A, 5912 or 5912A, and sidewall panels as required. (See chapter 6-12-0.) E. Remove and retain air-conditioning pressure regulator valve and . attaching parts. (See chapter 21-31-1, paragraph entitled, 'Removal/Installation Air-Conditioning Pressure Regulator Valve." F. Remove and retain air-conditioning flow control valve and attaching parts. (See chapter 21-31-2, paragraph entitled, "Removal/Installation Air-Conditioning Flow Control Valve.) G. Remove and retain insulation material from forward and aft sides of ventral aft pressure bulkhead. (See chapter 25-20-0, paragrapr entitled, Kemoval/Installation Insulation Blankets.") H. Perform eddy current or fluorescent penetrant inspection of ventral aft pressure bulkhead as shown on service sketch 3110B (attached) and accomplish the following: Condition 1 - (No Cracks) Install five-leaf doublers and replace AD4 rivets with ADS rivets as shown on service sketch 31108 (attached). Conditions 2 thru 16 (Cracks) Accomplish required repairs per applicable condition in Tables I and II. I. Reinstall insulation material. J. Reinstall firex bottles and attaching parts. K. Reinstall air-conditioning pressure regulator valve L. Reinstall air-conditioning flow control valve. M. Test air-conditioning flow control valve. (See chapter 21-31-2, paragraph entitled, Adjustment Test Air-Conditioning Flow Control Valve.") Bulletin A53-144 May 16/80 Page 12 Revision 2 February 23/84 ### Page 14 (OCR) ALERT MCDONNELL DOUaL - SERVICE BULLETIN ALERT N. Test pressure regulator valve. (See chapter 21-31-1, paragraph entitled "Adjustment/Test Air-Conditioning Pressure Regulator Valve.") 0. Reinstall lavatory equipment and attaching parts. P. Reinstall passenger aft entrance door and attaching parts. Q. Reinstall access and sidewall panels. Group II Eddy Current Or Fluorescent Penetrant Inspection A. Remove and retain passenger aft entrance door and attaching parts. (See chapter 52-12-0, paragraph entitled, "Removal/Installation Passenger Aft Entrance Door.") B. Remove and retain lavatory equipment and attaching parts. (See chapter 26-20-1, paragraph entitled, "Removal/Installation Lavatory Equipment.") C. Remove and retain firex bottles and attaching parts. (See chapter 26-20-1, paragraph entitled, "Removal/Installation Fire Extinguishing Containers.") D. Remove and retain access panels 5911 or 5911A, 5912 or 5912A, and sidewall panels as required. (See chapter 6-12-0.) E. Remove and retain air-conditioning pressure regulator valve and attaching parts. (See chapter z1-31-l, paragrapn entitled, "Removal/Installation Air-Conditioning Pressure Regulator Valve.". F. Remove and retain air-conditioning flow control valve and attaching parts. (See chapter 21-31-2, paragraph entitled, Removal/Installatior Air-Conditioning Flow Control Valve... G. Remove and retain insulation material from forward and aft sides of ventral aft pressure bulkhead. (See chapter 25-20-0, paragrapn entitled, "Removal/Installation Insulation Blankets.") H. Perform eddy current or fluorescent penetrant inspection of ventral aft pressure bulkhead as shown on service sketch 31108 (attached) and Condition 1 - (No Cracks) Replace existing five-leaf doublers with AD5 rivets as shown on service sketch 3110B (attached). May 16/80 