FUSELAGE - Main Frame - Inspect/RepairAft FuselageVentral PressureBulkhead Web. Thispage transmitsRevision 2 for DC-9 ServiceBulletinA53-144 to incorporate the following changes: NOTE: This revision constitutes a complete reissue. Reason for Revision; To incorporateengineering releasedsubsequenttoprior issues of this Service Bulletin which adds eddy current inspectioninstructions. No additional work is required by this revision for aircraftmodifiedper prior issueof this ServiceBulletin. Pages2 RevisedServiceBulletin effectivityto reflectcurrentoperatorsof

and 3: affected aircraft. Pages4 RevisedDescription.

thru 7: thru RevisedCompliance. Added eddy current inspection to Manpower requirements. RevisedApprovalparagraph. Page 10: Changed referencedServiceBulletinto 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: RevisionSequence OriginalDate May 16/80 Revision 1 September8/80 Revision2 February23/84

OJH JEM-1 May 16/80 BulletinA53-144 Revision 2 February 23/84 Page of 1FUSELAGE - Main Frame - Inspect/RepairAft 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 replaceAD4 rivetswith 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 firexwye 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 19Factory 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 47015Factory 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 incorporatedprior to delivery on all DC-9 and C-9 series aircraft,manufacturer's fuselage number 268 and subsequent, as applicable. (2) SparesAffected: None. B. Reason: Recent tests revealed fatigue cracks in the bulkheadweb area under the firexwye 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 couldprogress and causeweb failure resulting in loss of pressurization. Inspection of the forward and aft sides of the aft fuselagepressure bulkheadwill determine condition of web. Accomplishment of this Service Bulletin will ensure structural integrity and enhance web service life.

May 16/80 BulletinA53-144 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 3C. 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 firexwye 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 firexwye support vertical stiffeners, at rivet holes for horizontal stiffeners, and at rivetholes for scallops of upper diagonal doublers, and accomplishes the following: Condition 1 (NoCracks) Repetitively inspects until five-leaf doublers are installed with AD5 rivets at upper and lower ends of firexwye support vertical stiffeners and allAD4 rivets in firexwye support vertical stiffeners, in horizontal stiffeners, and in scallops of upper diagonal doublers are replacedwith AD5 rivets. Conditions 2 thru 16 (Cracks) Removes doublers, as applicable, and installs reinforcing doublers and shims.. Group II Performs eddy current or fluorescentpenetrant inspection of bulkhead web at rivet holes for scallops of five-leaf doublers at upper and lower ends and along attach rivets for firexwye 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 (NoCracks) 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 firexwye vertical stiffeners, in horizontal stiffeners, and in scallops of upper diagonal doublerswith AD5 rivets. Conditions 2 thru 16 (Cracks) Removes doublers, as applicable, and installs reinforcing doublers and shims.

Bulletin A53-144 May 16/80 Revision 2 February 23/84 Page 4

### 0. Compliance: It is recommended that this inspection/repair/modifcationbe 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 issuedateof this ServiceBulletin or after

aircraft reachesnext higher accumulatedlandings increment. 

## **Indicates after completionof initial inspection. 1/ Visually inspect bulkheadwebfor cracks at upperandlower ends 

## of firex wyesupportvertical stiffeners. 2/ If nocracks are found, repetitively inspect until five-leaf doublers are installedwith AD5 rivets at upper and lowerends of firexwye 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 initialvisual inspection. 4/ Remove appropriateAD4 rivets andperform eddy current or fluorescentpenetrant inspection of bulkheadweb for cracks at rivetholes at upper and lower ends and at attach holes for firex wye support vertical stiffeners, at rivetholes for horizontal stiffe ers, and at rivetholes for scallops of upper diagonal doublers. If no cracks are found, install five-leaf doublers at upper and lower ends of vertical stiffenerswithADS rivets and replace all AD4 rivets in stiffeners and in scallops of upper diagonal doublerswith AD5 rivets.

