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 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 "B", was 3110 "New".

Pages 11 Added eddy current as an authorized procedure for inspection.

thru 13: thru 13 Added change letter "B" 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 of 1
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 DC-9 Service Bulletin 53-49, are to

accomplish instructions outlined for Group II

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 AD5 rivets.

1. Planning Information:

A. Effectivity:

(1) Aircraft Affected

Model DC-9, Series 10, 30, and 40

May 16/80 Bulletin A53-144

Revision 2 February 23/84 Page 1 of 19
Factory Serial No. Operator

Group I

OZ

thru 47052

RC

and 47039

TN

VE

XZD

YA

ZNV

ZN3

ZRS

ZS8

ZVB

ZWH

Factory Serial No.

45772

45798

47001

47027

47033

45787

45827

47063

47073

47078

47007

47009

45710

47025

45826

47011

45732

47003

47012

47014

45797

47013

47000

45731

and

and

thru

45773

45799

47029

and 47064

and 47004

Group II

AL

AM

AO

AY

Bulletin A53-144

Page 2

47099

47130

47146

47106

47091 and 47092

47044 and 47045

AZ

CO

EA

47046

47101

47128

45788

47062

47110

47120

and 47047

and 47129

thru 47112

May 16/80

Revision 2 February 23/84

Operator

AL

AM

AO

AZ

CO

EA

GB

IB

IH

IW

ML

NY

00

47026

47050

45785

47006

47080

47038

45786

47098

45717

47002

47008

.47037

47076

47079

45724

45841

47005

47067

47094

47010

47015
Factory Serial No. Operator

Group II (cont)

thru 47090

RC

(cont)

thru 47133

SK

SR

VE

thru 47109 ZBM

ZCA

47031

47083

47086

47103

47149

47153

47155

47160

47204

and

and

47156

47205

47114 and 47115

45790

47104 and 47105

47087

47154

47061

RC 45828

47016

ZN3 47055

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.

B. 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

47084

47088

47093

47312

47102

47131

47190

IB

KL

NY

00

OZ

45789

47113

47152

47030

47035

47107

47172

47248

47251

Factory Serial No. Operator

Paae 3
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 AD5 rivets.

Conditions 2 thru 16 (Cracks)

Removes doublers, as applicable, and installs reinforcing doublers and

shims..

Group II

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 1 (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
0. 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

I Less than 4000 4000 1/ 2/ 6/

40,000

More than 2000 1/ 3/ 6/

40,000

More than 1000 4/ 6/

60,000

II 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.

2/ If no cracks are found, repetitively inspect until five-leaf

doublers are installed with AD5 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.

4/ 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

stiffe ers, 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 ADS rivets and

replace all AD4 rivets in stiffeners and in scallops of upper

diagonal doublers with AD5 rivets.

May 16/80 Bulletin A5S-144

Revision 2 February 23/84 Pege 5
5/ Remove appropriate A04 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 16, 1984.

F. Manpower:

Groups I

The visual inspection may be accomplished in the following approximate

man-hours or elapsed hours per aircraft:

Wnrk 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 vision 2 February 23/84
Group I or II

The eddy current or fluorescent penetrant inspection may be accomplished

in the following approximate man-hours or elapsed hours per aircraft:

Work Phases

Gain Access

Inspect

Close Up

Functional Check

Total Man-Hours

Total Elapsed Hours

Man-Hours

47.0

32.0

53.5

0.5

133.0

36.3

The repairs or modifications may be accomplished in the

approximate man-hours or elapsed hours per aircraft:

following

Man-Hours

Work Phases

Conditions

1 2 3 and 4 and 5 and 7 and

6 15 12 16

8 9 and

10

11 13 and

14

Modify (Aircraft) 61.6

Repair 30.0 40.0 43.1 41.7 16.0 24.1 14.6 26.2

Total Man-Hours 61.6 30.0 40.0 43.1 41.7 16.0 24.1 14.6 26.2

Total Elapsed 30.8 15.0 20.0 21.6 20.8

Hours

8.0 i2.0

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.

2. 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: Examples; planning,

engineering liaison, parts requisition, shift change

coordination, and report writing.

Operators should take the above into consideration when

scheduling this modification.