Bulletin A53-144 Revision 2 February 23/84 Page 13 ### Page 15 (OCR) ALERT MCDONNELL DOUGL SERVICE BULLETIN ALERT Conditions 2 thru 16 (Cracks) Accomplish required repairs per applicable condition in Tables I and II. I. Reinstall insulation material. J. Reinstall firex bottles and attaching parts. K. Reinstall air-conditioning pressure regulator valve. L. Reinstall air-conditioning flow control valve. M. Test air-conditioning flow control valve. (See chapter 21-31-2, paragraph entitled, "Adjustment Test Air-Conditioning Flow Control Valve.") N. Test pressure regulator valve. (See chapter 21-31-1, paragraph entitleo "Adjustment/Test Air-Conditioning Pressure Regulator Valve.") 0. Reinstall lavatory equipment and attaching parts. P. Reinstall passenger aft entrance door and attaching parts. Q. Reinstall access and sidewall panels. Bulletin A53-144 May 16/80 Page 14 Revision 2 February 23/84 ### Page 16 (OCR) ALERT MCDONNELL DOUGL SERVICE BULLETIN ALERT TABLE I CONFIGURATION REFERENCE DRAWING CONDITION OPERATION PART NO. QTY KEY WORD J060111 ZONE SPECIAL INSTRUCTIUNS REMOVE 5910130-121 2 FIVE-FINGER DOUBLER 3 ANO 15 APPLY A FAYING SURFACE SEAL OF PR-1422 SEALANT TO AFFECTED PARTS PRIOR INSTALL J060111-3 NTD 1110 SPLICE DOUBLER TO INSTALLATION. J060111-23 NTD DOUBLER J060111-43 NTD SHIM J060111-47 NTD SHIM REMOVE *4917913-1 1 SUPPORT ASSY - 503 3 AND OR 15 4917913-513 5910130-121 4 FIVE-FINGER DOUBLER TRIM 5910130-103 DOUBLER INSTALL J060111-7 NTD SPLICE DOUBLER J060111-27 NTD 1 DOUBLER **4917913-1 J060111-47 NTO 1 SUPPORT ASSY SHIM BOND SUPPORT ASSEMBLY 4917913-513 OR TO STRUCTURE USING EC-2216 ADHESIVE OR EQUIVALENT. REMOVE 5910130-121 2 FIVE-FINGER DOUBLER -507 3 AND 20 TRIM 5910130-101 DOUBLER INSTALL J060111-11 NTD -179 SPLICE DOUBLER J060111-31 NTD DOUBLER J060111-47 NTD SHIM TRIM 5910130-99 1 DOUBLER SEAL OF PR-1422 SEALANT TO APPLY A FAYING SURFACE INSTALL J060111-35 NTD J060111-15 NTO DOUBLER SPLICE DOUBLER -511 3 AND 20 INSTALLATION. AFFECTEL PARTS PRIOR TU J060111-47 NTO SHIM 6 REMOVE *4917913-1 1 SUPPORT ASSY -515 OR 4917913-505 TRIM 5910130-97 DOUBLER INSTALL J060111-19 NTO SPLICE DOUBLER J060111-39 NTO DOUBLER J060111-47 NTO SHIM **4917913-1 SUPPORT ASSY BOND SUPPORT ASSEMBLY TO OR STRUCTURF USING EC-2216 4917913-505 ADHESIVE OR EQUIVALENT. REMOVE 5910130-81 DOUBLER APPLY A FAYING SURFACE SEAL OF PR-1422 SEALANT TO INSTALL J060111-59 NTD DOUBLER - 527 31 AFFECTED PARTS PRIOR TO J060111-61 NTO SPLICE DOUBLER INSTALLATION. 8 REMOVE 5910130-121 FIVE-FINGER -519 26 DOUBLER INSTALL J060111-49 NTO DOUBLER J060111-51 NTD SPLICE DOUBLER 9 REMOVE 5910130-121 2 FIVE-FINGER -523 29 DOUBLER INSTALL J060111-55 NTD SPLICE DOUBLER J060111-57 NTO DOUBLER 10 REMOVE 5910130-121 2 FIVE-FINGER -521 28 DOUBLER INSTALL J060111-53 NTO DOUBLER J060111-55 NTO SPLICE DOUBLER *RETAIN FOR REINSTALLATION *RETAINED PART May 16/80 Bulletin A53-144 Revision 2 Februarv 23/94 Page 15 ### Page 17 (OCR) ALERT MCDONNELL DOUGL SERVICE BULLETIN ALERT TABLE II CONFIGURATION REFERENCE DRAWING CONDITION OPERATION PART NO. jOTY KEY WORD J060111 ZONE SPECIAL INSTRUCTIONS 11 TRIM 5910130-107 1 DOUBLER -501 3 ALO APPLY A FAYING SURFACE SEAL OF PR-1422 SEALANT TO INSTALL J060111-5 NT0 SPLICE DOUBLER AFFECTED PARTS PRIOR TO J060111-25 NTD DOUBLER INSTALLATION. J060111-45 NTO 1 SHIM J060111-47 NTO 2 SHIM REMOVE *4917913-1 1 SUPPORT ASSY -505 3 AND OR 4917913-513 INSTALL J060111-9 NTO SPLICE DOUBLER J060111-29 NTD DOUBLER J060111-47 NTD SHIM **4917913-1 1 SUPPORT ASSY BONO SUPPORT ASSEMBLY TO OR STRUCTURE USING EC-2216 4917913-513 ADHESIVE OR EQUIVALENT. 