May 16/80 Bulletin A5S-144 Revision 2 February 23/84 Pege 5

### 5/ Removeappropriate A04 rivets and perform eddy current or 

## fluorescent penetrant inspection of bulkheadwebfor cracks at rivet holesfor scallops of five-leaf doublersat upperand lower endsandat attach rivet holes for firex wyesupport vertical 

## stiffeners, at rivet holesfor horizontalstiffeners, andat rivet holes in scallops of upper diagonal doublers. If nocracks are 

## found, replaceexisting five-leaf doublersusingADSrivets and replaceall AD4rivets in stiffeners andin scallops of upper diagonal doublers with AD5rivets. 6/ Repair cracks per appropriate condition shownin paragraph 2, Table I or II. NOTE: Accomplishment of the following constitutes closing action for this Service Bulletin: (1) Repair and/or replaceAD4 rivetswith AD5 rivets at all horizontal stiffeners, in firexwye support vertical stiffeners, and in scallops of upper diagonal doublers. (2) Install/replace five-leaf doublers at upper and lower ends of firexwye support vertical stiffeners using ADS rivets. E. Approval: The resultant modification described in paragraph 1.C has been shown to complywith the applicable FederalAviation Regulations and Revision 

### 2 isapproved by the Manager, Los Angeles Area Aircraft Certification Office, FAANorthwest Mountain Region, on February 16,1984. F. Manpower: 

### Groups I 

### Thevisual inspection maybeaccomplished in the following approximate man-hours or elapsed hours per aircraft: 

### WnrkPhases Man-Hours GainAccess 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 23/84Group I or II The eddy current or fluorescent penetrant inspectionmay be accomplished in the following approximate man-hours or elapsed hoursper 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 ormodifications may be accomplished in the approximateman-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 calculatedbased on the assumption that the aircraft/unit has beenplaced in a maintenance status. The man-hour/elapsed time estimates do not include: 1. Preparation for the modification: Examples; defueling, purging, placingwork stands, opening standard access doors, obtaining tools, and jackingwhen 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 reportwriting. Operators should take the above into considerationwhen scheduling thismodification. May 16/80 Revision 2 February 23/84 BulletinA53-144 Page 7

44.2 44.2 7.3 13.1 22.1G. Material

- Cost andAvailability: (1) Aircraft: Parts required to accomplish this modification are listed in paragraph 3.A and are to be procured as indicated. Partswith 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-9Alert ServiceBulletin A53-144) (2) Spares: 

### Not applicable. 

## H. Tooling - Price andAvailability: None. I. Weiqht and Balance: Group I or II This modificationwill 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 INDEXUNIT CHANGE (MEW) None None None 

## +0.3 +0.4 +0.5 +0.4 +0.5 +0.5

BulletinA53-144 

### May 16/80 Page 8 Revision 2 February 23/84 CONDITION

2

3SERIES 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 BulletinA53-144 Page 9J. 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 

## thisService Bulletin. NOTE: One reproducible and two copies or aperture cards of service rework drawing J060111 "New" are being furnished to each affected operator. K. PublicationsAffected: 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 23/842. Accomplishment Instructions: WARNING: TOAVOID INJURY TO PERSONNEL OR DAMAGE TO EQUIPMENT, MAKE CERTAIN ADEQUATE PRECAUTIONS ARE TAKENWHILE PERFORMINGANY WORK IF ELECTRICAL POWER ISAPPLIED TO THEAIRCRAFT. CAUTION: ELECTRICALLY GROUND THEAIRCRAFT. NOTE: Chapterswithin parentheses refer to sections of the Maintenance Manual. 

## Conditionsrelative to service are asfollows: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 attachingparts. (See chapter 26-20-1, paragraph entitled, "Removal/InstallationFire Extinguishing Containers.") B. Roll back or remove and retain ventral aft pressure bulkhead. entitled, "Removal/Installationinsulation material from aft side of (Seechapter 25-22-0,paragraph InsulationBlankets.") C. Visually inspectupper and lowerends of firexwye support vertical stiffeners as shown on service sketch 3109 (attached)and accomplish the following: Condition 1 (NoCracks) Perform repetitive visual inspection until five-leaf doublers are installedwith AD5 rivets as shown on service sketch 3110B (attached). Condition 2, 3, and 4 (Cracks) Accomplish required repairsper applicable condition in Table I.