May 16/80

Revision 2 February 23/84

Bulletin A53-144

Page 7

44.2

44.2

7.3 13.1 22.1
G. Material - Cost and Availability:

(1) 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 be

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. Weiqht and Balance:

Group I or II

This modification will increase the weight of the aircraft as follows:

APPROXIMATE STATION

SERIES LOCATION OF

AIRCRAFT WEIGHT INCREASE

10 None

30 None

40 None

10

30

40

10

30

40

817.0

996.0

1072.0

817.0

996.0

1072.0

MFR'S EMPTY

WEIGHT (MEW)

INCREASE LBS

None

None

None

+1.4

+1.4

+1.4

+1.5

+1.5

+1.5

MOMENT CHANGE

(MEW)

IN.-LBS

None

None

None

+332

+423

+476

+356

+453

+510

INDEX UNIT

CHANGE

(MEW)

None

None

None

+0.3

+0.4

+0.5

+0.4

+0.5

+0.5

Bulletin A53-144 May 16/80

Page 8 Revision 2 February 23/84

CONDITION

2

3
SERIES

CONDITION AIRCRAFT

4 10

30

40

5, 6, 10

and 12

30

40

7 10

30

40

8 10

30

40

9 and 10

10

30

40

11 10

30

40

13 thru 10

15

30

40

16 10

30

40

APPROXIMATE STATION MFR'S EMPTY

OCATION OF WEIGHT (MEW)

WEIGHT INCREASE INCREASE LBS

817.0 +2.0

996.0 +2.0

1072.0 +2.0

817.0 +1.7

996.0 +1.7

1072.0 +1.7

817.0 +0.6

996.0 +0.6

1072.0 +0.6

817.0 +1.0

996.0 +1.0

1072.0. +1.0

817.0 +0.5

996.0 +0.5

1072.0 +0.5

817.0 +1.2

996.0 +1.2

1072.0 +1.2

817.0 +1.8

996.0 +1.8

1072.0 +1.8

817.0 +0.7

996.0 +0.7

1072.0 +0.7

MOMENT CHANGE

(MEW)

IN.-LBS

+474

+604

+680

+403

+513

+578

+142

+181

+204

+237

+302

+340

+119

+151

+170

+284

+362

+408

+427

+544

+612

+166

+211

+238

INDEX UNIT

CHANGE

(MEW)

+0.5

+0.6

+0.7

+0.4

+0.5

+0.6

+0.1

+0.2

+0.2

+0.2

+0.3

+0.3

+0.i

+0.2

+0.2

+0.3

+0.4

+0.4

+0.4

+0.5

+0.6

+0.2

+0.2

+0.2

May 16/80

Revision 2 February 23/84

Bulletin A53-144

Page 9
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 B 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.

K. 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
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

are as follows:

Drawing J060111

-1

-503

-507

-511

-515

-527

-519

-523

rework drawing J060111 configurations

Condition

10

11

12

13

14

15

16

Drawing J060111

-521

-501

-505

-509

-513

-517

-525

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.")

B. Roll back or remove and retain

ventral aft pressure bulkhead.

entitled, "Removal/Installation

insulation material from aft side of

(See chapter 25-22-0, paragraph

Insulation Blankets.")

C. 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

Condition

2

3

4

5

6

7

8

9

Page 11
Eddy Current Or Fluorescent Penetrant Inspection

A. Remove and retain passenger aft entrance ddor 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

25-41-0, parigraph 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, paragraph

entitled, "Removal/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 AD5 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,

paraqraph entitled, "Adjustment Test Air-Conditioning Flow Control

Valve.")

Bulletin A53-144 May 16/80

Page 12 Revision 2 February 23/84
N. Test pressure regulator valve. (See chapter 21-31-1, paragraph entitled

"Adjustment/Test Air-Conditioning Pressure Regulator Valve.")

O. 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 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, paragraph

entitled, "Removal/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)

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
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 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.

Bulletin A53-144

Page 14

May 16/80

Revision 2 February 23/84
TABLE I

May 16/80

Revision 2 February 23/R4

Bulletin A53-144

Page 15
TABLE II

Bulletin A53-144

Page 16

May 16/80

Revision 2 February 23/84
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.