13 REMOVE *4917913-1 SUPPORT ASSY -509 3 AND OR 10 4917913-513 TRIM 5910130-102 DOUBLER INSTALL J060111-13 NTO SPLICE DOUBLER J:60111-33 NTU DOUBLER J060111-47 NTO SHIM **4917913-1 1 SUPPORT ASSY BOND SUPPORT ASSEMBLY TO OR STRUCTURE USING EC-2216 4917913-513 ADHESIVE OR EQUIVALENT. 14 REMOVE *4917913-1 SUPPORT ASSY APPLY A FAYING SURFACE SEAL OF PR-1422 SEALANT TO TRIM 5910130-100 DOUBLER -513 3 AND AFFECTED PARTS PRIOR TO 10 INSTALLATION. INSTALL J060111-17 NTD SPLICE DOUBLER • 060111-37 NTD DOUBLER J060111-47 NTD 2 SHIM **4917913-1 1 SUPPORT ASSY BOND SUPPORT ASSEMBLY TO STRUCTURE USING EC-2216 ADHESIVE OR EQUIVALENT. 15 TRIM 5910130-98 1 DOUBLER -517 3 AND 10 INSTALL C060111-21 NTO SPLICE DOUBLER :060111-41 NTO DOUBLER. J060111-47 NTD SHIM 15 REMOVE 5910130-79 1 DOUBLER TRIM 5910130-13 DOUBLER -525 31 OR 5910130-133 INSTALL J060111-63 NTD DOUBLER J060111-65 NTO SPLICE DOUBLER *RETAIN FOR ALINSTALLATION **RETAINED PART Bulletin A53-144 May 16/80 Page 16 Revision 2 February 23/84 ### Page 18 (OCR) ALERT SERVICE BULLETIN ALERT 3. Material Information: A. The basis for the following material data is per aircraft. (1) Parts to be purchased as end item spares. NOTE: NTD parts are furnished with pilot holes omitted and trim-on-assembly material added as applicable. Group I or II Unit Qty Per Condition Net Part No. 1 2 3 8 9 10 11 12 13 15 16 Price Key Word J060111-11 NTD $108.00 Splice Doubler J060111-13 NTD 109.00 Splice Doubler J060111-15 NTD 108.00 Splice Doubler J060111-17 NTD 109.00 Splice Doubler J060111-19 NTO 107.00 Splice Doubler J060111-21 NTD 109.00 Splice Doubler J060111-23 NTD 106.00 Doubler J060111-25 NTD 105.00 Doubler J060111-27 NTD 105.00 Doubler J060111-29 NTD J060111-3 NTD 108.00 104.00 Doubler Splice Doubler J060111-31 NTD 108.00 Doubler J060111-33 NTD 108.00 Doubler J060111-35 NTD 108.00 Doubler J060111-37 NTD 108.00 Doubler J060111-39 NTD 106.00 Doubler J060111-41 NTD 108.00 Doubler J060111-43 NTD 77.50 Shin J060111-45 NTD 41.30 Shim J060111-47 NTD 42.90 Shim J060111-49 NTO 106.00 Doubler J060111-5 NTD 103.00 Splice Doubler J060111-53 NTD J060111-51 NTD 101.00 97.10 Splice Doubler Doubler J060111-55 NTD 94.60 Splice Doubler J060111-57 NTD 101.00 Doubler J060111-59 NTD 102.00 Doubler J060111-61 NTD 95.20 Splice Doubler J060111-63 NTD 1 94.60 Doubler J060111-65 NTD 95.90 Splice Doubler Bulletin A53-144 May 16/80 Page 17 Revision 2 February 23/84 ### Page 19 (OCR) ALERT SERVICE BULLETIN ALERT Group I or II Unit Uty Per Condition Net Part No. 1 2 3 4 10 11 12 13 14 16 Price Key Word J060111-7 NTD $106.00 Splice Doubler J060111-9 NTD 108.00 Splice Doubler 5910130-121 NTD 29.60 Five-Finger Doubler or 5910130-349 NTD (2) Parts and Material to be procured from operator's stock or sources indicated. NOTE: FSCM indicates Federal Supply Code for Manufacturers. Part/Material 1 2 3 Supplier EC-2216 Adhesive 2 Oz Minnesota Mining and or Manufacturing Company Equivalent Adhesives, Coatings and (DPM 3279) Sealers