May 16/80 BulletinA53-144 Revision 2 February 23/84 Condition 2 3 4 5 6 7 8 9

Page 11

### EddyCurrent OrFluorescent Penetrant Inspection A. Remove andretain passengeraft entrance ddor andattaching parts. (See chapter 52-12-0, paragraphentitled, "Removal/Installation PassengerAft EntranceDoor.") B. Removeandretain lavatory equipment and attaching parts. (See chapter 

## 25-41-0,parigraphentitled, "Removal/Installation LavatoryEquipment.") C. Remove andretain firex bottles andattaching parts. (Seechapter 

## 26-20-1,paragraphentitled, "Removal/Installation Fire Extinguishing Containers.") D. Remove and retain access panels 5911 or 5911A, 5912 or 5912A, and 

### sidewall panels as required. (Seechapter 6-12-0.) E. Remove andretain air-conditioning pressure regulator valve and 

## attaching parts. (Seechapter21-31-1,paragraphentitled, "Removal/Installation Air-Conditioning PressureRegulatorValve.") F. Remove andretain air-conditioning flow control valveandattaching parts. (Seechapter 21-31-2, paragraphentitled, "Removal/Installation 

## Air-Conditioning FlowControl Valve.") G. Remove andretain insulation material fromforward andaft sides of ventral aft pressure bulkhead. (Seechapter 25-20-0, paragraph 

## entitled, "Removal/InstallationInsulationBlankets.") H. Performeddycurrent orfluorescent penetrantinspection of ventral aft pressure bulkhead as shownon service sketch 3110B (attached) and 

### accomplishthe following: Condition 1 - (NoCracks) 

### Install five-leaf doublers andreplace AD4rivets with AD5rivets as shownon service sketch 31108 (attached). Conditions 2 thru 16 (Cracks) 

## Accomplishrequired repairs perapplicable condition in TablesI andII. 

## I. Reinstall insulationmaterial. J. Reinstall firex bottles andattaching parts. K. Reinstall air-conditioning pressureregulator valve L. Reinstall air-conditioning flow control valve. M. Test air-conditioning flow control valve. (Seechapter 21-31-2, paraqraphentitled, "Adjustment Test Air-Conditioning FlowControl 

## Valve.") Bulletin A53-144 May16/80 Page 12 Revision 2 February 23/84N. Test pressure regulator valve. (See chapter 21-31-1, paragraph entitled "Adjustment/TestAir-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/InstallationPassengerAft Entrance Door.") B. Remove and retain lavatory equipment and attaching parts. (See chapter 26-20-1, paragraph entitled, "Removal/InstallationLavatory Equipment.") C. Remove and retain firex bottles and attaching parts. (See chapter 26-20-1, paragraph entitled, "Removal/InstallationFire Extinguishing Containers.") D. Remove and retain access panels 5911 or 5911A, 5912 or 5912A, and sidewallpanels as required. (Seechapter 6-12-0.) E. Remove and retain air-conditioning pressure regulatorvalve and attaching parts. (See chapter 21-31-1, paragraph entitled, "Removal/InstallationAir-Conditioning Pressure Regulator Valve.") F. Remove and retain air-conditioning flow control valve and attaching parts. (Seechapter 21-31-2, paragraph entitled, "Removal/Installation Air-Conditioning Flow Control Valve.") G. Remove and retain insulationmaterial from forward and aft sides of ventral aft pressure bulkhead. (See chapter 25-20-0, paragraph entitled, "Removal/Installation InsulationBlankets.") 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

- (NoCracks) Replace existing five-leaf doublerswithAD5 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) 

## Accomplishrequired repairs perapplicable condition in TablesIandII. I. Reinstall insulation material. J. Reinstall firex bottles andattaching parts. K. Reinstall air-conditioning pressureregulator valve. L. Reinstall air-conditioning flow control valve. M. Test air-conditioning flow control valve. (Seechapter21-31-2, paragraph entitled, "Adjustment Test Air-Conditioning FlowControl 

## Valve.") N. Test pressure regulator valve. (Seechapter 21-31-1 paragraph entitled 

## "Adjustment/TestAir-Conditioning PressureRegulatorValve.") 0. Reinstall lavatory equipmentandattaching parts. P. Reinstall passengeraft entrance doorandattaching parts. Q. Reinstall accessandsidewall panels.

Bulletin A53-144 Page 14 May 16/80 Revision 2 February 23/84TABLEI



### May 16/80 Revision 2February 23/R4 Bulletin A53-144 Page 15TABLEII

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 QtyPer 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 SpliceDoubler SpliceDoubler SpliceDoubler SpliceDoubler SpliceDoubler SpliceDoubler Doubler Doubler Doubler Doubler SpliceDoubler Doubler Doubler Doubler Doubler Doubler Doubler Shim Shim Shim 