Part No.

Group I or II

Qty Per Condition

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

J060111-11 NTD

J060111-13 NTO

J060111-15 NTD

J060111-17 NTD

J060111-19 NTD

J060111-21 NTD

J060111-23 NTD

J060111-25 NTD

J060111-27 NTD

J060111-29 NTD

J060111-3 NTD

J060111-31 NTD

J060111-33 NTD

J060111-35 NTD

J060111-37 NTD

J060111-39 NTD

J060111-41 NTD

J060111-43 NTD

J060111-45 NTD

J060111-47 NTD

J060111-49 NTD

J060111-5 NTD

J060111-51 NTD

J060111-53 NTD

J060111-55 NTD

J060111-57 NTD

J060111-59 NTD

J060111-61 NTD

J060111-63 NTD

J060111-65 NTD

Unit

Net

Price

$108.00

109.00

108.00

109.00

107.00

109.00

106.00

105.00

105.00

108.00

104.00

108.00

108.00

108.00

108.00

106.00

108.00

77.50

41.30

42.90

106.00

103.00

97.10

101.00

94.60

101.00

102.00

95.20

94.60

95.90

Key Word

Splice Doubler

Splice Doubler

Splice Doubler

Splice Doubler

Splice Doubler

Splice Doubler

Doubler

Doubler

Doubler

Doubler

Splice Doubler

Doubler

Doubler

Doubler

Doubler

Doubler

Doubler

Shim

Shim

Shim

Doubler

Splice Doubler

Splice Doubler

Doubler

Splice Doubler

Doubler

Doubler

Splice Doubler

Doubler

Splice Doubler

Bulletin A53-144

May 16/80

Page 17

Revision 2 February 23/84
Group I or II

Qty Per Condition

1 2 3 4 b 6 7 8 9 10 11 12 13 14 lb 16

J060111-7 NTD

J060111-9 NTD

5910130-121 NTD

or

1

8

$106.00

108.00

29.60

Splice Doubler

Splice Doubler

Five-Finger Doubler

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

Group I or II

Qty Per Condition

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

EC-2216 Adhesive

or

Equi valent

(DPM 3279)

HLT336-6-5

HLT336-6-6

HLT336-6-7

HLT636-6-3

HLT636-6-4

HLT636-6-5

FSCM

04963

Pin 73197

Pin

Pin

Pin

Pin

Pin

Supplier

Minnesota Mining and

Manufacturing Company

Adhesives, Coatings and

Sealers Division

3M Center

St. Paul, Minnesota 55101

Hi-Shear Corporation

2600 Skypark Drive

Torrance, California 90509

MS20426AD5-6 Rivet

MS20426AD6-7 Rivet

MS20426AD6-8 Rivet

MS20470AD5-5 Rivet

MS20470AD5-6 Rivet

MS20470AD5-7 Rivet

MS20470AD5-8 Rivet

MS20470AD6-7 Rivet

MS20470AD6-8 Rivet

MS20470AD6-9 Rivet

MS21042L3 Nut

NAS1252-10L Washer

PR-1422 Sealant 83574

or

Equivalent

(DMS2082)

Products Research and

Chemical Corporation

5430 San Fprnando Road

Glendale, California 91203

Bulletin A53-144

Revision ? February 23/84

Part No.

Unit

Net

Price Key Word

Page 18

May 16/80
(3) Parts removed. Discard.

NOTE: Not applicable to conditions 5, 6, and 11 th

Group I or II

Qty Per Condition

Part No. 2 3 4 7 8 9 10 16

5910130-121

5910130-79

5910130-81

B. The basis for the following material data is per spares.

None.

OJH

JEM

May 16/80

i inn F hr rv / R4

ru 15.

Key Word

Five-Finger

Doubler

Doubler

Doubler

Bulletin A53-144

Page 19
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 1 OF DIRT, GREASE, AND FOREIGN MATERIALS

USING LINT FREE WIPERS AND 1,1,1, TRICHLOROETHANE SOLVENT, OR EQUIVALENT.

DO NOT 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)

SHEET 1 OF 2
VISUAL INSPECTION AREA.