Division 3M Center St. Paul, Minnesota 55101 HLT336-6-5 Pin 73197 Hi-Shear Corporation HLT336-6-6 Pin 2600 Skypark Drive HLT336-6-7 Pin Torrance, California 90509 HLT636-6-3 Pin HLT636-6-4 Pin HLT636-6-5 Pin 1 MS20426AD5-6 Rivet 12 MS20426AD6-7 Rivet 12 MS20470AD5-5 Rivet MS20426AD6-8 Rivet 56 40 44 48 40 10 26 44 48 48 44 10 MS20470AD5-6 Rivet MS20470AD5-7 Rivet 25 38 44 38 42 15 25 40 44 48 46 MS20470AD5-8 Rivet MS20470AD6-7 Rivet 130 150 182 174 178 32 102 60 60 199 176 192 198 192 26 MS20470AD6-8 Rivet MS20470AD6-9 Rivet MS21042L3 Nut 16 19 17 17 17 16 17 1 17 17 NAS1252-10L Washer 16 19 PR-1422 Sealant 1 Pt 1 Pt 1 Pt 1 Pt 1 Pt 1 Pt 1 Pt 1 Pt 1 Pt 1 Pt 1 Pt 1 Pt 1 Pt 1 Pt 1 Pt 83574 Products Research and or Chemical Corporation Equivalent 5430 San Fernando Road (DMS2082) Glendale, California 91203 Bulletin A53-144 May 16/80 Page 18 Revision ? February 23/84 ### Page 20 (OCR) ALERT MCDONNELL DOUGLAS SERVICE BULLETIN ALERT (3) Parts removed. Discard. NOTE: Not applicable to conditions 5, 6, and 11 thru 15. Group I or II Qty Per Condition Part No. 2 Key Word 5910130-121 2 4 2 2 Five-Finger Doubler 5910130-79 Doubler 5910130-81 1 Doubler 8. The basis for the following material data is per spares. None. OJH JEM May 16/80 Bulletin A53-144 Rovicinn 2 Fohriaru 23/94 Page 19 ### Page 21 (OCR) DC-9 VENTRAL BULKHEAD 1. GENERAL THE FOLLOWING VISUAL INSPECTION PROCEDURE IS INTENDED TO ASSIST OPERATORS IN DETECTION OF CRACKS AT THE ATTACH POINTS OF THE WYE SUPPORT (FIREX) TO THE VENTRAL AFT PRESSURE BULKHEAD WEB. (SEE FIGURE 1.) 2. TEST EQUIPMENT/MATERIALS FLASHLIGHT 3 X TO 5 X GLASS 1,1,1, TRICHLOROETHANE SOLVENT, OR EQUIVALENT 3. VISUAL CHECK A. CLEAN AREA INDICATED IN FIGURE L OF DIRT, GREASE, AND FOREIGN MATERIALS USING LINT FREE WIPERS AND 1,L,L, TRICHLORDETHANE SOLVENT, OR EQUIVALENT. DO NUT SPRAY SOLVENT DIRECTLY ON BULKHEAD. LET SOLVENT DRY FOR 5 MINUTES. B. USING FLASHLIGHT AND 3 X TO 5 X GLASS, INSPECT AREAS NOTED IN FIGURE 1 FOR CRACKS. 4. DISPOSITION: MARK AND RECORD LENGTH AND LOCATION OF ALL CRACKS FOUND. REPORT DETAILS TO DAC. DIRECT INFORMATION TO: DOUGLAS AIRCRAFT COMPANY P.O. BOX 1771 LONG BEACH, CALIFORNIA 90801 ATTN: MANAGER, CUSTOMER SERVICE 7-21 (SERVICE BULLETIN A53-144) REF: DC-9 S/B A53-144 WOL TITLE VISUAL INSPECTION OF VENTRAL AFT PRESSURE BULKHEAD SCALE NONE APPR. A. HUTCHISON 5/13/30 SERVICE SKETCH MODEL APPR J. CHIM 513/72 3109 LONG BEACH, CALIF. 90801 DC -9 OrTSuM. S/Imenti v/13-ge SHEET 1 OF 2 ### Page 22 (OCR) 5917691-7 STIFFENER (REF) 5917691-5 5917691-13 STIFFENER STIFFENER (REF) (REF) - TYPICAL CRACK LOCATIONS 9915558 HORIZONTAL STIFFENER (TYP) 5917691-11 STIFFENER (REF) VIEW LOOKING AFT VENTRAL BULKHEAD VERTICAL STIFFENER 9915558 HORIZONTAL STIFFENER (TYP) VIEW LOOKING FORWARD REF: DC-9 S/8 A53-144 FIGURE 1. VISUAL INSPECTION AREA_ VENTRAL BULKHEAD SERVICE SKETCH SHEET _ NO. 3109 OF - 2 ### Page 23 (OCR) DC-9 VENTRAL BULKHEAD GENERAL THE FOLLOWING FLUORESCENT PENETRANT OR EDDY CURRENT PROCEDURE IS INTENDED TO ASSIST OPERATORS IN DETECTION OF CRACKS IN THE VENTRAL AFT PRESSURE BULKHEAD WEB AT SELECTED HORIZONTAL AND VERTICAL STIFFENERS AND DOUBLERS. (SEE FIGURE 1.) NOTE: EITHER WATER WASHABLE OR SOLVENT REMOVABLE FLUORESCENT PENETRANT IS ACCEPTABLE. 