### Doubler SpliceDoubler SpliceDoubler 

### Doubler 

### Splice Doubler Doubler Doubler 

### Splice Doubler Doubler 

### Splice Doubler

BulletinA53-144 May 16/80 

### Page 17 Revision 2 February 23/84Group I or II Qty Per Condition 1 2 3 4 b 6 7 8 9 10 11 12 13 14 lb 16 J060111-7NTD J060111-9NTD 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-2216Adhesive or Equivalent

(DPM 3279)

HLT336-6-5 HLT336-6-6 HLT336-6-7 HLT636-6-3 HLT636-6-4 HLT636-6-5 FSCM 04963

73197 Pin Pin Pin Pin Pin Pin Supplier MinnesotaMining and

ManufacturingCompany Adhesives, Coatings and



### SealersDivision 3M Center 

### St. Paul, Minnesota 55101 Hi-ShearCorporation 2600 Skypark Drive Torrance, California 90509

MS20426AD5-6Rivet MS20426AD6-7Rivet MS20426AD6-8Rivet MS20470AD5-5Rivet MS20470AD5-6Rivet MS20470AD5-7Rivet MS20470AD5-8Rivet MS20470AD6-7Rivet MS20470AD6-8Rivet MS20470AD6-9Rivet MS21042L3 Nut NAS1252-10LWasher PR-1422 Sealant 83574 or Equivalent (DMS2082) ProductsResearchand 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 Fhr rv /R4 ru 15. Key Word Five-Finger

Doubler Doubler Doubler

Bulletin A53-144 Page 19DC-9 VENTRAL BULKHEAD

1. GENERAL THE FOLLOWING VISUAL INSPECTION PROCEDURE IS INTENDED TOASSIST OPERATORS IN DETECTION OF CRACKS AT THE ATTACH POINTS OF THE WYE SUPPORT (FIREX) TO THE VENTRALAFT 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 LENGTHAND LOCATION OF ALL CRACKS FOUND. REPORT DETAILS TO DAC. DIRECT INFORMATIONTO: DOUGLAS AIRCRAFT COMPANY P.O. BOX 1771 LONG BEACH, CALIFORNIA 90801 ATTN: MANAGER, CUSTOMER SERVICE 7-21 (SERVICEBULLETINA53-144)

SHEET 1 OF 2VISUAL 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 STIFFENERSAND DOUBLERS. (SEE FIGURE 1.) NOTE: EITHER WATER WASHABLE OR SOLVENT REMOVABLE FLUORESCENT PENETRANT ISACCEPTABLE. 2. TEST EQUIPMENT A. HIGH SENSITIVITY FROM: DMS 1908 GRADE 3 MANUFACTURERS DESIGNATION P-133, P-133A

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 LOSANGELES, CALIFORNIA 90046 MAGNAFLUX CORP 6800 EAST WASHINGTON BOULEVARD LOSANGELES, CALIFORNIA 90040 SHERWIN, INC. 5007 EAST WASHINGTON BOULEVARD LOSANGELES, 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 1MANUFACTURERS 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 INDUSTRIALEQUIP. 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-100D. 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 7300WEST LAWRENCEAVENUE CHICAGO, ILLINOIS 60656

E. EDDY CURRENT PROBES: VM501-4 VM501-5 VM501-6

(100-300KHZ) OR EQUIVALENT (SEE FIGURE 2) VM PRODUCTS 7420 PARKAVENUE TACOMA,WASHINGTON

F. EDDY CURRENT REFERENCE STANDARD: VM501RS OR EQUIVALENT (SEEFIGURE 2) VM PRODUCTS 7420 PARKAVENUE TACOMA,WASHINGTON

REF: DC-9 S/B AS:

SERVICE SKETCH 3-144 SHEET 3 12 31108 OF 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 FIREXWYE SUPPORT VERTICAL STIFFENERS AND SCALLOPS OF UPPER DIAGONAL DOUBLERS AND REMOVE ALL AD4 RIVETS ATTACHING FIVE-LEAF DOUBLERS TO BULKHEAD WEB-. (SEEFIGURE 1.) C. PERFORM PENETRANT INSPECTION PER PARAGRAPH 4.A. OR 4.B.OR EDDY CURRENT INSPECTION PER PARAGRAPH 5. IF INSPECTIONAROUND 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 INSTALLAD5 RIVETS IN HORIZONTAL STIFFENERS, VERTICAL STIFFENERS, AND UPPER DIAGONAL DOUBLERS. (3) IF PENETRANT OR EDDY CURRENT INSPECTIONREVEALS CRACKS, ENLARGE HOLE USING A NO. 20 DRILL AND REINSPECT. IFCRACK 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 HOLESWITHOUT 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 12 