VENTRAL BULKHEAD SHEET 

2

OF 

2

FIGURE 1.
1. 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

A. HIGH SENSITIVITY

FROM:

DMS 1908

GRADE 3

MANUFACTURERS

DESIGNATION

P-133, P-133 A

ZL-16, ZL-17B,

ZL-60B

DUBL-CHEK, HM3,

HM3A

FLUOROCHEK

WP-10OMD

F-4A-B

OD-2800-1

WATER WASHABLE FLUORESCENT FENETRANTS MAY BE PURCHASED

DMS 1908

GRADE 4

MANUFACTURERS

NAME & ADDRESS

MANUFACTURERS

DESIGNATION

P-134

ZL-54

HM-405

NONE

F-4A-C

00-2800-2

SHANNON LUMINOUS MATERIALS CO.

7356 SANTA MONICA BOULEVARD

LOS ANGELES, CALIFORNIA 90046

MAGNAFLUX CORP

6800 EAST WASHINGTON BOULEVARD

LOS ANGELES, CALIFORNIA 90040

SHERWIN, INC.

5007 EAST WASHINGTON BOULEVARD

LOS ANGELES, CALIFORNIA 90040

TURCO PRODUCTS, INC.

DIVISION OF PUREX CORP., LTD

P. 0. BOX 6200

CARSON, CALIFORNIA 90749

EISHEN KAGAKU CO., LTD

1-2-13 HIGASHI-SHINBASHI

MINATO-KU, TOKYO, JAPAN

TOKOSHU TORYO CO., LTD

17, NISHI 4-CHOME

OMORI, OHTA-KU

TOKYO, JAPAN

SHEET 1 OF 1
MANUFACTURERS

NAME & ADDRESS

NIPPON OILS AND FAT CO.

LTD 5 YURAKU-CHO 1-CHOME

CHIYODA-KU, TOKYO

100 JAPAN

OXY METAL INDUSTRIES

LIDYLITE DIVISION

5640 KNOTT AVENUE

BUENA PARK, CALIFORNIA 90620

B. HIGH SENSITIVITY SOLVENT REMOVABLE PENETRANT MAY BE PURCHASED FROM:

SUPPLIERS

MAGNAFLUX CORPORATION

6800 EAST WASHINGTON

BOULEVARD

LOS ANGELES, CALIF.

90040

TURCO PRODUCTS,

DIVISION OF PUREX

CORPORATION LIMITED

P.O. BOX 6200

CARSON CALIF. 90740

SHERWIN, INCORPORATED

5007 EAST WASHINGTON

BOULEVARD

LOS ANGELES,

CALIFORNIA 90040

MATERIALS.

FLUORESCENT

PENETRANT

ZL-22A, OR ZL-23A,

OR ZL-30A

FLUOR-CHECK

R-REMOVER

DUBL-CHEK CLEANER

DR-61

MONAQUEOUS ZP-9

SPRAY

DEVELOPER

FLUOR-CHECK

DEVELOPER

C. ASSOCIATED EQUIPMENT/MATERIALS

BLACK LIGHT, PORTABLE

SUPER LIGHT, BLACK LIGHT

MAGNAFLUX CORP.

L.A., CA, ULTRAVIOLET

PRODUCTS, SAN GABRIEL, CA

OR URESCO, INC., DOWNEY, CA

HUFF'S WESTERN

INDUSTRIAL EQUIP. CO.

DOWNEY, CA

COTTON SWABS

1,1,1, TRICHLOROETHANE

SOLVENT, OR EQUIVALENT

SHEET

OF 12

DMS 1908

GRADE

N-BP

DMS 1908

GRADE 4

N-4P

BIO-PEN

P6F-3

BIO-PEN

P6F-4

PART NO.