2. TEST EQUIPMENT HIGH SENSITIVITY WATER WASHABLE FLUORESCENT FENETRANTS MAY BE PURCHASED FROM: DMS 1908 DMS 1908 MANUFACTURERS GRADE 3 GRADE 4 NAME & ADDRESS MANUFACTURERS MANUFACTURERS DESIGNATION DESIGNATION P-133, P-133 A P-134 SHANNON. LUMINOUS MATERIALS CO. 7356 SANTA MONICA BOULEVARD LOS ANGELES, CALIFORNIA 90046 ZL-16, ZL-178, ZL-54 MAGNAFLUX CORP ZL -60B 6800 EAST WASHINGTUN BOULEVARD LOS ANGELES, CALIFORNIA 90040 DUBL-CHEK, HM3, HM-405 SHERMIN, ING. НМЗА 5007 EAST WASHINGTON BOULEVARD LOS ANGELES, CALIFORNIA 90040 FLUOROCHEK NONE TURCO PRODUCTS, INC. WP -100MD DIVISION OF PUREX CORP., LTD P. O. 80X 6200 CARSON, CALIFORNIA 90749 F-4A-B F-4A-C EISHEN KAGARU CO., LIU 1-2-13 HIGASHI-SHINBASHI MINATO-KU, TOKYO, JAPAN 0D-2800-1 0D-2800-2 TOKOSHU TORYO CO., LTD 1, NISHI 4-CHOME OMORI, OMTA-KL TOKYO, JAPAN REF : DC-9 S/8 A53-144 TITLE DOUOLAS A WY FLUORESCENT PENETRANT INSPECTION OF VENTRAL AFT PRESSURE BULKHEAD мово SCALE APPR. A HUTCHIS:101 3/60 SERVICE SKETCH MODEL APPR I CHISAT 3110B LONG BEACH, CALIF. 90801 OFTSUM. Sclimenti 5-13-80 SHEET 1 OF 1 DAC 08-729 (12-68) ### Page 24 (OCR) DMS 1908 DMS 1908 MANUFACTURERS GRADE : GRADE 4 NAME & ADDRESS N-BP N-4P NIPPON OILS AND FAT CO. • LTD 5 YURAKU-CHO 1-CHOME CHIYODA-KU, TOKYO 100 JAPAN BIO-PEN BIO-PEN OXY METAL INDUSTRIES P6F-3 P6F-4 LIDYLITE DIVISION 5640 KNOTT AVENUE BUENA PARK, CALIFORNIA 90620 B. HIGH SENSITIVITY SOLVENT REMOVABLE PENETRANT MAY BE PURCHASED FROM: SUPPLIERS MAGNAFLUX CORPORATION TURCO PRODUCTS, SHERWIN, INCORPORATED 6800 EAST WASHINGTON DIVISION OF PUREX 5007 EAST WASHINGTON BOULEVARD CORPORATION LIMITED BOULEVARD LOS ANGELES, CALIF. P.O. BOX 6200 LOS ANGELES, 90040 CARSON CALIF. 90740 CALIFORNIA 90040 MATERIALS. PART NO. FLUORESCENT LL-22A, OR LL-23A, FLUOR-CHECK DUBL-CHEK CLEANER PENETRANT OR ZL-30A R-REMOVER DR-61 MONAQUEOUS ZP-9 FLUOR-CHECK D-100 SPRAY DEVELOPER DEVELOPER C. ASSOCIATED EQUIPMENT/MATERIALS BLACK LIGHT, PORTABLE SUPER LIGHT, BLACK LIGHT COTTON SWABS 1,1,1, TRICHLOROETHANE SOLVENT, OR EQUIVALENT MAGNAFLUX CORP. L.A., CA, ULTRAVIOLET PRODUCTS, SAN GABRIEL, CA OR URESCO, INC., DOWNEY, CA HUFF'S WESTERN INDUSTRIAL EQUIP. CO. DOWNEY, CA REF: DC-9 S/B A53-144 SERVICE SKETCH SHEET NO. - 31108 OF 12 ### Page 25 (OCR) D. EDDY CURRENT INSTRUMENTS: NORTEC NDT-3, NDT-6, NDT-8, NORTEC CORPORATION NDT-16, OR NDT-18 421 NORTH QUAY KENNEWICK, WASHINGTON 99336 MIZ-10A, EM3300 OR AUTOMATION INDUSTRIES INCORPORATED MATERIALS EVALUATION GROUP SHELTER ROCK ROAD DANBURY, CONNECTICUT 06810 ED520, ED-530 MAGNAFLUX CORPORATION OR 7300 WEST LAWRENCE AVENUE CHICAGO, ILLINOIS 60656 EQUIVALENT E. EDDY CURRENT PROBES: VM501-4 VM PRODUCTS VM501-5 7420 PARK AVENUE VM501-6 TACOMA, WASHINGTON 98408 (100-300 KHZ) OR EQUIVALENT (SEE FIGURE 2) F. EDDY CURRENT REFERENCE STANDARD: VM501RS VM PRODUCTS OR 7420 PARK AVENUE EQUIVALENT TACOMA, WASHINGTON 98408 (SEE FIGURE 2) REF: DC-9 S/B A53-144 SERVICE SKETCH SHEET. NO. 3110B OF 12 ### Page 26 (OCR) 3. INSPECTION/MODIFICATION A. REMOVE AD4 RIVETS IN HORIZONTAL STIFFENERS. (SEE FIGURE 1.) CAUTION: SEE NOTE IN FIGURE 1. REMOVE ALL AD4 RIVETS ATTACHING FIREX WYE SUPPORT VERTICAL STIFFENERS AND SCALLOPS OF UPPER DIAGONAL DOUBLERS AND REMOVE ALL AD4 RIVETS ATTACHING FIVE-LEAF DOUBLERS TO BULKHEAD WEB. (SEE FIGURE 1.) C. PERFORM PENETRANT INSPECTION