### NO. 3110B OF(4) REMOVE EXCESS PENETRANT BYWIPING FIRST WITH A CLEAN, DRY,WIPER FOLLOWED BYA WATER DAMPENED WIPER. REMOVE RESIDUAL MOISTURE WITH A CLEAN, DRY,WIPER. WIPERS ARE TO BE LINT FREE PAPER OR CLOTH MATERIALS. DISCARD CONTAMINATEDWIPERS. (5) APPLY A LIGHT FILM COAT OF NONAQUEOUSWET DEVELOPER OVER AREA TO BE INSPECTEDAND ALLOW FIVE (5)MINUTES MINIMUM DEVELOPMENT TIME. (6) USING BLACK LIGHT, INSPECT FOR CRACKSAROUND PERIPHERY OF HOLES. NOTE: ALL BLACK LIGHT INSPECTIONSMUST BE OBSERVED IN DARKENEDAREA. (7) WHEN INSPECTION IS COMPLETED, REMOVE DEVELOPERWITH CLEAR WATERAND ANY RESIDUAL FLUORESCENT PENETRANTWITH 1,1,1, TRICHLOROETHANE SOLVENT, OR EQUIVALENT. E. HIGH SENSITIVITY SOLVENT REMOVABLE PENETRANT. (1) CLEAN THE AREA TO BE INSPECTEDUSING CLEAN LINT FREE WIPERSAND 1,1,1, TRICHLOROETHANE SOLVENT, OR EQUIVALENT. ALLOW TO DRY FOR A MINIMUM OF 5 MINUTES. (SEE FIGURE 1.) (2) APPLY SOLVENT-REMOVABLEFLUORESCENT 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 SWABWITH PENETRANT MATERIALWHEN 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 HOLESWITHOUT GETTING PENETRANT INSIDEOF HOLE. FAYING SURFACEWILL ENTRAP PENETRANTAND CAUSE EXCESSIVE BACKGROUNDFLUORESCENCE. (3) REMOVE EXCESS PENETRANTWITHA CLEAN, LINT FREEWIPER AND THEN WITH A CLEANWIPER SLIGHTLY DAMPENEDWITH SOLVENT. ALLOW SOLVENT TO EVAPORATE FOR 5 MINUTES MI IMUM. DISCARD CONTAMINATEDWIPERS. (4) AFPLY A LIGHT UNIFORM COAT OF NONAQUEOUS DEVELOPER TO INSPECTION AREA AND ALLOW 5 MINUTES MINIMUM DEVELOPMENT TIME. (5) USING BLACK LIGHT, INSPECTFOR CRACKSAROUND PERIPHERY OF OLES. NOTE: ALL BLACK LIGHT INSPECTIONSMUST BE OBSERVED INA DARKENEDAREA. (6) WHEN INSPECTION IS COMPLETED, REMOVE DEVELOPERWITH CLEARWATER AND ANY RESIDUAL FLUORESCENT PENETRANTWITH 1,1,1,TRICHLOROET ANE SOLVENT, OR EQUIVALENT.

REF: DC-9 S/BA53-I44 

### SERVICESKETCH SHEET 5 NO. 3110B OF 125. EDDY CURRENT INSPECTION A. TEST SET-UP: (1) CONNECT PROBE TO INSTRUMENTAND SET FREQUENCY BETWEEN 100AND 300 KHz FOR SURFACE PROBES. (SEE FIGURE 2.) (2) SELECT EDDY CURRENT REFERENCE STANDARD AND PLACE PROBE IN THE UNCRACKED AD4 HOLE. CALIBRATE INSTRUMENT INACCORDANCE WITH MANUFACTURER'S INSTRUCTIONS. (SEE REFERENCE STANDARD IN FIGURE 2.) (3) PLACE PROBE INNOTCHED AD4 HOLEAND 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 DOUBLERATTACHMENT 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 SHOWINGA METER OR OSCILLOSCOPE READING INEXCESS 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. OF 12 3110B6. DISPOSITION: MARK AND RECORD LENGTH AND LOCATION OFALL 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' (SERVICEBULLETINA53-144)

REF: DC-9 S/BA53-144 SERVICE SKETCH 3110B OF SHEET 7 NO. 12SHEET 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 12SERVICE SKETCH NO. 3110B SHEET 1 OF 12SHEET 11 OF 12FIGURE 3

SHEET 12 OF 12