D-100
D. EDDY CURRENT INSTRUMENTS:

NORTEC NDT-3, NDT-6, NDT-8,

NDT-16, OR NDT-18

OR

MIZ-1OA, EM3300

OR

ED520, ED-530

OR

EQUIVALENT

NORTEC CORPORATION

421 NORTH QUAY

KENNEWICK, WASHINGTON 99336

AUTOMATION INDUSTRIES INCORPORATED

MATERIALS EVALUATION GROUP

SHELTER ROCK ROAD

DANBURY, CONNECTICUT 06810

MAGNAFLUX CORPORATION

7300 WEST LAWRENCE AVENUE

CHICAGO, ILLINOIS 60656

E. EDDY CURRENT PROBES:

VM501-4

VM501-5

VM501-6

(100-300 KHZ)

OR

EQUIVALENT

(SEE FIGURE 2)

VM PRODUCTS

7420 PARK AVENUE

TACOMA, WASHINGTON

F. EDDY CURRENT REFERENCE STANDARD:

VM501RS

OR

EQUIVALENT

(SEE FIGURE 2)

VM PRODUCTS

7420 PARK AVENUE

TACOMA, WASHINGTON

REF: DC-9 S/B AS:

SERVICE SKETCH

3-144

SHEET 3

31108 OF 12

98408

98408

NO.
3. INSPECTION/MODIFICATION

A. REMOVE AD4 RIVETS IN HORIZONTAL STIFFENERS. (SEE FIGURE 1.)

CAUTION: SEE NOTE IN FIGURE 1.

B. 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 AD5 RIVETS.

(2) ENLARGE OPEN HOLES USING A NO. 20 DRILL AND INSTALL AD5 RIVETS IN

HORIZONTAL STIFFENERS, VERTICAL STIFFENERS, AND UPPER DIAGONAL

DOUBLERS.

(3) 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.

4. PENETRANT INSPECTION

A. HIGH SENSITIVITY WATER WASHABLE PENETRANT.

(1) INSPECT FORWARD OR AFT SIDE OF VENTRAL BULKHEAD AS APPLICABLE,

WHERE SKIN IS EXPOSED BEHIND NOTED STIFFENERS (SEE FIGURE 1.)

(2) 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. DO NOT

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 DISCARD

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. 12 3110B OF
(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 INSPECTIONS MUST BE OBSERVED IN

DARKENED AREA.

(7) WHEN INSPECTION IS COMPLETED, REMOVE DEVELOPER WITH CLEAR WATER AND

ANY RESIDUAL FLUORESCENT PENETRANT WITH 1,1,1, TRICHLOROETHANE

SOLVENT, OR EQUIVALENT.

E. HIGH SENSITIVITY SOLVENT REMOVABLE PENETRANT.

(1) CLEAN THE AREA TO BE INSPECTED USING CLEAN LINT FREE WIPERS AND

1,1,1, TRICHLOROETHANE SOLVENT, OR EQUIVALENT. ALLOW TO DRY FOR A

MINIMUM OF 5 MINUTES. (SEE FIGURE 1.)

(2) APPLY SOLVENT-REMOVABLE FLUORESCENT PENETRANT TO INSPECTIO'N 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

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.

(3) REMOVE EXCESS PENETRANT WITH A CLEAN, LINT FREE WIPER AND THEN WITH

A CLEAN WIPER SLIGHTLY DAMPENED WITH SOLVENT. ALLOW SOLVENT TO

EVAPORATE FOR 5 MINUTES MI IMUM. DISCARD CONTAMINATED WIPERS.

(4) AFPLY 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 OLES.

NOTE: ALL BLACK LIGHT INSPECTIONS MUST BE OBSERVED

IN A DARKENED AREA.

(6) WHEN INSPECTION IS COMPLETED, REMOVE DEVELOPER WITH CLEAR WATER AND

ANY RESIDUAL FLUORESCENT PENETRANT WITH 1,1,1, TRICHLOROET ANE

SOLVENT, OR EQUIVALENT.

REF: DC-9 S/B A53-I44

SERVICE SKETCH SHEET 5

NO. 3110B OF 12
5. EDDY CURRENT INSPECTION

A. 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 T3 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.)

(3) 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.)

NOTE: 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 6

NO. 3110B OF 12
6. 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

SERVICE SKETCH

3110B OF

SHEET 7

NO. 12
SHEET 

8

FIGURE 1. DC-9 VENTRAL AFT OF 12

PRESSURE BULKHEAD.
REF: DC-9 S/B A53-144

SERVICE SKETCH SHEET 9

NO. 3110B OF 12
SERVICE SKETCH

NO. 3110B

SHEET 1

OF 12
SHEET 11

OF 12
FIGURE 3

SHEET 12

OF 12