PER PARAGRAPH 4.A. OR 4.B.OR EDDY CURRENT INSPECTION PER PARAGRAPH 5. IF INSPECTION AROUND OPEN HOLES REVEALS NO CRACKS, ACCOMPLISH THE FOLLOWING: (1) INSTALL/REPLACE FIVE-LEAF DOUBLERS WITH NEW 5910130-121 OR -349 DOUBLERS USING ADS RIVETS. ENLARGE OPEN HOLES USING A NO. 20 DRILL AND INSTALL AD5 RIVETS IN HORIZONTAL STIFFENERS, VERTICAL STIFFENERS, AND UPPER DIAGONAL DOUBLERS. IF PENETRANT OR EDDY CURRENT INSPECTION REVEALS CRACKS, ENLARGE HOLE USING A NO. 20 DRILL AND REINSPECT. IF CRACK INDICATION STILL EXISTS, ENLARGE HOLE USING A 3/16 DRILL AND REINSPECT. IF CRACKS STILL EXIST, REPORT DETAILS TO DAC PER PARAGRAPH 6. PENETRANT INSPECTION A. HIGH SENSITIVITY WATER WASHABLE PENETRANT. INSPECT FORWARD OR AFT SIDE OF VENTRAL BULKHEAD AS APPLICABLE, WHERE SKIN IS EXPOSED BEHIND NOTED STIFFENERS (SEE FIGURE 1.) CLEAN AREA AROUND REMOVED FASTENER HOLES, WHERE BULKHEAD SKIN IS EXPOSED, OF DIRT, GREASE, AND FOREIGN MATERIALS USING LINT FREE WIPERS AND 1,1,1, TRICHLOROETHANE SOLVENT, OR EQUIVALENT. SPRAY SOLVENT DIRECTLY ON BULKHEAD. LET SOLVENT EVAPORATE FOR 5 MINUTES. CAUTION: AVOID GETTING PENETRANT MATERIALS OR SOLVENTS ON RUBBER PARTS. OBSERVE ALL SAFETY PRECAUTIONS WHEN WORKING WITH SOLVENTS OR ELECTRICAL EQUIPMENT. (3) APPLY HIGH SENSITIVITY, WATER WASHABLE FLUORESCENT PENETRANT WITH COTTON SWABS OR SMALL BRUSH AROUND PERIPHERY OF HOLES TO BE INSPECTED. ALLOW 10 MINUTES MINIMUM FOR PENETRATION TIME. NOTE: DO NOT SATURATE COTTON SWAB WITH PENETRANT MATERIAL WHEN PERFORMING INSPECTION. DAMPEN END OF COTTON SWAB WITH ENOUGH MATERIAL TO INSPECT 5 OR 6 HOLES, THEN DISCARL SWAB. EXTREME CARE SHOULD BE TAKEN TO APPLY PENETRANT AROUND PERIPHERY OF HOLES WITHOUT GETTING PENETRANT INSIDE OF HOLE. FAYING SURFACE WILL ENTRAP PENETRANT AND CAUSE EXCESSIVE BACKGROUND FLUORESCENCE. REF: DC-9 S/B A53-144 SERVICE SKETCH SHEET NO.: 31108 OF 12 ### Page 27 (OCR) (4) REMOVE EXCESS PENETRANT BY WIPING FIRST WITH A CLEAN, DRY, WIPER FOLLOWED BY A WATER DAMPENED WIPER. REMOVE RESIDUAL MOISTURE WITH A CLEAN, DRY, WIPER. WIPERS ARE TO BE LINT FREE PAPER OR CLOTH MATERIALS. DISCARD CONTAMINATED WIPERS. (5) APPLY A LIGHT FILM COAT OF NONAQUEOUS WET DEVELOPER OVER AREA TO BE INSPECTED AND ALLOW FIVE (5) MINUTES MINIMUM DEVELOPMENT TIME. (6) USING BLACK LIGHT, INSPECT FOR CRACKS AROUND PERIPHERY OF HOLES. NOTE: ALL BLACK LIGHT İNSPECTIONS MUST BE OBSERVED IN DARKENED AREA. (7) WHEN INSPECTION IS COMPLETED, REMOVE DEVELOPER WITH CLEAK WATER ANU ANY RESIDUAL FLUORESCENT PENETRANT WITH 1,1,1, TRICALOROETHANE SOLVENT, OR EQUIVALENT. E. HIGH SENSITIVITY SOLVENT REMOVABLE PENETRANT. (1) CLEAN THE AREA TO BE INSPECTED USING CLEAN LINT FREE WIPERS AND MINİMUM OF S MINUTES. SOLE FIGURE SUVALENT. ALLOW TO DRY FOR A (2) APPLY SOLVENT-REMOVABLE FLUORESCENT PENETRANT TO INSPECTIOV AREA USING CLEAN, LINT FREE WIPERS OR A SMALL BRUSH. ALLOW 10 MINUTES FOR PENETRANT DWELL TIME. NOTE: DO NOT SATURATE COTTON SWAB WITH PENETRANT MATERIAL WHEN PERFORMING INSPECTION. DAMPEN END OF COTTON SWAB WITH ENOUGH MATERIAL TO INSPECT 5 OR 6 HOLES, THEN DISCARD EXTREME CARE SHOULD BE TAKEN TO APPLY PENETRANT AROUND PERIPHERY OF HOLES WITHOUT GETTING PENETRANT INSIDE OF HOLE. FAYING SURFACE WILL ENTRAP PENETRANT AND CAUSE EXCESSIVE BACKGROUND FLUORESCENCE.. (3) RE CLEAN MESS SEIGHTLY DAMPENED WEH SOLVENT. ALLOW SOLVET YOHITH EVAPORATE FOR 5 MINUTES MINIMUM. DISCARD CONTAMINATED WIPERS. (4) APPLY A LIGHT UNIFORM COAT OF NONAQUEOUS DEVELOPER TO INSPECTION AREA AND ALLOW 5 MINUTES MINIMUM DEVELOPMENT TIME. (5) USING BLACK LIGHT, INSPECT FOR CRACKS AROUND PERIPHERY OF HOLES. NOTE: ALL BLACK LIGHT INSPECTIONS MUST BE OBSERVED IN A DARKENED AREA. (б) WHEN INSPECTION IS COMPLETED, REMOVE DEVELOPER WITH CLEAR VATER AND ANY RESIDUAL FLUORESCENT PENETRANT WITH 1,1,1, TRICHLOROETHANE SOLVENT, OR EQUIVALENT. REF: DC-9 S/B A53-144 SERVICE SKETCH SHEET 5 NO. 3110B OF 12 ### Page 28 (OCR) 5. EDDY CURRENT INSPECTION TEST SET-UP: (1) CONNECT PROBE TO INSTRUMENT AND SET FREQUENCY BETWEEN 100 AND 300 KHZ FOR SURFACE PROBES. (SEE FIGURE 2.) (2) SELECT EDDY CURRENT REFERENCE STANDARD AND PLACE PROBE IN THE UNCRACKED AD4 HOLE. CALIBRATE INSTRUMENT IN ACCORDANCE WITH MANUFACTURER'S INSTRUCTIONS. (SEE REFERENCE STANDARD IN FIGURE 2.) (3) PLACE PROBE IN NOTCHED AD4 HOLE AND ADJUST BALANCE AND/OR LIFT-OFF CONTROLS SO THAT LIFTING THE PROBE FROM THE HOLE OR WOBBLING THE PROBE IN THE HOLE PRODUCES MINIMUM LIFT-OFF. BALANCE INSTRUEMENT SO THAT LIFT-OFF WILL DRIVE THE METER IN ONE DIRECTION AND PASSING THE COIL OVER THE NOTCH WILL DRIVE THE METER IN THE OPPOSITE DIRECTION. (4) ROTATE COIL OVER REFERENCE NOTCH AND ADJUST SENSITIVITY TO PRODUCE A MINIMUM OF 50 PERCENT FULL-SCALE DEFLECTION. NOTE: ON INSTRUEMENTS WITH OSCILLOSCOPE READOUTS, ADJUST THE HORIZONTAL AND VERTICAL GAIN AND SENSITIVITY CONTROLS TO PRODUCE A NOTCH RESPONSE OF 50 PERCENT FULL-SCALE DEFLECTION. (SEE FIGURE 3.) B. AIRCRAFT PREPARATION: (1) VERIFY THAT THE RIVETS ARE REMOVED BEFORE BEGINNING EXAMINATION. (2) VERIFY THAT THE EXAMINATION AREA AROUND THE RIVET HOLE IS CLEAN AND FREE OF CRACKED AND LOOSE PAINT, NICKS, AND BURRS. C. EDDY CURRENT TESTING: (1) EXAMINE THE RIVET HOLES (SCAN EACH 360°) ON THE BULKHEAD WEB ALONG THE LENGTH OF THE HORIZONTAL STIFFENERS FROM THE AFT SIDE ABOVE THE FRP. (SEE FIGURE 1.) (2) EXAMINE THE UPPER DIAGONAL SCALLOPED DOUBLER ATTACHMENT RIVET HOLES IN THE BULKHEAD WEB FROM THE FORWARD SIDE. (SEE FIGURE 1.) EXAMINE THE FIREX WYE SUPPORT VERTICAL STIFFENERS AND FIVE-LEAF DOUBLERS TO BULKHEAD WEB ATTACHMENT RIVET HOLES FROM THE AFT SIDE. (SEE FIGURE 1 DETAILS A AND B.) MARK AND RECORD ALL AREAS SHOWING A METER OR OSCILLOSCOPE READING IN EXCESS OF 25 PERCENT FULL-SCALE DEFLECTION. CRACK LENGTH MAY BE DETERMINED BY FLUORESCENT PENETRANT INSPECTION. REF: DC-9 S/B A53-144 SERVICE SKETCH SHEET NO. 31108 OF _ 12 ### Page 29 (OCR) 6. DISPOSITION: MARK AND RECORD LENGTH AND LOCATION OF ALL CRACKS FOUND. REPURT DETAILS TO DAC. DIRECT INFORMATION TO: DOUGLAS AIRCRAFT COMPANY P.O. BOX 1771 LONG BEACH, CALIFORNIA 90801 ATTN: MANAGER, CUSTOMER SERVICE 7-21' (SERVICE BULLETIN A53-144) . REF: DC-9 S/B A53-144 SERVICE SKETCH SHEET NO. 31108 OF 12 ### Page 30 (OCR) STA Y=817 (SERIES 10 AND 20) Y=996 (SERIES 30) Y=1072 (SERIES 40) PERFORM PENETRANT OR EDDY Y=1167 (SERIES 50) CURRENT INSPECTION FROM AFT SIDE OF BULKHEAD WITH ATTACHMENTS REMOVED (SEE PARAGRAPH 3 "INSPECTION") NOTE: PERFORM PENETRANT OR EDDY CURRENT INSPECTION AT UPPER DIAGONAL SCALLOPED DOUBLERS FROM FORWARD SIDE OF BULKHEAD WITH MOTED ATTACHMENTS REMOYED. REMOVE RIVETS IN ALTERNATE STIFFENERS AND REPLACE OR REPAIR BEFORE REMOVING ADDITIONAL RIVETS. FROM MORE THAN TWO STIFFENERS EACH SIDE DO NOT REMOVE RIVETS AT ONE TIME EXERCISE CARE DURING ALL RIVET REMOVAL TO AVOID CRACKING AND BUCKLING OF STIFFENERS. VISUALLY INSPECT FOR CRACKED STIFFENERS AND REPAIR OR REPLACE. HORIZONTAL HORIZONTAL STIFFENER STIFFENERS RIVET REQUIREMENTS 9915558 - 505 -503 STIFFENER CONFIG. RIVET P/N QTY -509 -507 -503 MS20426AD5-6 2 MS20470AD5-6 27 -511 -505 MS20426AD5-6 -513 MS20470AD5-6 24 -517 -515 -509 -507 MS20470AD5-6 MS20426AD5-6 42 2 -521 -519 MS20470A05-6 40 -511 MS20470AD5-6 45 FRP - C O c - FRP -513 MS20426AD5-6 MS20470A05-6 44 2 -515 MS20426AD5-6 4 MS20470AD5-6 38 -517 MS20470AD5-6 48 -519 MS20470AD5-6 42 -521 MS2047'JAD5-6 46 •SEE PARAGRAPH 3 "INSPECTION" (TYP) VIEW LOOKING AFT REF: DC-9 S/B A53-144 SERVICE SKETCH SHEET FIGURE 1. DC-9 VENTRAL AFT NO. 31108 OF _ 12 PRESSURE BULKHEAD. ### Page 31 (OCR) *NOTE: SEE PARAGRAPH 3. "INSPECTION" *5910130-79 SCALLOPED DOUBLERS (REF) • MS20470AD5-5 RIVET (11 PLACES) *5910130-81 SCALLOPED *5917691-5 DOUBLERS *5917691-7 STIFFENER (REF) STIFFENER (REF) (REF)- MS20470AD5-5 RIVET *5917691-13 (10 PLACES) STIFFENER (REF) *5917691-11 STIFFENER (REF) MS20470AD5-5 RIVET (11 REQD) (TYP AT 5917691-5, -7, -11, AND -13 STIFFENERS) VIEW LOOKING AFT REF: DC-9 S/B A53-144 SERVICE SKETCH SHEET NO. 3110B OF - 12 ### Page 32 (OCR) NOTE: FASTENERS A THROUGH F MUST MS20470AD5-6 BE REMOVED, THEN FIVE-LEAF RIVET DOUBLER MUST BE REMOVED TO (4 PLACES) PERFORM PENETRANT OR EDDY CURRENT INSPECTION AT FASTENER • HORIZONTAL LOCATIONS A, B, C, D, E, AND F. STIFFENERS NOTE: MUST BE PERFORMED ON AFT INSPECTION FOR RIVET HOLES FORWARD SIDE -507, -511 SIDE OF BULKHEAD. - 5910130-121 OR -349 FIVE-LEAF DOUBLER : AFT SIDE (TYP 4 PLACES) MS20470AD5-5 MS20470AD5-5 RIVET RIVET VIEW A • LOOKING FORWARD 5910130-121 OR -349 FIVE-LEAF DOUBLER AFT SIDE (TYP 4 PLACES) CERTAIN CONFIGURATIONS MAY REQUIRE TRIMMING TO CLEAR EXISTING DOUBLER. • HORIZONTAL STIFFENERS - 503, -507 FORWARD SIDE. - MS20470AD5-6 RIVET (4 PLACES) VIEW B LOOKING FORWARD REF: DC-9 S/B A53-144 SERVICE SKETCH SHEET NO. 31108 OF . 12 ### Page 33 (OCR) NOTES: MAKE FROM 2014-T651 OR 2024-T651 MATERIAL 0.42 - .048 INCH THICK. PAINT REFERENCE STANDARD WITH FR PRIMER. VM5 01 RS •5 AD5 AD 6 REFERENCE STANDARD SIB A53-144 DC-9 :5 .1562 • 1875 AD4 1.0 .125 • EDM NOTCH C.025 LONG BY .OOS WIDE ) THRU THICKNESS (3 PLACES) PILOT AD4 PILOT <.5 COIL VN501-4 TEFLON TAPE (OPTIONAL VM501-5 • .125 (MAX) 1.75 - AD5 - PILOT PROBE VM501-6 ADG - COIL • COIL -. 75 DIA (MAX) FIGURE 2 CRACK REFERENCE STANDARD AND SURFACE PROBE REF: DC-9 S/B A53-144 SERVICE SKETCH SHEET . 11 NO. 31108 OF 12 ### Page 34 (OCR) CRT PRESENTATION EM3300 CRACK INDICATION- LIFTOFF RESPONSE NOTES: 1. 100 kHz 2. NOTCH RESPONSE FROM REFERENCE STANDARD. 3. LIFT-OFF RESPONSE MAY BE ROTATED 90° TO HORIZONTAL PLANE. FIGURE 3 REF: DC-9 S/B A53-144 SERVICE SKETCH SHEET. 12 NO. 3110B OF 12 --- OpenAirDocs.org is an independent research project of [Contrail Labs](https://contraillabs.com/). It is not affiliated with the FAA or the NTSB. Source documents are U.S. government works in the public domain, except the copies of manufacturers’ service documents, which belong to their rights holders.